Custom dicut polybag: Full ink coverage and alternatives

6-18-16

Full bleed ink coverage on custom dicut handle polybags is comparatively more expensive than the same bag with less coverage.  The less coverage bag will keep the print approximately ¼” or more from all edges.  The reasons full ink coverage bags are higher priced than bags with less coverage are …

1. Extra scrap and slitting step:  In order to completely cover a bag with ink, the material has to be printed on larger film and trimmed to size.  It is not possible to custom print on press to the edge of the material.  The printing is done and then slit to size so the end result appears as if the print bleeds off the edge.   The extra slitting step and scrap adds to the cost of the custom polybag.
2. Extra print plate and ink station: An additional plate is needed to fully cover a custom poly bag in ink.    To print the material, print plates are mounted on cylinders.  The print plates for full coverage require the print plates to be a full wrap of the cylinder.    After wrapping the print plate around the cylinder, the edges of the plate butt upon against one another.  The gap between the edges is very thin but to completely cover the bag, the thin area of no print needs to be covered with a plate of the same color in the next inked station.     The additional plate and additional inked station add cost to the custom polybag.
3. Inks:  Full print coverage requires more ink and heat sealable inks.    Each forces a  bit more cost to the custom polybag.
4. Larger material: As noted above, larger than normal material is needed to print and then trim to size to achieve the fill bleed appearance.  The larger material adds cost to the custom polybag.
5. Print plates: Full coverage requires very large print plates to cover the entire surface of the bag on the front and the back.   Print plate costs are directly proportional to the print coverage area desired.

The additional costs associated with full bleed prints versus less than 100% coverage can be as much as 50%.   At times, the full bleed is needed to get the desired affect for the custom dicut polybag.   Other times, slight alterations to the bag can result in the same net affect with less cost.   We keep a wide range of custom dicut polybag samples that serve as ideas for clients.    We can send sample packs for FREE to allow the client to determine the right mix of cost and appearance or their particular use.

The picture shows 3 printed white dicut polybags:  a full coverage bag (Central perk—full color black—the white is a knockout for the black plate), a bag with 95% covberage (NH Lottery shows 1/4″ white border) and a bag with 30% coverage (Williams purple ink plate).

Thanks for reading!!