The single-face laminate (SFL) process is an innovative technique that combines the strength of corrugated board with the smooth surface and high-quality printing capabilities of paperboard. This process involves laminating a printed top sheet onto a single-face corrugated medium, resulting in a sturdy and visually appealing mailer box. To create high-quality mailer boxes using the single-face-laminate process, it is essential to select the appropriate corrugated flute size (C, B, E, F, or N) based on the product’s specific requirements. The SFL process allows for a smooth surface ideal for high-end printing requirements, making it a popular choice for brands looking to elevate their packaging and create a memorable unboxing experience for customers. This technique is suitable for a wide range of products, including electronics, cosmetics, food, and luxury goods.
The Difference between Single Face Lamination and Other Lamination Techniques for Mailer boxes
The critical difference between single-face lamination (SFL) and other lamination techniques for mailer boxes is the construction and resulting properties of the laminated board. Single-face lamination produces a board with superior printing quality, rigidity, and a smooth surface. The SFL process allows for a smooth surface ideal for high-end printing requirements, making it a popular choice for brands looking to elevate their packaging and create a memorable unboxing experience for customers. In contrast, other lamination techniques result in a multi-layer board with the printed sheet centered and framed by bare areas. SFL also eliminates the issue of printed sheets cracking when wrapped around corners, ensuring the integrity of the packaging and the aesthetics of the design.
1. Single-Face Lamination (SFL)
In the SFL process, a pre-printed top sheet is laminated to a single-face corrugated medium. This results in a board that exhibits the rigidity and strength of corrugated but with the smooth surface and high-quality printing capabilities of paperboard. SFL mailer boxes are produced by laminating a printed top sheet, usually SBS paperboard, onto a fluted corrugated medium like C, B, E, F, or N flute. This allows for excellent print quality on the top sheet before lamination.
2. Other Lamination Techniques
Traditional lamination techniques involve laminating a printed sheet onto a finished corrugated board, resulting in a structure with four components: bottom layer, medium, top layer, and printed sheet. In this method, the printed sheet is usually centered on the corrugated board, set in from the edges, and framed by bare areas. The color of these areas will be brown (natural kraft) unless a bleached top layer is used. Another key difference is that with traditional lamination, if the printed sheet is positioned to wrap around a corner, it tends to crack along that location due to a lack of tensile properties. This tendency can be reduced by film laminating the sheet before applying it to the corrugated board.
Is a Mailer Box Easy to Assemble
Yes, mailer boxes are designed for easy assembly. With the pre-scored folds and straightforward assembly process, they can be quickly and confidently assembled by following the provided instructions, even for those with no prior experience. The boxes are shipped flat and pre-scored, making assembly a breeze.
Here are the key steps to assemble a mailer box:
• Fold all pre-scored lines on the interior side of the unassembled box towards the interior.
• Fold up the front and back flaps.
• Bring up the side walls of the box, tuck them inside, and snap them into place.
Some additional tips for easy assembly:
• Work on a clean, flat surface with enough space
• Fold the two closely spaced scores on the sidewalls separately
• Ensure the tops of the side walls are flat when snapped into place
A Unique Unboxing Experience with Custom Mailer Boxes
Customizing the packaging is not just about aesthetics; it’s about creating a memorable and engaging customer interaction when they receive and open their packages. This experience is not only crucial for businesses, but it can also significantly impact customer loyalty and brand perception. By customizing the packaging with unique themes, discount offers, tutorials, eco-friendly materials, box inserts, and product samples, brands can elevate the unboxing process, making customers feel special and excited about their purchases. Incorporating handwritten notes, introducing the brand or maker, and using technology like QR codes can further personalize the experience and build a stronger customer connection. Ultimately, investing in remarkable unboxing expertise can increase customer satisfaction, loyalty, and positive brand recognition.