printing – TwonaBlog

February 13, 2023

Version 1.1….version 1.1_new….version 1.1_final

Document versioning is an essential aspect of packaging design, as it ensures the accurate tracking of changes made to the design from one iteration to the next. If you have ever received or sent an email with a subject or a filename that reads something along the lines of “Version 3_final_final”, then keep reading.

Version Control

Version control is the first aspect of document versioning in packaging design. It involves keeping track of all changes made to the design, including modifications to text, graphics, and other elements. This helps ensure that all stakeholders can identify the latest version of the design, reducing the risk of confusion and errors. When I say identify, I mean it. It is not just about downloading the right version, but about being able to uniquely identity a file by just looking at it.

By using version control (keep on reading, we get to the main course soon), the complete creation and modification process is properly tracked. This is particularly critical in highly regulated environments such as packaging design for pharmaceutical companies.

Version Numbering

Version numbering involves assigning a unique version number to each iteration of the design. It is not really relevant HOW the number is defined. Some companies prefer to use a combination of numbers and letters (Version 1 revision A, Version 1 revision B), while others prefer a more straightforward model based on integers (Version 1, Version 2). We do prefer a mixed approach with 2 versioning digits: Version.Subversion. This allows us to track easily major revisions with the first digit and feedback rounds with the second (1.1, 1.2, 2.1, 2.2). The version number NEEDS to be included in the design itself in a way that can be printed. This allows port print identification of design versions which will be critical in the event of a product recall or an audit.

By using version numbering, designers can easily identify which version of the design they are working on, reducing the risk of errors and ensuring that everyone is working with the same version. This also helps with traceability, as the version number can be used to track changes and identify the origin of any issues that may arise.

Version History

It is also important to keep a record of all changes made to the design, including who made the change, when it was made, and why it was made. The link between the version history and the design itself is made via the version number. For every version number, there has to be a historic record of changes and change requests. If you rely on emails, papers or phone calls for this…..you should read this.

Version history is critical at the Quality Control stage or the workflow when someone needs to validate that the changes made are what was expected and nothing else was introduced by mistake.

I don’t wanna

Many teams are reluctant to implement a printable version control system. This can be due to fear of being perceived as a team that needs more than one iteration to get it right. However, when multiple version 1s exist on a given system (email, shared folders, wetransfer) the risk of printing the wrong file becomes a very serious concern. No auditor in its right mind would ever pass a packaging company that does not implement version control from conception to printing.

February 7, 2023

Packaging perspective correction (with your phone)

Perspective Correction Algorithm for Cell Phone Photography

Cell phone photography has become increasingly popular in industrial and business applications in recent years, with the increase in resolution, accuracy and connectivity. One of the biggest challenges with cell phone photography when applied to Quality Control is correcting the perspective of an image. This is especially important when comparing a master design file with a printed a packaging material. A perspective correction algorithm can be used to address this issue.

The perspective correction algorithm is a software-based solution that adjusts the perspective of an image to make it look as though it was taken from a straight-on angle (thus, correcting the perspective distortion). This is achieved by identifying key points in the image, such as the corners or the edges of a packaging material, and adjusting the image to align these points. The process follows a set of determined steps:

Extract key points on both the design and the photo
Match those points to identify corredpondance
Calculate the required transformation
Modify the photography according to the calculated parameters to obtain a corrected image

The use of a perspective correction algorithm is especially important when overlaying a cell phone photo on a packaging design. This can be particularly useful when comparing a master design file (the artwork) with a photography taken with a cellphone of the printed material before it goes into full production. Being able to identify wether the approved master artwork corresponds exactly with the printed material helps reduce (or even eliminate) the risk of printing a packaging material from an un-approved or modified version. This sometimes happens when a stakeholder takes the liberty to modify an artwork for technical reasons and by mistake, something else goes amiss.

Content-based quality checks on printed packaging are crucial to avoid product recalls.
Every Quality Person in the world

There are industrial applications that involve in-line high resolution cameras to compare printed materials with master files. However, they are usually applied for Quality Control on already approved files. Therefore, being able to check before giving the green light for production on a print proof file has tremendous value, specially for highly regulated environments.

If you want to know more about how the perspective correction algorithm works, don’t hesitate to get in touch and we will be happy to chat with you. In the meantime, just to prove this is possible and valuable, you can see how the algorithm works with a really difficult case.

February 2, 2023

The nightmare of technical specs

Working in the pharmaceutical industry, the creation of packaging designs can be a challenging and complex process, especially when dealing with multiple Contract Manufacturing Organizations (CMOs) and Printing companies. There are many factors that can impact the design, including regulatory requirements, branding, marketing, and of course, technical considerations. One of the biggest challenges that packaging designers face when working with multiple printing stakeholders (weather it is a CMO or a printer directly) is the varying technical requirements. Different companies have different machinery and different Standard Operating Procedures (SOPs) (sometimes they don’t even have SOPs).

Oh man…this is hard.

The first challenge related to working with multiple printers is the differences in print and packing capabilities. Each printer may have different printing processes and equipment that they use. For example, one printer may use a rotogravure printing process while another may use flexographic printing. This can result in differences in color accuracy, registration, and overall quality of the final print. Additionally, some printers may not be able to accommodate certain design elements, such as holographic foils or raised printing, which can impact the design and the overall look of the packaging. Additionally, and more specifically for the packaging industry, the printed materials are going to be the input of a packing machine which is going to fold, fill, glue and whatnot in an automated machine. This process is critical since failure can have a high cost impact. Most “reasonable” printing companies and CMOs provide technical specifications to their design agencies (or their clients) so the design materials can be created to specs.

The second challenge is the complex technical documentation that designers must understand in order to create compliant designs. Technical documentation often includes specifications on dielines, varnish free areas, margins, folding lines, visual marks used for automated packing and many more. Understanding these guidelines and ensuring that the design meets them can be a time-consuming and confusing process, particularly for designers who are not familiar with the specific requirements of each printer and considering some of these technical specification documents can be 40 page long. If you are dealing with 10 suppliers, times 40 is a 400 page documentation. That is not easy to manage. This can result in mistakes and miscommunications between the design team and the printer, which can ultimately impact the time to market.

What can we do to fix this?

There are ways to improve the process when technical specification documentation is complex and there are many different suppliers:

Write and maintain proper design manuals specifically for each printer/CMO. This will help ensure that the design team has all of the information they need to create designs that are compatible with each printer’s technical requirements. This can also help avoid misunderstandings and miscommunications between the design team and the printer. Additionally, it will be required should you have to face a customer audit.
Perform training of the design team on all technical requirements. This will help ensure that the design team is aware of the specific requirements of each printer and can create designs that are compatible with those requirements. Furthermore, it will help designers find and interpret information faster and accurately.
Allow a direct line of communication with the printer instead of via the client. A direct line of communication can help avoid misunderstandings and miscommunications that may occur when the design team is communicating through the client. Let the technical people speak to technical people directly, otherwise you will face the broken phone syndrome.

The creation of packaging designs can be challenging, especially when working with multiple CMOs and printers. The varying technical requirements of each printer and the long and complex technical documentation can be a pain in the arse to deal with and a high risk factor. But don’t despair, by following these three tips – writing and maintaining proper design manuals, performing training on technical requirements, and allowing a direct line of communication with the printer – designers can improve the process and ensure that the final product meets all of the necessary requirements.