Printed Packaging Producer - Boxes, Envelopes, Packaging

Expert Structural & Graphic Packaging Design Services

At Polycart, we bridge the gap between creative concepts and industrial manufacturing. Unlike stand alone design agencies, our packaging design studio is integrated directly into our factory in Bulgaria. This ensures that every box, envelope, and folder we design is not only visually stunning but also engineered for efficient, cost-effective mass production.

1. Structural Packaging Engineering (CAD)

The foundation of great packaging is its structure. Our engineers use advanced CAD software to create custom die-cut templates tailored to your product's dimensions and protection needs. We calculate precise allowances for material thickness—whether it’s litho laminated corrugated board or folding boxboard—to ensure a perfect fit.

• Custom Die-Lines: We provide professional vector die-lines (AI/PDF) for your artwork designers.
• Material Optimization: We engineer designs to minimize waste during the die-cutting process, saving you money on raw materials.
• Load Bearing Analysis: Ensuring your boxes can withstand stacking and shipping stresses across the EU supply chain.

2. Rapid Prototyping & Sampling

Never go to print without certainty. We produce physical white samples (mock-ups) using our cutting plotters. This allows you to test the size, closing mechanisms, and unboxing experience before committing to a run of 10,000+ units. We can ship samples anywhere in Europe via courier within 24-48 hours.

3. Prepress & Graphic Design

A beautiful design on a screen doesn't always translate to print. Our prepress team specializes in optimizing artwork for offset and flexo printing. We handle:

• Color Management: Precise matching of CMYK and Pantone (PMS) spot colors.
• Print Finishes: Setting up masks for UV spot varnish, hot foil stamping, and embossing.
• Litho Lamination Adjustments: Accounting for paper stretch during the lamination process to ensure perfect registration.