DVD Packaging Design
Industry: Print Finishing
Purpose: Tradeshow product demonstration – Graph Expo 2006, Chicago, IL
The challenge
Twin cities marketing and communication firm, Beamond Creative was awarded the project to design a packaging product that would demonstrate the high-speed capabilities of their clients (print manufacturer) latest automatic folding and gluing machine. A DVD wallet is a common configuration for this type of machinery. This model in particular is capable of running a DVD wallet job at speeds of up to 22,000 pieces per hour (pph). So the idea was to create a single pocket DVD package that would later be used for distribution with the company’s product demonstration DVD.
The packaging
There are literally hundreds of different CD or DVD production formats that are currently used in the packaging market today. Beamond Creative worked with one of the clients folding and gluing technicians to come up with a configuration that would be suitable. There were limitations on the layout of the DVD wallet as follows:
- The DVD wallet should only hold a single DVD
- There should be no booklet insert pocket
- The layout could not be a repeat of a tradeshow job from previous years.
A reinforced DVD wallet was chosen. The wallet featured four main panels requiring artwork depicting the company’s products and would incorporate foil stamping and embossing finishing techniques that could be stamped on one of the clients finishing presses, also to be on display at the show.
The finished artwork file was configured 6-up on a 32” x 43” sheet that could be “Blanked” on booth, again utilizing the company’s automatic blank separating machine.
The design
The design of the piece was left wide open for Beamond Creative to incorporate the client’s product line and the theme of the Print Finishing Industry. First we shot several photographs of their equipment from all product lines. Since the foil stamping, embossing and die cutting press is the most well known of all their products, a close-up of the company logo and model number was selected for the front of the DVD wallet. An Omni lighting effect was applied with a wide black-feathered edge to add distinction to the photograph. The image would be of the machine at the tradeshow that would foil stamp and emboss the DVD wallet prior to folding and gluing on the new automatic folding and gluing machine. Foil stamping and embossing features were used to highlight the text on the front cover, which listed the company’s product lines and disc format.
To tie in with the production process for the show, a photograph showing the full length and features of the new folding and gluing machine fit nicely and spanned across the two inside panels, one of which would hold the DVD. The corporate blue color (Pantone 280C) was used as a background inside the piece and text decorated the panels with flat foil stamped lettering.
While leaving room for the sealing flap, the rear of the DVD wallet needed a little information regarding sponsors for the piece. Vendor logos and contact information was added to a black background and the client’s logo and information was flat stamped with gold foil.
Finally, both spines of the DVD wallet indicated the title of the DVD with white text on a black background.
Working with foil stamping and embossing
This DVD packaging piece included several uses of foil stamping and embossing techniques over printing. This involved two foil colors, Gold and Silver and three brass dies, which provided two design limitations as follows:
- Since this was to be a single-pass job, the gold and silver foil stamped and embossed text need to be spaced so that the three rolls of foil would not overlap as the job was fed into the press in a landscape direction before finishing. The foil is mounted horizontally onto the foil control system, a total of three rolls were needed one for each panel of the wallet, silver would be used for the inside stamping and gold for the front and back of the piece.
- Dies were required for both the foil and embossing parts of the piece. Beamond Creative worked with top brass die and foil manufacturers to design and supply artwork for the dies to be made. The concept of foil stamping small text could have been a problem. The foil may not have “released” easily with letters that have hollow (or cut out characteristics) such as “O” or “B”. To eliminate this risk, Beamond Creative made a slight design alteration and replaced part of the inside text foil content with printed information as an alternative. White was chosen to contrast sufficiently with the dark blue background.
To summarize
In conclusion, the design and format of the DVD was a hit! The full-sheet 6-up printed and pre die-cut sheets, blanked well on the automatic blank separator, the correct amount of foil and die combinations finished the product smoothly on the press and finally the new automatic folder/gluer was able to convert the wallet at speeds of 22,000 + pph. Show attendees took many samples and the client walked home with several equipment orders and numerous leads at the end of the four-day tradeshow.
About the author
Samuel Beamond is President of Twin Cities strategic marketing and communications company, Beamond Creative, LLC. The creative firm is primarily a national business, but has also established clientele across the globe since it was founded in 1997. Beamond Creative has found its home within the Printing & Packaging, Legal and Recruiting industries. In addition to these specialties, Beamond Creative has successfully marketed crafting, retail and executive rental businesses. Visit them on the web at www.beamondcreative.com.info@beamondcreative.com
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