Die Cutting – 6 Step Die Cut Envelope

6 Step Die Cut Envelope

Die Cutting is just one of the services we provide, and we do it all in-house. This reduces the time required to complete jobs, so we can often accommodate tight turnarounds.

The Tear-Strip Envelope featured in the email arrived in our plant printed on 10pt stock. We took the 28” x 40” sheets from start to finish in 6 operations:

1.  Die cutting the sheet

6 Step Die Cut Envelope

2.   Folding the two long, narrow side flaps

6 Step Die Cut Envelope3.    Folding the large panel from the bottom up

4.   Our box gluers applied a plastic tear strip and Kleen Stik double-sided tape all in-line.

5.    Folding and gluing a full-sized pocket panel

6.    Folding and gluing the folder closed

“A picture is worth a thousand words; and a sample is worth a thousand pictures!” Need a sample? Please ask us for one! E-mail us at norm@sgfteam.ca

For a quote or more information, please select an email address listed below:

Quotes at quotes@sgfteam.ca
Email us at norm@sgfteam.ca
Visit our website at www.sgfteam.ca
Phone me, Norm, on my cell (416) 895-9355

USA CUSTOMERS

When you receive an estimate from us, our price includes two-way shipping (dock-to-dock). Our shipping team handles all:

  • Trucking & Expediting
  • Carrier communication & Border paperwork
  • Customs charges & Brokerage fees
  • Our production time includes two-way shipping

 

Custom Setup Boxes

This video features three of the most common types of Setup Boxes that we produce all in-house. We have two machines that produce these boxes, which go by various trade names.

The first orange box shown above is the most common type of Setup Box. If there’s confusion as to what type of box that is (because there are so many!), I just call it a “chocolate box,” which is a better descriptor.

This style has a separate bottom, which nests into the upper lid. To make these boxes, we start by cutting 20pt to 40pt board and then use one of our machines to add paper tape to fasten the corners. Setup Boxes can be wrapped with anything from standard paper to faux leather or cloth. The next two images show a “naked” box before it has had the final wrap applied.

The yellow Setup Box has a wraparound lid, which almost always has a closure. The most common closure methods are Velcro fasteners, a hidden magnet or button and tie (aka button and string). The red Setup Box is similar, but unlike the yellow box, has a flush lid.

We can produce all three of these Setup Box styles in-house in a wide range of sizes and wrap materials. Give us a call when you’re looking for a custom Setup Box supplier!

ANGLED FOLDER BOX

I’ve previously shown a new product for us, which the industry calls Setup Boxes. I often use the term “chocolate box” as it’s a bit more descriptive. The product I’m showing this week is largely produced on our Setup Box machines but is designed to hold booklets. A piece like this requires regular die cutting, the normal application of “staying strips” (or tape) on each of the corners and the application of two different pieces of printed wrap. The larger piece is wrapped around the box and the other smaller piece is a liner for the inside of the box. We do all these operations in-house!

 

ANGLED FOLDER BOX

Where you, the printer or designer, comes into the equation is the fact that the “wrap” needs to be designed and printed! So, if you need Setup Boxes or an unusual box like the one featured, please call us!

ANGLED FOLDER BOXANGLED FOLDER BOX

 

SETUP BOXES

Setup Boxes is an industry term for boxes that are not collapsible and are very sturdy. They’re also wrapped boxes, meaning the actual box is chipboard, but the final product is covered in a material like litho printed sheets, cloth, faux leather, plastic film laminate, etc.

SETUP BOXES

SETUP BOXES

We make Setup Boxes in unusual sizes – as small as 3” wide x 3” deep x 1/2” high and as large as 17” wide x 22” deep x 4” high. If you have an unusually sized Setup Box or want to use an unusual material, we can likely do the job. Please give me a call at (416) 895-9355 if you have a Setup Box job!

SETUP BOXES

There are three steps to making Setup Boxes: First, we start with the right chipboard, which is die cut. Then, the four corners are taped with paper tape, which you can see in the image below. Lastly, the box is surfaced-glued and the wrap is applied.

SETUP BOXES

Google Box

This probably is the most impressive, single ply, die-cut, glued box hat I ever seen!!!  One of the genius components of this box is the extent to which it can be assembled automatically, while at first glance the piece appears to be complex, when it is taken apart, it appears to be much simpler.  The required die-cutting is rather straight forward.  The inline gluing if the right equipment is available is easily doable.

The box wins the competition for creativity, function, uniqueness and intrigue.

Setup Boxes

What is a Setup Box? It is simply a box that cannot be collapsed and is very sturdy. There are fundamentally two styles of boxes: Setup Boxes and Folding Boxes. An example of a Folding Box (see image of flattened white box below) is the box your tube of toothpaste came in. Folding boxes are just one pieces and are produced at rates of many thousands per hour. Setup Boxes, on the other hand, have a top and bottom and are produced at a much slower rate as the process relies more on hand assembly.

Setup Boxes

We make Setup Boxes but only in unusual sizes and small quantities. We’ve made Setup Boxes as small as 3/4” high x 2” wide x 2” deep and as large as 8” high x 9” wide x 16” long! We can produce virtually any size of Setup Box – generally, size isn’t an issue for us!

Setup Boxes

Setup Boxes

Setup Boxes

Setup Boxes

We can produce Setup Boxes that are wrapped in litho printed sheets, paper, cloth, faux leather and foil. We have even wrapped Setup Boxes in plastic film laminate! We can add foil stamping, duplexing and debossing to Setup Boxes.

Some ideas for what can go into Setup Boxes are pencils, pens, shows, jars, bottles, cutlery, tools, etc.

Setup Boxes

Setup Boxes

Setup Boxes

Setup Boxes

Features

  • Square, permanent corners
  • Has a separate base and lid
  • Sturdy and durable
  • Can’t be collapsed

Benefits

  • Permanent box shape
  • Users know how to open & close the boxes and don’t need instructions

Factor to Consider

  • If your box is to be wrapped or mounted with litho-printed paper, we need to specify sheet sizes and print positioning