When you’re responsible for sourcing folding cartons, there’s no room for error. Whether you’re packaging consumer goods, health products, food items, or electronics, your cartons have to be more than just attractive – they must be functional, durable, and compliant.
At RoyerComm, we’ve spent over 55 years helping businesses avoid costly packaging mistakes. We’re not just a printer – we’re a proactive partner that works alongside your team to ensure every order runs smoothly, looks sharp, and performs reliably. Here are five common pitfalls we see – along with how to avoid them.
1. Underestimating Lead Times – Especially for Custom Finishes
The Mistake: Assuming folding cartons can be turned around quickly, regardless of complexity.
Why It Matters: Many products require custom finishes – like foil stamping, embossing, or precision die cuts – that demand time and technical prep. Misjudging production timelines can lead to missed deadlines and costly delays.
What to Do Instead: Collaborate early with your packaging partner to build a realistic timeline. At RoyerComm, we reverse-engineer production schedules from your launch date and flag potential timing issues before they cause problems.
2. Providing Artwork Without Print-Ready Adjustments
The Mistake: Sending well-designed files that aren’t properly formatted for print (e.g., missing bleeds, misaligned dielines, or color inconsistencies).
Why It Matters: Packaging isn’t just about design – it’s about precision. Even a minor error can result in print shifts, incorrect barcodes, or non-compliant labeling.
What to Do Instead: Work directly with your supplier’s prepress team. RoyerComm reviews every file for print-readiness and can liaise directly with your designers to ensure everything’s technically sound – before anything hits the press.
3. Choosing Style Over Structural Integrity
The Mistake: Prioritizing visual appeal without fully considering the physical demands on your packaging.
Why It Matters: A visually stunning carton that collapses during shipping or fails to protect the product does more harm than good. Packaging must hold up throughout distribution and use – especially if the product is heavy, fragile, or oddly shaped.
What to Do Instead: Request prototypes and real-world tests based on your specific product specs. RoyerComm offers structural consultations and testing to make sure your packaging works just as well as it looks.
4. Neglecting Content and Compliance Until It’s Too Late
The Mistake: Finalizing the design and then trying to “fit in” required information like ingredients, safety info, barcodes, or legal disclaimers.
Why It Matters: Cramming content in at the last minute often leads to messy redesigns and delays. In regulated industries, it could even result in non-compliant packaging.
What to Do Instead: Align your design and regulatory/compliance needs early. RoyerComm helps clients plan packaging layouts that accommodate all required content from the very start – without sacrificing visual appeal.
5. Treating Your Packaging Supplier Like a Vendor – Not a Partner
The Mistake: Sourcing based solely on price per unit without evaluating reliability, service, and support.
Why It Matters: Saving a few cents up front can cost thousands later in reprints, returns, or missed launch windows. You want a supplier who’s invested in your success – not just fulfilling a transaction.
What to Do Instead: Choose a packaging provider with deep experience and a collaborative mindset. RoyerComm has been the trusted packaging partner for businesses across industries for over five decades – offering expert guidance, responsive service, and consistently high-quality results.
Your folding cartons are the first touchpoint customers have with your product – and one of the last steps before it hits the shelf or the customer’s hands. Avoiding these common mistakes isn’t just about saving money; it’s about protecting your brand, your timeline, and your bottom line.
Looking for a smarter, more reliable packaging partner? Let’s talk. RoyerComm brings 55+ years of expertise, a hands-on approach, and a reputation built on trust – not transactions. Contact us today!
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