It is important to know how to correctly use the Packstyle template to set up the pouch graphics because in packaging, production techniques always guide and affect the layout. In this article we will analyse in detail all the technical information to be observed in order to achieve error-free results and gain awareness in the design phase.

Also have a look at the webinar ‘How to use the Packstyle template’ from the ‘Pack with style’ series on our YouTube channel.

Index

• Where to find the template
• What the template looks like
• The parts of the template
• Reserved spaces
• Graphics tip

We recommend using Adobe Illustrator software to create the graphic layout of the packaging.

Where to find the template

When you place an order on the Packstyle website, you choose the pouch with its characteristics such as size, material, accessories. At the moment the accessories are zip, hole, degassing valve. All these elements influence the size and what the template must include. Once the order has been placed and the quote received, the Download Template button appears.

If you click on the button, you get a zip file containing the Packstyle template in different formats: an Illustrator file, a pdf file and a png file. It is therefore possible to use the template with different software, although it is better to use Adobe Illustrator. The template is a very important part of the design because it is a guide for creating the packaging layout and helps to compose the content of the graphics in the correct way to ensure production quality.

In addition to the template, the instruction file explaining how to use the template is also always available for download.

What the template looks like

Opening the template file with Illustrator, see picture 1, there are:

• the name and dimensions of the product,
• the caption indicating the reserved areas and abundance
• the actual template area
• the layers Template, Artwork, Instructions

Picture 1 - Example of a flat bottomless pouch template. All Template, Artwork and Instructions layers are visible.

The Template layer

The Template layer is where the reserved areas are placed. These show the fixed elements of the pouch such as the seals, the position of the hole, the zip, the valve. It is placed above the Artwork layer so you can see how these areas relate to the graphics. The Template layer is a locked, non-printable layer that must not be modified. Both the Template layer and the Instructions layer can be hidden to leave the layout design area free.

The Artwork layer

The Artwork layer is the one to be used to place all graphics: images, logos, text elements and backgrounds. The layer is editable and everything placed on this layer will be printed.

The Instructions layer

The Instructions layer is where both the legend and basic template information are contained; it is a layer that should not be edited and will not be printed. All elements on this level are outside the document area.

The parts of the template

The document consists of the front, bottom (if there is one, depending on the type of product) and back of the pouch that make up a single vertical strip. In fact, when designing the layout of the packaging, one must imagine the extended and open format of the pouch.

This is because when the product is produced, the front, bottom and back are printed together on the same sheet. Then the sheet is cut, folded and sealed. The template must be imagined as an open pouch, disassembled and flattened on a surface. The front of the pouch is the top, the bottom (if any) is in the middle and the back of the pouch is the bottom of the template and it is turned 180°, upside down. Consequently, the graphics on the back should also be rotated by 180° and the template should be divided into three parts or into two if there is no bottom.

Depending on the pouch chosen and especially on the material, the bottom in the template may

• be present and printable;
• be there and not printable. In this case it is indicated with a red area, and any element placed in the red area will be removed and will not be printed.
• not to be there.

Reserved spaces

Reserved spaces are clearly marked and explained in the template legend. They may change in the future due to updates in production methods. They must always be respected in order to achieve quality end results. In addition to the reserved spaces that are mentioned in the template, it should never be forgotten that a machining tolerance of about one millimetre, one and a half millimetres must be taken into account near a cut or a seal.

The zip

The zip allows the contents to be sealed and is made to be opened or closed several times. The zip is a plastic band that is welded to the pouch. This sealing creates a distortion of the surface and can interfere with the graphics of the packaging. If you look at already printed products, you can see how the zip affects the surface of both a coloured and a white background, creating a slight deformation and alteration of the colour. You should therefore avoid placing graphics or important product information in this area

The seals

The pouch is sealed with a seal that goes around the perimeter of the pouch and on the bottom. Again, this creates a surface distortion that may be visible especially on certain materials, especially glossy materials and plastic films. Be careful, therefore, because the sealing is visible on the edges of the pouch and even more on the bottom. In fact, the bottom of the pouch requires special strength, it is an important point for the structure of the pouch or doypack so the surface of the seal on the bottom of the product is relevant. What happens when there is a seal? It can affect the way colour is perceived because it creates light, shadows and reflections. An inscription, logo or design in the area of the weld may have a slight alteration in colour or even shape. Important elements should not be placed in the reserved space or immediately next to the weld!

Easy opening, tear-off text

To open the product, there is always a small tear-off text at the top of the pouch, which allows you to remove the sealed strip and open the pouch. When tearing, a small part of the pouch will be removed and what is printed on this part will no longer be there once the product pack is opened. It will also create a tear that may not be accurate, may have small imperfections. In this area it is essential not to put important information or information that must go with the product such as the expiry date. Another unpleasant effect that could be created is writing or contents torn in half: one part remaining on the pouch and another part ending up on the tear and being thrown away.

The hole

The hole is an element of the pouch for displaying the product; it can be round or euro-hole with a standard size. If you choose the hole as an accessory, depending on the size of the pouch there may be one or the other. Of course, where there is a hole there is the removal of a small part of the material by die-cutting and any printed items near the hole or on the hole area will be removed. It is best not to place important information or information that is part of the communication in this area because it will be lost when the material is punched to create the hole.

The degassing valve

Some products require the degassing valve to be applied to the pouch for proper storage; the valve is one of the options that can be chosen when ordering. The degassing valve has a diameter and thickness of several millimetres, it is applied by welding to the inside of the packaging but produces three small holes visible on the outside of the pouch. Thus, in this area not only a weld is created but also a slight deformation of the pouch due to the thickness of the valve. In addition, when the pouch is filled with product, the film or paper may shrink slightly around the valve. This is quite normal in the packaging industry where the material and production techniques affect the final appearance of the product, but it is something that needs to be studied and investigated if you are only used to paper printing and flat products without volume. This area is always shown on the template, see picture 2. Obviously, you should not place graphics or important text on top of the degassing valve.

Picture 2 - Example of doypack template with printable bottom, eurohole, zip and degassing valve.

The bottom

It is important to remember the bottom, which is one of the most delicate parts. The bottom is only printable on certain materials while it is not printable on others, such as certain types of paper, for technical production reasons. So in some cases we can print the bottom and use it as part of the communication to enhance the product experience; in other cases if the bottom is not printable it will always be white or the colour of the material. To know whether the background is printable or not, always check the characteristics of the material and the information in the template. A non-printable background is indicated with a red area, as in picture 3. As materials and printing techniques evolve, things may change, so attention must always be paid to whether or not the background is printable.

As already mentioned, the seals on the bottom are relevant and so are the deformations, so it is recommended to reserve the content of the bottom for logos, patterns, colours or information that are not crucial to the interpretation of what is in the pouch.

Picture 3 - Example of doypack template with non-printable background highlighted by red area.

Graphics tips

Finally, a short summary list with some important tips:

• Do not place the brand logo too close to the zip and tear area.
• The greatest readability is in the centre of the pouch where there is less deformation
• The graphics on the back of the pouch should be rotated by 180°!
• Place the barcode in an area free of any interference and with about 2 millimetres of white area around it, to make it easier to read by scanner.
• If you use backgrounds or live graphics, always extend the elements to the margin of abundance.
• Never place text or important elements beyond the red safety line near cuts and welds.
• Always consider production tolerances, especially between different batches
• Production techniques and fixed packaging elements always guide the graphics!

To learn more about this topic also watch the dedicated webinar on our YouTube channel. In the webinar there are practical examples explained step by step.