Template Making and Die-Cutting Process

1. Template making is drawing die-cutting pattern, which is the unfolded diagram of the entire cardboard box. Currently, the most commonly used die-cutting templates are made of wood plywood, typically about 18 mm thick. Hardwood plywood is the most durable and widely preferred option.
2. Template cutting is typically using laser cutting technology. The process is performed on a computer controlled laser die-cutting machine, ensuring high cutting accuracy, clean edges, and consistent precision across all templates.
3. An automatic bending machine is used to bend the template into its corresponding shape. The die-cutting blades, creasing rules, and connection points are then installed according to the cutting, folding, and gluing positions specified in the die-cutting pattern.
4. After mounting the die-cutting blades on the die-cutting plate, elastic die-cutting tape is applied to both sides of the cutting lines. This effectively prevents the blades and creasing rules from sticking to the paper during the die-cutting and creasing process, ensuring smooth operation and clean results.
5. An initial test cut is performed on the die-cutting machine. If any area is not fully cut through, a 0.05 mm thick pad is applied to the underside of the die-cutting plate to slightly raise the affected section, allowing the machine to achieve precise and complete cutting.

Two-piece boxes require two sets of die-cutting plate for the bottom and the lid. In order to let the lid and bottom fit together perfectly, it is essential to providing accurate dimensions.

Grey Board Die-Cutting and Creasing

Grey board is the inner layer material for two-piece boxes. Die-cutting involves using a die-cutting blade to cut the grey board into the desired shape.

Gray board crease refers to pressing creases along the crease lines on the gray board to ensure that the cardboard will not break during folding and that the creases are clear for easy subsequent assembly.

Folding and Four-Corner Reinforcement

After template production, die-cutting, and creasing of the grey board are completed, the paper box is folded along the crease lines and assembled to “stand up” the flat pattern of the box.

Nowadays, most factories use fully automatic corner-pasting machines. In this process, the die-cut grey board is automatically transferred to the corner-pasting unit via a paper lifting and feeding system, where the four corners are precisely positioned and secured.

During corner pasting, the machine applies a controlled and precise amount of adhesive only at the four corner joints, rather than along the crease lines or across the entire board. Excessive glue would interfere with folding and may cause the creases to crack or wrinkle, so accurate glue control is essential for maintaining box integrity and appearance.

Outer Layer Printing and Surface Finishing

Then, a grey cardboard box blank, with its four corners fixed at 90° and capable of standing independently on a table, is complete. However, the outer cover paper is not yet wrapped; the surface is grey or natural-colored cardboard, and the seams of the grey cardboard are still visible.

Therefore, printing and finishing the outer cover paper are necessary to meet customized needs in terms of visual appeal, tactile feel, and detail.

For example, cosmetic clients may require non-reflective packaging to convey a sense of luxury. In such cases, a matte finish is applied to the outer cover paper to create a low-reflective, smooth surface.

Alternatively, clients may want to highlight their brand logo or key information, using customized techniques such as hot stamping, embossing, or spot UV coating to enhance the logo’s texture.

In practical applications, manufacturers capable of producing customized two-piece boxes often use the combination of multiple surface finishes based on the client’s description and desired effect.

For instance, when Meiyin was making packaging for a Spanish edible oil brand, the client requested both a silky texture and a shiny logo.

After several adjustments, the technicians suggested using silver card paper as the face paper, filling a large area with white ink, printing the logo in color and then applying a matte UV coating to the entire surface. These processes were completed simultaneously by the machine.

Matte UV coating is a UV varnish with a matte effect applied to the face paper. Because this varnish contains fine particles, it forms a rough surface under UV curing, giving the printed material a soft feel.

The gloss level is lower than regular UV varnish, effectively reducing light reflection and making the printed material have a subtle sheen under different lighting conditions, like silk. The resulting effect was stunning, and the client exclaimed, “Yes, that’s exactly it!”

Automatic/Semi-automatic Laminating

After the paper printing is completed, the printed paper needs to be mounted onto a grey board box. This process is called lamination. For two-piece boxes, the lid and bottom need to be laminated separately.

Two types of machines are used for Laminating:

• Fully Automatic Laminating Machines
  A fully automatic Laminating machine performs all processes—including paper feeding, adhesive application, box positioning, edge wrapping, and corner pressing—entirely automatically.
• Semi-Automatic Laminating Machines

  Compared to the fully automatic machine, the semi-automatic Laminating machine incorporates manual intervention. Operators must assist with positioning the box body, edge wrapping, and corner pressing, making this process highly dependent on operator skill.

  For instance, when the machine vacuum-adheres the printed paper and performs the initial pressing against the grey board box surface, the operator must accurately observe whether the printed paper is misaligned with the box surface, if air bubbles form during pressing, or if the paper is skewed. Failure to do so will result in subpar box quality.

Inner Lining 

Quality Inspection and Adjustment

Quality inspection is an indispensable step in the production of two-piece boxes, ensuring that every box meets structural, visual, and functional requirements before shipment.

For instance, structural checks verify whether the lid and base fit together smoothly, if the box body is square, and if the inner lining adequately protects the product.

Appearance inspections examine whether printing has color differences, if surface finishes are clear and complete, and if laminated surfaces have bubbles or scratches.

Packaging and Shipping

This is the final step in the two-piece box production process, ensuring boxes arrive undamaged and neatly delivered to customers.

Finished products are typically packed according to customer requirements, such as layered packing in fixed quantities and separate packing of lids and bases. It can reduce volume and shipping costs.

Outer shipping cartons are typically constructed from heavy-duty corrugated cardboard and securely sealed with packing straps. Clear labeling on the outer boxes includes product details, quantity, batch numbers, and shipping markings to facilitate handling and transportation.

Shipping methods include ocean freight, air freight, and truck transport. For cross-border shipments, the choice between ocean and air freight depends on actual conditions such as cargo volume, expected delivery time, and cost structure.

Reliable suppliers typically reconfirm the shipping method, packaging details, and relevant documentation with the customer before dispatch. For trial orders where time sensitivity is a priority, air freight can be selected to ensure certainty.