Specialty Printing FAQs

How can I utilize Cooley to coordinate multiple suppliers of project components?
Cooley will work with you to completely understand the project components. We will then work to establish the best suppliers of the components based on capabilities, pricing, and logistics. Cooley will coordinate the entire project to fulfill your requirements.

What are the different substrates used in folding cartons and what are their applications?
There are many different substrates used in the manufacture of folding cartons. As a rule, thickness of the material varies from .010 to .028 and the materials can be made of recycled materials with different fiber content. The thickness used depends on the weight of the product being packaged. These materials are usually identified as chipboard, kraft, white clay coated news, and white clay coated kraft. These are great to use especially when a "green" material is requested. There are other materials, such as solid bleached sulfate, that contains no recycled content. This may be used when a better print surface is required. Pharmaceutical and cosmetic packaging are good examples of packaging that utilizes this material. The Cooley design team will work directly with the customer to establish the required materials.

What different printing methods can be used in paperboard packaging, specifically corrugated and folding cartons?
There are many different printing methods that are used in paperboard packaging. Most options are driven by the required detail in the artwork along with quantity being purchased. Folding cartons primarily utilize offset printing, with the use of process colors to achieve photographic results. Presses can print several colors in one pass and many print two sides at the same time. Corrugated packaging uses flexo print, litho label, direct print top sheets, and combinations of each to achieve the required result. It is important to have a good idea of the art being used when any job is being priced for accurate information. Cooley will offer optional ideas to enhance the graphics, such as leaf stamping, embossing, film lamination, and special coatings.

Once artwork is approved, what is the standard lead time in specialty printing and packaging?
After proofs are approved, the normal lead time for most packaging projects is approximately two weeks. Tooling is created once approvals are received so it is very important to review proofs thoroughly. While the proofs are being approved, other processes are moving forward, including purchase of raw materials and scheduling.

What is the best method to use to buy packaging and are warehousing and release programs available?
Suppliers of packaging will want to know how the items will be released when the quotation is being assembled. Corrugated suppliers usually will run the boxes as needed, which means there may be multiple manufacturing runs within one job. This is due to the fact that corrugated boxes usually take up a large amount of room and warehousing is at a premium. On the other hand, folding cartons suppliers will run up to six months supply and warehouse as the customer requires. Again, the better the information is up front, the more accurate the pricing will be.  

Is there an economical way to purchase small quantites of specialty packaging and what quantity is too small?
First of all, with the advent of digital printing, no quantity is too small. However, specialty printing and packaging pricing is driven by quantity. Better pricing is available when the make readies on machines being used can be amortized over quantity. Your Cooley representative can work with you to determine the best quantity to purchase at a time, allowing for better pricing with the ability to make any necessary changes down the road.

How will tooling charges impact packaging pricing?
Tooling charges may have a major impact on pricing depending on the printing method being used and the quantity being ordered. For example, flexo plates, primarily used in corrugated, can be very expensive but are used on large runs, thus limiting the impact on the box price. The Cooley team will be sure to include the tooling costs in any quotation so the customer is aware of all costs.

If I need help with structural or graphic design, are these services available through Cooley?
The Cooley sales team will coordinate structural design and graphic design as the customer requires. Any necessary costs for these services will be advised at the inception of any project. In many cases, structural samples are supplied at little or no cost.

I am new to specialty printing, can Cooley offer suggestions and alternate solutions to my requirements?
Cooley works with their customers to determine the best solutions to specialty print and packaging needs. We have relationships with many of the finest suppliers in the field.  We will analyze the requirements at the very beginning to offer cost effective alternatives where applicable.

How does my facility’s location affect my prices, specifically delivery charges?
Cooley has relationships with suppliers across the country. We will ask up front where the packaging will be delivered and arrive at the best supplier to use to take advantage, wherever possible, of economical shipping charges. Obviously, smaller releases will incur additional shipping charges.

Will members of the Cooley team coordinate press proofs and accompany me at press proofs to help with the process?
Members of the Cooley team will work hand in hand to assist you as requested with press proofs. These proofs will be scheduled for your convenience through Cooley at the required suppliers.

Is it possible to get samples and mockups prior to actual manufacturing?
It is actually a good idea to have samples and mockups created as part of the approval process, prior to manufacturing. It is Cooley's desire to supply product that meets your needs, and making sure everything "checks out" prior to manufacturing is a first step to making that happen.

Will Cooley work with me to find the best resources for my project and how do they determine the resources.
The initial communication with the customer is very important for Cooley in order to understand specific requirements. This includes materials to be used, processes of manufacturing required, quantities to quote, alternatives as suggestions for manufacturing options, and budget numbers that are being assessed. We work as a team with the customer to identify the best resources in moving forward.

If my packaging is machine filled, how does Cooley make sure the packaging will work?
We have relationships with suppliers that understand the requirements of machine filled packaging. As part of the approval process, the manufacture of a small unprinted "test run" prior to manufacturing would be a viable option. 

Are fulfillment resources available?
Cooley has multiple suppliers of fulfillment resources. In addition, these suppliers can tailor the fulfillment to exactly meet the needs of the customer, including special packing, and drop shipments as required.

Are there overall physical size constraints that I need to be aware of?
It is good to understand that the larger the item, the higher the potential is for increased costs. However, with Cooley there really are no size constraints.

What type of proofs are supplied?
The proofs supplied will depend on the processes being used. Print proofs may be supplied in two parts - one for color and one for copy. Structural samples are always supplied. Multiple proofs of each, graphics and structure, are supplied with the consideration of sign offs of each being returned to Cooley prior to manufacturing. It is a very good idea to make any necessary changes in the proofing stage.

Can Cooley offer translation services when multiple languages are required in my graphics? 
Yes, Cooley has resources to offer translations for multiple language graphics. It is requested to know that this is needed at the start of the project so that the timing and the costs of these services can be advised.