**Optimizing Your Artwork for Corrugated Printing**

Designing artwork for shipping boxes isn’t the same as designing for web assets or product packaging. The corrugated material, print limitations, and cost factors all play a critical role in ensuring your design looks great and stays within budget. This guide will walk you through the key considerations to help you avoid common mistakes, optimize for production, and create effective, professional packaging that performs well, without unnecessary costs or delays.

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Key Takeaways (TL;DR)

Keep Ink Coverage Low for Cost Savings: Designs with ≤25% ink coverage are the most affordable. Heavy ink coverage increases production time and costs.
Know the Print Area Limits: Corrugated boxes have size constraints—edge-to-edge printing isn’t always possible, and tall boxes have a maximum 12” print height.
Design Flaps with Messaging in Mind: Flap space is limited. Use our simple formula to calculate the printable area and ensure critical information isn’t cut off.
Use the Right File Formats: Submit artwork in vector formats (AI, EPS, or SVG) with fonts outlined to ensure the sharpest possible print.
Avoid Heavy Patterns and Gradients: Stick to bold, simple designs that work well with black ink printing on kraft material.
Consider Functional Upgrades: Add QR codes for marketing, handling icons for better shipping care, and clear calls-to-action that turn each shipment into a brand touchpoint.

INK COVERAGE AND SATURATION

Tier 0 – Standard Coverage (≤25%)

Minimal ink usage, such as logos or small text.
Pricing: Included in the base box cost.

Tier 1 – Moderate Coverage (25–50%)

Significant ink usage, including large graphics or partial backgrounds.
Pricing: Additional surcharge applied due to increased ink consumption and potential drying time

Tier 2 – High Coverage (>50%)

Extensive ink usage, such as full-pattern backgrounds or near-full coverage designs.
Pricing: Higher surcharge reflecting the substantial ink use and production considerations.

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Ink Coverage Surcharges Explained

Light Ink, Tier 0 (≤ 25%)	Moderate Ink, Tier 1 (25–50%)	Heavy Ink, Tier 2 (>50%)
Included	+$2.50 per 100	+$5.00 per 100

Prices are illustrative and subject to change based on design specifics and order volume.

PRINTING EDGE-TO-EDGE PATTERNS

When incorporating patterns into your box designs, it’s important to understand a few key production limitations. Our maximum print height area is 12 inches, which means designs on boxes taller than 12 inches cannot achieve full edge-to-edge printing. Additionally, because boxes are folded and glued at the corners, there will naturally be a break in the pattern between panels.

To help you get the best possible result, our package design team is available to work with you on optimizing your pattern layout. Whether it’s adjusting scale, positioning, or flow, we’ll ensure your design looks intentional and polished by working with the structural limitations and your brand.

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FLAP PRINT MESSAGING

For boxes with a height of 8 inches or less, we’re able to print directly on the top flaps—but there are a few things to keep in mind to ensure your design fits perfectly:

Your flap design can span the entire length of the box’s longest panel space for messaging or branding.
Total print height is limited to 12 inches, so we must subtract the height of the box itself and allow an additional 1 inch for printer margins near the scored fold of the flap.

Example:
If your box is 6 inches tall, the maximum print height on the flap would be:

12" - 6" (box height) - 1" (printer margin) = 5" of vertical print space.

This makes top flaps a great place for compact logos, taglines, or QR codes designed with the available space in mind.

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SCANNING BARCODES

Pick the Right Barcode Type

UPC-A / EAN-13: For retail products sold in stores.
Code128: Perfect for internal tracking, inventory, or shipping.
ITF-14: For outer cartons or bulk shipments.

Tip: If you’re unsure, Code128 is flexible and works great for most business needs.

Use a High-Quality File

Upload a vector file (AI, PDF, or EPS)—this keeps the barcode sharp and scannable.
Don’t use low-quality images like JPG or PNG. They can blur when printed and we do not guarantee scanability.

Keep Space Around the Barcode (Quiet Zone)