A cosmetic product isn’t complete without its unit carton. This guide explains how carton structure, printing & finishing, and paper stocks drive both cost and brand perception, and how to move from structure selection to dieline-ready design.

1) Carton structures & inserts

Choose a structure that fits both the component and shelf strategy. Common options:

• Square/rectangular tuck boxes — efficient and cost-effective; widely used for tubes/jars.
• Flap or wing boxes — enhanced unboxing; suited to premium SKUs.
• Inserts (paperboard or molded pulp) — add volume and protect the component; elevate perceived value.

Structural choices affect material yield, make-ready time, and packing line speed.

2) Printing & premium finishes

Printing specifications heavily influence cost and brand impact:

• Offset printing for accurate imagery and small text.
• Silk screen for dense spot colors on limited areas.
• UV spot varnish to add gloss contrast on logos/patterns.
• Foil stamping (gold/silver/holographic) for luxury cues.
• Embossing/debossing for tactile branding.
• Lamination/varnish (matte, gloss, soft-touch) for surface protection and feel.

Specify Pantone vs. CMYK, trapping, and overprint to avoid color surprises in production.

3) Paper stocks & sustainability

The substrate sets stiffness, print quality, and sustainability claims:

• Folding box board (FBB) — the cosmetic standard; good printability and rigidity.
• Coated art paper + liner — smooth finish; vivid color.
• Recycled/FSC-certified boards — sustainability cues; may slightly change brightness/feel.
• Metallic/specialty papers — premium look; higher cost and longer lead times.

4) From structure to dieline design

Once the structure and paper are chosen, request a dieline from your converter. Place brand elements and mandatory copy on the dieline, then run pre-press checks (bleeds, safe areas, overprint) before proof approval.

5) Compliance & mandatory copy

Allocate space for ingredients (INCI), net contents, usage directions, warnings, manufacturer/importer, batch/lot, and country-specific symbols as applicable. Coordination with regulatory is essential prior to press.

6) Cost drivers checklist

• Structure (complexity, insert usage, window cuts)
• Size (material yield & sheet-up efficiency)
• Print (colors, Pantone hits, coverage)
• Finishes (foil, spot UV, emboss/deboss, lamination type)
• Paper (board weight, specialty or sustainable stocks)
• MOQ & lead time (smaller runs raise unit cost; rush charges apply)

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