Respiratory Device Packaging Box Customization Case
Project Metrics
【Project Overview】
Industry: Healthcare
Product: Respiratory devices
Quantity: Small batch initial sampling + subsequent mass production | Type: Single product
Material: White cardboard 350g (mounted forming)
Process: Four-color printing + matte lamination + die cutting + box folding
Delivery time: Digital sampling 3 days + offset mass production
【Client Background】
A medical device enterprise mainly produces respiratory products. Original packaging used universal paper boxes with insufficient structural strength, prone to deformation during storage and transportation; lacked standardized medical device labels and barcode information.
💬 Customer Needs
The client's original packaging had two prominent issues: First, insufficient box strength - respiratory products have certain weight, and lower packaging deformed under pressure during stacked storage. Second, lack of standardized medical device product labels and barcode information on packaging, affecting end-user identification and traceability. The enterprise planned to upgrade packaging, with small initial quantities, hoping to confirm the solution through sampling before mass production.
Core demands: Structural strength + Compliance labeling + Small batch sampling confirmation.
Project challenges:
✓ Respiratory products have certain weight, single-layer cardboard boxes easily deform
✓ Need to add standardized medical device labels and barcodes
✓ Small initial quantity, traditional plate-making sampling costs high
✓ Need to switch to offset printing for subsequent mass production to reduce unit price
💡 Solution
White cardboard mounting structure is used to improve box stiffness. Digital printing is used during sampling phase for quick sample production, then switched to offset printing for mass production after confirmation to control unit price.
Selection analysis:
Why choose white cardboard mounting instead of single-layer white cardboard?
Respiratory products have weight, single-layer 350g white cardboard stiffness is insufficient for stacked storage. After mounting, 350g white cardboard stiffness approaches 700g cardboard, but surface flatness is much better than 700g single-layer cardboard, maintaining fine printing quality.
Why not use corrugated cardboard?
Although corrugated has good compression resistance, surface flatness is not as good as white cardboard mounting, reducing printing precision. Respiratory device packaging requires detailed medical device labels, product parameters, and barcodes on the box surface, requiring high printing accuracy.
Why digital printing for sampling, offset printing for mass production?
Only a few samples are needed during sampling phase to confirm box structure and printing effect. Digital printing has zero plate cost and zero waiting, delivering samples in 2-3 days. After confirmation, switching to offset printing for mass production reduces unit cost. This "digital sampling → offset mass production" combination is commonly used for medical device packaging.
Production implementation and quality control:
① Sampling confirmation (digital printing zero plate cost) → ② Mounting cardboard preparation
③ Film output → Plate making (switch to offset for mass production) → ④ Four-color printing
⑤ Matte lamination → ⑥ Die cutting → ⑦ Box folding and gluing
⑧ Inspection (dimensions, creases, gluing firmness) → ⑨ Packaging and shipping
✅ Project Results
【Project Results】
【Delivery Data】
✓ Delivered products: Respiratory device white cardboard mounted boxes
✓ Material specifications: White cardboard 350g (mounted forming)
✓ Printing method: Digital printing sampling → Offset mass production
✓ Process combination: Four-color printing + matte lamination
【Usage Effects】
✓ Box strength meets respiratory product storage and transportation requirements
✓ No obvious deformation during stacking and handling
✓ Box surface label information is complete and clear, barcodes can be scanned normally
Case Summary:
Due to the relatively heavy weight of respiratory medical devices, packaging box strength directly affects storage stacking safety and end-user display. This case adopts 350g white cardboard mounting forming solution, through mounting process achieving cardboard stiffness close to 700g level while maintaining surface flatness. Digital printing with zero plate cost is used during sampling phase for quick sample delivery, then switched to offset printing for mass production to control unit cost, balancing small batch verification and large batch supply needs.
Lexiang Experience:
Applicable scenarios: Medical device packaging, color boxes requiring high stiffness, products requiring sampling verification before mass production
Material recommendations: Choose 350g single-layer white cardboard for regular stiffness; choose white cardboard mounting (350g+350g) for high stiffness; choose F-flute for lightweight products
Not applicable scenarios: Not suitable for fragile items requiring cushioning protection (recommend corrugated); not suitable for moisture-resistant environments
Notes: Color effects between digital sampling printing and offset mass production may differ, recommend using same batch cardboard for sampling confirmation
Professional Knowledge:
What scenarios are suitable for digital sampling → offset mass production process?
This process is most suitable for "small sampling quantity + large batch quantity" scenarios. Digital sampling has zero plate cost and fast turnaround, but high unit price; offset printing's plate cost is spread over large batches, resulting in lower unit cost. This combination is most economical when product packaging is confirmed and won't be frequently revised.
Why choose Lexiang:
✓ Flexible switching between digital sampling and offset mass production
✓ Mounting process improves stiffness while maintaining printing quality
✓ Mature experience in medical device label and barcode printing
✓ Small batch sampling confirmation before mass production, controlled risk
📸 📸 Results Gallery
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