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Single-face Laminated Packaging

Throughout its history, corrugated board has been known more for brawn than beauty.

Sterling Anthony

The traditional role of corrugated boxes (i.e. shippers), for example, has been tertiary—protecting contents up to final destination, then getting unloaded and disposed of or recycled. Within that role, there has been minimal need for the communication function and no need for shelf-impact.

More recently, and increasingly, corrugated is being used as primary and secondary packaging. In that capacity, corrugated requires aesthetics that meet the demands and challenges of self-service retailing, including e-commerce. Automatically, printing enters the discussion; however, corrugated board is not the ideal substrate for direct printing, at least not for those printing methods that yield high-resolution, photo-faithful results.

Single-face lamination, which consists of a bottom liner and a medium flute, is a proven answer. A top liner is printed prior to being laminated to the single-face, completing the liner-medium-liner structure of single-wall (also called double-face) corrugated board.

Regarding the choice of printing methods, lithography (which utilizes printing plates, along with the principle that oil and water don’t mix) can produce come-hither graphics that invite consumer inspection, facilitate consumer recognition for repeat purchases, and even trigger impulse purchases. The printed surface can be embellished with coatings, for either a glossy or matte finish. For added boldness, there’s hot-stamping (aka foil-stamping), embossing, and other special effects.

Single-face lamination, as primary packaging, is used for a sweeping diversity of products, including food & beverage (especially club store varieties), cell phones, computers and accessories, other electronics, pet products, toys & games, automotive items, kitchen appliances, and power tools. Such a list requires packaging that’s versatile not only vis-à-vis graphic design, but also structural design. Examples of the latter include features such as opening flaps, automatic bottoms, cut-out sections, perforated sections, and customized shapes.

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