We Manufacture Custom Rollstock and Bags 

Now that you know what the physical properties of your packaging will be, pre-press will take you through the process of getting your custom art and labeling designs on the packaging itself.

 

Our art department will review your designs to ensure a match on our state of the art flexographic printing machines, generate a die line for print design and add your artwork to the die line. If you’re not sure what ‘die lines’ or ‘flexographic’ means, don’t stress, we’re happy to do the technical work while keeping you posted on the progress.

 

In the final stage of pre-press you’ll get a proofing content package. A PDF that shows your custom print laid on the die line, the print positon on the packaging schematics, the number of colors, and other technical specifications for our production team. We can also send a color (GMG) proof which will mimic the final look of the product, printed on a sheet of paper scaled to size.

At this stage we have all the details necessary to start a production run. The process can diverge quite a bit depending on your specific needs, but in general, the manufacturing process goes something like this.

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Stock check and assembly
This stage involves checking and gather all the required materials for the production run; this can be rolls of paper or plastic, glue, inks, solvents and adhesives. These are then portioned out in the appropriate quantities for the run while the ink kitchen prepares the ink for production.

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Machine setup
As each production run is unique, our machines have to be setup and calibrated to ensure a consistent output of high quality products. This step involves mounting printing plates, adjusting cylinders, running inspections and quality checks on the machines and material.

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Production
Once setup and inspection is complete the production run can start. This usually involves printing the design on a substrate, passing the printed substrate through a converter (which shapes the packaging) and finally ‘catching’ and labeling the finished goods. Quality checks are performed at each stage of production to ensure that requirements are met and outputs are consistent.

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Packaging
Yes, even packaging materials get packaged. This will be done in accordance to your specifications, usually to accommodate the intended end use. Often plastic bags are shipped as rolls, for example with perforated lines to easily tear off a single bag, while paper bags are frequently shipped in cases of 250 to 4000 which can be left at counters or produce stations for bagging.

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Shipping

Once production is complete and all related documentation processed, your order will be moved to a warehouse. Depending on your consignment arrangement, the products will then picked and move to the shipping dock for loading and dispatch.
Bulldog Bag holds Certificates of Origin for cross-border shipment of packaging products.