Custom Packaging Process

So you're looking for some custom packaging, great! Packaging projects often involve additional considerations that flat pieces do not.

Information we need to begin (the more information, the better!):

  • Quantity (how many pieces do you need? One version or several?)

  • Desired size (flat or folded)

  • Do you have a physical sample of the contents? (jar, tube, bottle, pen, etc.) We require a sample so we can size our packaging for the best fit.

  • Do you have any preliminary artwork? You may provide art to be placed on packaging die lines that we develop, or we can design something custom for you.

  • Budget (either the cost per piece or an overall project budget)

  • Any desired design specifications you have in mind? (papers, PMS spot colors, inks, foils, etc.) Do you have needs for additional pieces such as a tamper evident seal or a variable info label?

  • Do you have references to other packaging or printing projects that will help us understand your vision?

  • When do you need these in hand? Custom packaging takes time. We recommend having at least two months in your timeline for development ahead of production. Most projects take a little longer, depending on complexity and client response time.

Our process

Custom packaging is unique to every project, depending on what your needs are. Generally, you can expect:

1. submit a request

Provide as much of the information above as possible.

2. initial consultation

Our team will follow up on your request. If your project is a good fit for our capabilities, please ship us the primary packaging or product (jar, tube, bottle, pen, etc.) so we can begin our package development. We may provide you a rough timeline during this consultation phase and will offer paper stock recommendations.

3. initial packaging development

Within 2 weeks of receiving your physical sample, we will send you an assembled sample for your review. You may submit initial artwork to be placed on our packaging die lines. Any die lines and production files remain property of Studio On Fire.

4. revisions

Allow time for multiple rounds of testing. Plan for each round of changes to take about a week. The faster we receive feedback, the faster we can make our revisions.

5. project estimate

Once we have an approved packaging sample and your final artwork files (more on that here), we can estimate your project cost based on final production specs (paper, inks, foils, etc.) and desired quantities. Please note that project estimates are only valid for 30 days and subject to material availability.

6. estimate approval

You must approve your estimate, sign our Project Payment Agreement (PPA), and submit a 50% deposit to begin your project. The full balance is due at time of shipment.

7. production proof

Once we have your deposit and production-ready art files, we will prepare a PDF proof of the actual production artwork. This proof typically takes 1-3 business days and will be sent to you by email. We recommend viewing your proof at actual size (or larger) on a computer screen, not on a mobile device. We then require an email confirmation that the proof is approved for us to begin production. Changes made after this point are very costly as we order materials following proof approval; clients will be subject to any resulting fees or charges and may be responsible for the full cost of reprint.

8. production timeline

Due to the custom nature of our work, we do not have a standard turn time. Turn time is based on the complexity of your project and our current shop production schedule. Generally our turnaround time for packaging is at least 25 business days starting from proof approval. Packaging projects with large quantities may require additional time and this will be discussed during the development phase. Please also note that our production timeline does not include shipping time.

9. shipping

We will reach out when your project is complete to review shipping options. Shipping costs are calculated upon completion of the project (based on final size and weight). We primarily ship on our UPS account for both parcel and freight service, but we can bill to your account (either UPS or Fedex) if you'd prefer.

Please keep in mind:

Packaging development takes time. We recommend having at least two months in your timeline for development ahead of production. Most projects take a little longer than that, depending on complexity and client response time. Please allow for several rounds of mockups and die line refinement. The key to a quality piece of packaging is a good fit for your unique product; it may take several mockups to get there.

When it comes time to move into final production, most packaging (especially large quantity orders or complex multi-component projects) may require extended production time.

Many of our clients’ packaging has evolved over the years. Some things that might change how we make your packaging include: die line adjustments (which may change how many flat pieces fit on a sheet of paper), dramatic shifts in the quantity of your order, or unit costs (as you order larger quantities, the price per piece often comes down). We're happy to work with you as your business grows to figure out the best production path.