In each house, cereal is part of the breakfast. When you eat them in the morning, have you ever looked at the box? Did this thought ever come into your mind on how these boxes are made? How did just a piece of cardboard get transformed into such a box that it could hold food? For food brands of different sizes, be they large-scale businesses or new business owners wanting to place an order of custom cereal boxes for small businesses, they must know the process. This helps them select the best materials and techniques. This will let them make the right choices for their businesses. In this blog, you will know about the making of custom cereal boxes in 8 simple steps:

1. Structuring and designing
2. Selecting the raw material
3. Pre-Press Setup
4. The Printing Process
5. Finishing and Coating
6. Cutting
7. Folding and Packing
8. Distribution

Step 1: Structuring And Designing

The first step of making a box starts at the computer and not in the factory. The designer first makes a dieline, which is a 2D blueprint of the box. The manufacturer asks the clients for the size of the box. After final dimensions are decided, the designer makes the dieline, which has 2 major lines:

Cutting lines:

Lines that determine where to cut the box.

Folding lines:

These are dotted lines that determine where the box will have folds.

After that the designer makes designs for customized cereal boxes.  Many companies want custom cereal boxes with logos, so they provide the design according to that. The final design includes different items such as nutrition labels, product information, eye masks, or catching games for kids, and some other options. This is the first step and extremely critical also, as the printing depends on the file provided.

Step 2: Selecting The Raw Material

The next step is to select the raw material to make personalized cereal boxes. The raw material should be selected carefully, as this determines the quality of the box in which the food will be displayed. The following are the types of raw materials from which these boxes are made:

• Corrugated boxes
• Cardboard boxes
• Rigid boxes
• Kraft boxes
• Chipboard boxes
• Buxboard boxes

Step 3: Pre-Press Setup

In this phase, the designs are converted to the formats that physical machinery can understand. On digital screens the colors are displayed in RGB, while the physical printing machines use the CMYK color model. For specific printing of icons and logos, the PMS technique is used. After this, the physical printing is started for the production on a large scale for wholesale cereal boxes.

Step 4: The Printing Process

After the final approval of designs by technicians, the printing process begins. Custom cereal box suppliers mainly use 4 types of printing techniques:

Step 5: Finishing And Coating

After printing, the newly painted surface is prone to damage and scratches. To protect the custom-printed cereal boxes from damage, manufacturers usually apply a protective layer of finishing and coating such as

• Aqueous coating
• UV coating
• Soft touch coating
• Gloss lamination
• Matte lamination

Step 6: Cutting

After the complete drying of the printed sheets, the simple paperboard is moved to the next process of cutting. This process transforms the single sheet of cardboard into a box. A steel rule die is made, which has sharp blades, and the layout of this is completely according to the die-cuts provided in step 1. A machine is then used to accurately cut the sheets. The excess material is thrown in the recycle bin to use for making more custom cereal box products. 

Step 7: Folding And Packing

This is the final step that converts the cut sheets into a cereal box. A folder-gluer is the machine through which these sheets are passed, and it works at the speed of 100 units per minute. In this process, a delicate and thin layer of glue is applied to join the edges of the box. Then the glued boxes are passed through compression, which applies pressure and makes sure that the glue is dried completely. This is essential to make the boxes durable so that they don’t get damaged.

Step 8: Distribution

After this complete process, the order is packed, made in a bundle, and wrapped in a packed stack. The packs are then made into bundles of 50 to 100 boxes. This stack is then wrapped with many layers of plastic to ensure safety. Manufacturers providing the custom cereal box services make sure that the order reaches the customers in the best condition.

Choosing The Best Seller

This is how custom cereal boxes are made in bulk at an industrial level. If you are a food business owner and want to connect with the best custom cereal box wholesale dealers, you should know the complete process so that you are not misguided. In this way you will choose the best material, printing technique, and packaging so that your product is made in the best way. If you want custom cereal boxes in the UK for your business, Custom Boxes Market is the right choice. We offer free custom designing along with free shipping and team assistance to help you in the order process.