An Explanation of Cardboard CD Packaging by henryjohn34


									               Cardboard CD

An Overview of General
Production Concerns

13581 Pond Springs Road, Suite 301
Austin, TX 78729
Over last few years in the disc production world, cardboard packaging for discs has
rivaled the plastic jewel case.

Here is a list of terms and packaging that has become somewhat standard.

CD size is usually when closed and finished approx 5 x 5 plus whatever spines

CD cardboard Sleeve - typically 5 x5 no spine

       single sleeve opens on side or top depending on how the artwork was set up

CD cardboard Sleeve Mailer

       this is like the cardboard sleeve except there is a portion that is pulled over and
then sealed so it can be mailed

CD cardboard Wallet -

       opens like a book, with a single pocket typically on inside right 13581 Pond Springs Road, Suite 301, Austin, TX 78729   (512) 388-1998
CD cardboard Wallet Mailer

       this is like the cardboard wallet except there is a portion that is pulled over and
then sealed so it can be mailed

CD cardboard multi-disc Wallet

       This can be similar to the above but with two pockets instead of just one
       -variations in the pocket - straight, scoop or thumb notch

       typically there may be multiple disc option up to three - after three other
       packaging option may make more sense -

CD digipak

         this is a combination of a plastic tray that is place on the inside right. The spine is
a little more substantial.

So view some videos of these packages - check out

Each of these options requires what is called a DIE LINE.

Much like when a printing piece is printed on a press - the artwork files must be made
into films and then resulting films plated onto metal plates - a die is basically the
equivalent to the press plate.

And like a press plate there are many steps to get to get from artwork file to plate. 13581 Pond Springs Road, Suite 301, Austin, TX 78729      (512) 388-1998
A DIE is made up of a base of wood - with metal either sharp enough to cut paper or
thick enough to cause a scoring of the paper so that folding is easier. (See above)

A DIE is used where paper is required to be cut other than a straight cut. Jewel case
inserts do not require a DIE since the paper is printed flat - straight line trimmed and
then folded.

Cardboard Packaging that is custom printed requires a DIE. The small tabs that are cut
and scored and glued become the foundation of a pocket.

Most CD formats are standardized in that templates have been created that match the
dies. This way the artwork can be set up to lay out across a flat sheet of paper so that
when its printed and the paper die cut, the spines have the text centered and everything
shows where its supposed to.

If you have a standard CD sleeve or wallet or a digpak that holds a single disc you can
be pretty sure that while the project will use a die, you’re not going to have to pay for or
wait for a die made as long as you are going with a printer who specializes in media
packaging. If you go to a general printer (eg. MinuteMan Press) then you’re probably
going to pay for a new die. 13581 Pond Springs Road, Suite 301, Austin, TX 78729    (512) 388-1998
How long does it take to make a die?

With exact dimensions (exhaustive exact dimensions include information on pocket
styles etc) provided in writing - and a sketch of the layout when all flat - it should only
take about 24 - 36 hours to make

How long does it take to make a die to match an existing piece?

With a physical sample that is not a standard configuration, you need to double the
amount of time due to the measuring and testing to ensure an exact match. This is a
hands on, time intensive process. This is not something that can or should be rushed.

If a physical sample already exists why does a new die have to made?

Unlike a library system, each printer has their own exclusive die library. They will not
share or send them out to another printer. So unless you can go back to the company
that first printed them, youʼre going to need to allow for time to make one.

*** Something important to keep in mind, in order to minimize the timeline, the order of
process should be as follows:

       Die Line -----> (Template) ------> Artwork file

To go from the reverse process will always cost you more in time and expenses.

       Artwork layout -----> Die Line

There’s no question that some projects will require their own process. Not everything
can or should be altered to fit an existing die. In those cases, it will be important for
adequate time to be allowed for a proper creation, testing, and approving of a new die

In either case, cardboard packaging must be manufactured just like the disc must be.

If you have questions concerning dies, die lines or any project, please feel free to
contact us at 800-678-1998. We are happy to answer any questions.

Please visit our contact page at 13581 Pond Springs Road, Suite 301, Austin, TX 78729     (512) 388-1998

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