6 Key benefits of die cutting for packaging

Many businesses are faced with the eternal question: how am I going to pack this product?

Unfortunately, there’s rarely an easy answer. Generic cardboard boxes might be too big or too small, or might require excessive void fill to prevent breakages, but what if we told you that there was another way?

It’s not magic, and we’re not wizards (we don’t think), it’s die cutting!

So, why is die cutting good for your business? In order to answer this question properly, first you’ll need to understand what it is.


What is die cutting?

Die cutting uses custom-built machines and tools to cut and create consistent impressions in cardboard sheets, cutting the sheet in such a way that it can be folded into a unique shape (determined by you!). 

Our team at ESS Packaging work closely with our clients to intricately design, assemble, cut and stock die cut cardboard boxes to specification, no matter the scale of the job.

As a result of this, die cutting allows us to create fully bespoke cardboard packaging for businesses that’s designed to perform a specific function (often used for shipping small components, or for shelf ready purposes).

This packaging can be branded or unbranded, but we’re getting ahead of ourselves; first we need to talk about the custom cutting tools that we supply.


What is a die cutting tool?

Custom die cutting tools are created for specific packaging requirements, each with its own unique rules that ensure you get the exact same result every time.

These are usually created on a single piece of hardwood. Steel rules (for cutting, creasing and more) are arranged in a unique pattern. This is coupled with foam pads ensure the board is cut/creased at the desired depth.

When pressed into cardboard sheets, the die cutter will produce packaging that easily folds into the desired shape – pretty nifty!

Custom die cutting rules

Different steel rules are arranged for varying purposes, helping to create a completed (flat) die cut box that’s ready to assemble. These rules can be used for:

  • Through cutting – as the name suggests, these rules will cut straight through the cardboard.
  • Perforating – creating a line of holes along the cardboard that doesn’t fully separate the material, but allows it to be easily ripped when required.
  • Creasing – creased material is designed to flex easily – these rules are usually blunt so as to not cut the material at all.
  • Scoring – similar to creasing, scoring cuts part-way through the material, providing a guide for where to fold when it comes to assembly. 


The benefits of die cut packaging

Die cut packaging boxes are custom built – designed to be uniform, efficient, consistent, sleek and bespoke.

1. Ensure uniform packaging

Once the die cutting tool is created, the machine will produce identical boxes every time, ensuring that your customers are provided the same experience every time they order from you. 

2. Quickly create large quantities

Using a die cutting machine allows us to quickly produce volumes of high-quality stock in no time at all.

3. Create a great first impression

Custom packaging shows that you clearly care about your products, as it looks and functions better than other packaging, and comes with no excessive void fill. There’s something exciting about opening up a custom box (think about smartphones, for example). 

4. Keep costs down

As tabs and slots can be used for assembly, there’s no need for glue, tape or staples with die cut cardboard boxes, meaning that’s one less thing for you to buy! Not only this, but once you’ve got your cutting tool, you have it forever.

5. Reduce waste

Not only does this help to keep costs down, but by removing glues and joiners, you’re ensuring that your packaging is 100% recyclable, helping to reduce your carbon footprint. 

6. Wide range of custom styles

No matter what your packaging requirements, there’s a die cut solution for you! The very nature of die cutting means that we can create designs to suit your unique needs, no matter how fancy you need your packaging.


Bespoke die cut packaging with ESS Packaging

It’s easy to get a little lost with die cutting – we’re here to help.

Our team at ESS Packaging have years of experience in creating custom packaging for businesses across the UK. We understand that your packaging represents your brand, so getting it right is important.

To find out more about how we can help you design packaging that creates a stunning first impression, get in touch with our friendly specialists today.

Alternatively, give us a call on 01889 272 784, or email us at sales@esspackaging.co.uk and we’ll answer any questions you might have.