Calculator

Double-Cut

In technical terms, double cutting in flexible packaging refers to the process of cutting a material twice using two rotary blades. This process is typically performed using a rotary die cutting machine, which uses a pair of circular blades to make two cuts in quick succession. The first cut partially cuts the material, and the second cut completes the cut, creating a clean, accurate edge.

We're not using an offline rotary machine to make double cuts - they are performed inline on the pouching line with two single blades spaced 4mm or 6mm apart.

The process of double cutting helps to ensure that the material is cut precisely and uniformly, reducing the risk of material unraveling or fraying. It also helps to prevent the material from stretching or deforming during the cutting process, which can result in an irregular edge. The use of double cutting in flexible packaging can also improve the strength of the cut edge, making it less likely to break or tear during handling, transport, or storage.

The advantages of double cutting in flexible packaging also include improved production speed, enhanced appearance, and better sealing. By cutting the material twice, the process can be completed more quickly and efficiently, allowing for increased production speed. The clean, accurate edge created by double cutting also results in a more professional-looking finished product. Finally, a smooth, clean edge can provide a better seal when used in conjunction with heat-sealing equipment, helping to prevent leaks and maintain product freshness.

Print Minimum

Minimum text size positive/negative 4 points

Line weight positive. 0.1322mm

Line wight negative. 0.222 mm

Trapping is handled by our software or PDF 1.7 defaults to: 0.088 mm

SunDance Catalogs

SunDance Catalogs

Download our exhibitors, PPE, and warehouse safety catalogs to review our expansive range of products and solutions! Our downloadable pdfs make it easy to search for and find exactly what you need.

SD - Exhibitors Catalog

View Catalog

SD - Warehouse Catalog

View Catalog

SD - PPE Catalog

View Catalog

SunDance Catalogs

SD Packaging Cheat Sheet

Great packaging design is key to differentiating your brand, attracting new customers, and building a passionate fanbase. Our team is experienced at creating award-winning, unique packaging solutions with exceptional design and functionality. We will guide you through the entire packaging process for a seamless experience

REVERSE TUCK-END (RTE) BOXES

• Lids tuck in opposite direction
• Ideal for personal care products, food products, and pharmaceutical products like vitamins and supplements

STRAIGHT TUCK-END (STE) BOXES

• Lids tuck in same direction
• Most popular box style
• Ideal for a variety of products like cosmetic, pharmaceutical, and retail display

FIVE PANEL HANGING BOXES

• Used mostly as retail display box
• Ideal for convenience products
• Great for electronic, pharmaceutical, household, and beauty products

BOX SLEEVE

• Decorative and protective sleeve
• Ideal to for branding generic packaging

PILLOW BOXES

• Simple and functional design
• Easily pops into shape
• Ideal for small and lightweight items

SEAL-END BOXES

• Supports heavy items
• Tamper proof and secure
• Ideal for food and health products

AUTO-LOCK BOTTOM BOXES

• Sturdy pre-glued bottom
• Quickly pops into place
• Great for personal care products, beverage products, and candle boxes

SNAP-LOCK BOTTOM BOXES

• Secure interlocking bottom closure
• Great for heavier products
• Ideal for soaps, candles, perfumes, food, and wellness products

ROLL-END BOXES

• Self-locking design
• Can contain multiple items
• Ideal as mailer/subscription boxes

THICKNESS GUIDE

INTERIOR DIMENSIONS

POPULAR TYPES OF PACKAGING WE PRODUCE:

• Food
• Personal Care
• Pharmaceutical
• Sports Nutrition
• Nutraceutical
• Luxury Gift Boxes
• Cosmetics
• Coffee / Tea
• Confectionary
• CBD

PREMIUM FEATURES:

Add a special touch to make your packaging extraordinary

• Embossing
• Spot UV
• Foil stamping
• Soft touch
• Debossing
• Raised UV

Custom dimensions

Full-color printing inside & outside

ALL PRINTING, FINISHING AND ANY ADDED EMBELLISHMENTS ARE ALL DONE ON SITE AND IN-HOUSE WITH DIGITAL AND OFFSET CAPABILITIES.

The materials we print on, the textures we add, and the finishes we use all combine to create custom packaging that will protect your product and make it stand out in the marketplace.

Quote Request New

Digital Plotter (Zund) Cutter File Preparation

• Files need to be created in Adobe InDesign or Adobe Illustrator as a vector image
• We need 3 or 4 sets of layers, depending on the application in this example we have a cut and score. It needs to have an Art layer, Thru-cut layer, Thru-cut score layer and a Register layer. The naming of the layers is case sensitive.

Color Swatches

• Create 3 color swatches: Register, Thru-cut, Thru-cut score, set the colors to be spot colors. The naming of the spot colors is case sensitive.

In the example below we have a score and a cut; the register marks should not exceed 0.25 inches in diameter all the cut and score lines should be set to overprint. Keep the stroke to 1pt size and solid lines, avoid dashed lines. Export the print ready PDF to include layers, always provide the native files in case we need to make a change.

The Ultimate Foil Cheat Sheet

Are you looking to choose the perfect foiling technique for your next project? Download our Foil Cheat Sheet, done in partnership with PaperSpecs, for tips and insights to make your work look the very best!

Download Our Foil Cheat Sheet!

Preparing Art for Canvas

Stretching printed canvas over a stretcher bar frame gives it an instant gallery look. Sizing your artwork large enough to cover the additional depth of the frame is vital to completing the look. First of all, the stretcher bar depth will add that size around the edge of the front facing area. If the stretcher bar is 1”, there will be an additional 1” all the way around the artwork. If the stretcher bar is 2”, there will be an additional 2” on all sides. Then, the stapled area behind the frame needs to be 1.5” to make sure the printed edge is not visible. So with a 1” stretcher bar, the artwork will need to be an additional 2.5” on all sides, or an additional 5” in width and length. With a 2” stretcher bar, there will need to be 3.5” of additional artwork on all sides, or 7” additional in width and length. Use the below diagram and follow these easy rules to make your artwork gallery ready every time.