Packaging Manufacturing Processes

Here at Wynalda Packaging, from design to fulfillment, we own the packaging manufacturing process. With over 55 years in packaging, we have perfected our process to optimize quality and lead times for our customers. We are proud of our continuous investment in state-of-the-art equipment and technology.

 

CUSTOM PACKAGE DESIGN

 

PREPRESS

 

INK ROOM

 

PRINTING

 

DIE CUTTING

 

GLUING

 

RIGID BOX MANUFACTURING

 

PULP MOLDING

Custom Package Design

Great packaging requires a perfect blend of both structural design and visual appeal. The design needs to be sturdy enough to protect its contents during transportation and handling, while allowing for easy assembly, filling, and closure. A well designed carton will enhance the user experience, while also maximizing space efficiency for storage and display. Additionally, innovative structural designs can differentiate a product on the shelf, attracting consumer attention and providing an increased perceived value.

At Wynalda, our team creates designs that balance all of these elements and are manufacturable at scale. Our designers can provide prototypes and detailed renderings before production begins. Additionally, digitally printed samples may be produced for review to ensure a seamless transition from conceptual development to final product.

Prepress

The Prepress Team at Wynalda Packaging transforms digital designs into print-ready formats. This includes several critical tasks, such as verifying the layout of the graphic elements, adjusting files to suit Wynalda’s printing methods, and ensuring the designs are optimized for the specific material being used.

The Prepress Team ensures that the final printed product meets all branding and quality expectations. This involves color management and proofing. By meticulously preparing and proofing all elements before printing, the prepress department helps avoid costly mistakes, reduces production lead-times, and ensures that the final packaging is visually appealing. Our proofing capabilities include water-based and solvent-based Epson systems, for accurate color. 

By making our own print plates utilizing our in-house computer-to-plate (CTP) technology, we are able to offer faster production times, reduced costs, increased flexibility, and improved print quality.

Ink Room

Housed within our manufacturing facility is our on-site Ink Room. This department formulates inks to ensure precise color matching and consistency across various substrates and different production runs. The Ink Room is responsible for keeping colors consistent with customers’ requirements, brand guidelines, and industry standards. This includes performing color adjustments and creating custom inks for unique applications.

By preparing and delivering the necessary inks to the production floor, the Ink Room plays a critical role in preventing downtime, ensuring that printing operations proceed smoothly without any delays related to ink supply or quality.

Packaging Printing

Wynalda Packaging is committed to providing the highest quality packaging printing to our customers. We utilize multiple offset lithographic printing presses in our manufacturing, allowing us to print up to 8 colors in a single pass. Our presses also have the capability to print with specialty UV and aqueous coatings, as well as cold foil, providing opportunities to create unique, premium packaging.

Additionally, our offset digital printing press blends the exceptional quality and speed of offset printing with the efficiency and flexibility of digital technology. This process delivers sharp, high-resolution images without the need for printing plates or setup, delivering variable printing, low-waste production, and cost-effective short to medium runs. Our offset digital press can produce 96% of Pantone colors with 7-color printing, ensuring exceptional quality and consistency.

Die Cutting

At Wynalda Packaging, our in-house die making and die cutting teams are key elements of our commitment to delivering custom packaging with precision, speed, and superior quality to our customers.

By maintaining a fully equipped die shop, we design, manufacture, and adjust custom dies in-house. This allows us to significantly reduce lead times and enhance our quality control.  

Our die making and die cutting process ensures that every folding carton we produce is crafted to exact specifications, providing consistent, high-quality results while keeping costs down. 

Gluing

At Wynalda Packaging, our advanced gluing capabilities allow us to create folding cartons that are both functional and visually impactful. From simple straight-line gluing to more complex designs, our equipment and expertise ensure precise application and consistent quality at high speeds.

We also offer enhanced features to elevate the customer experience, including the ability to integrate magnets for secure closure and windowing to showcase the product inside. These premium details not only add functionality but also strengthen brand presentation, creating a lasting impression at retail.

Rigid Box Manufacturing

With a focus on quality and craftsmanship, Wynalda’s rigid boxes are designed to provide both durability and elegance, making them ideal for luxury items such as cosmetics, electronics, and specialty goods. We produce a wide variety of custom rigid set-up boxes, including styles such as telescoping, game board, and drawer designs.

After the chipboard box is constructed, we apply a sheet paper wrap. This wrap can be printed with your design and enhanced with specialty coatings, foil, and embossing. We also have the option to add magnets for secure closure.

Rigid box manufacturing further enhances our ability to serve diverse industries with sophisticated, tailored packaging solutions that elevate brand presentation and protect products.

Pulp Molding

Molded paper pulp packaging marks an exciting expansion into additional sustainable and eco-friendly packaging solutions for our customers. With molded pulp, Wynalda is able to offer biodegradable and recyclable packaging options, ideal for companies looking to reduce their environmental impact.  

Custom molded pulp provides secure, form-fitting protection for a wide range of products and can include your branding and designs. Made from up to 100% recycled content, including paper waste collected from our own manufacturing facilities, paper pulp packaging offers a sustainable alternative to traditional plastic, foam, or styrofoam inserts.