Custom Packaging Quality Control Process

Stage 1 — Prepress Artwork Check

• Verify artwork resolution (min 300 dpi), bleed (3 mm), CMYK conversion, embedded fonts
• Pantone color spec review and closest CMYK build for reference
• Foil / spot UV / embossing / debossing zone alignment on the dieline
• Barcode / GS1 DataMatrix / QR code readability test
• Digital PDF proof sent to buyer for artwork sign-off

Stage 2 — Color Proofing

• Digital color proof (Epson calibrated)
• Wet proof for offset jobs above 5,000 PCS on request
• Pantone color matching on target material and coating
• Foil sample swatch (gold, silver, rose gold, holographic) confirmation

Stage 3 — Material Inspection

• Board thickness measurement (calliper)
• Paper weight verification (gsm)
• Project-specific material and food-contact documentation check for the intended use and destination market
• Magnet strength / neodymium grade verification for magnetic boxes
• Pouch film lamination bond strength and seal integrity test

Stage 4 — In-Process Inspection

• First-article inspection at each print run
• Color density inspection every 500 sheets
• Foil registration / embossing depth check
• Die-cut precision measurement
• Magnetic closure and structural assembly test

Stage 5 — Final AQL Inspection & Pre-Shipment Audit

• AQL 2.5 (major) / 4.0 (minor) sampling per ISO 2859-1
• Cosmetic defect check: color, print, foil, dent, scratch
• Structural defect check: assembly, closure, insert fit
• Functional test: magnetic closure hold, tamper-evident seal, pouch seal integrity
• Pre-shipment photo & video audit report sent to buyer before container loading

Project-Specific Compliance Review

FSC, ISO 9001, food-contact, REACH, GS1 DataMatrix and third-party inspection references are included only when supported by verified documents for the selected supplier, material, production route and destination market.

Drop Test & Transit Standards (ISTA 1A / 2A / 3A / 3E)

ISTA procedures verify that a custom package protects its product under real logistics conditions. The most common standards buyers reference are summarized below; the exact current procedure must be obtained from ISTA or an authorized laboratory before release.

ISTA standards at a glance

• ISTA 1A — Non-simulation test for individually packaged products weighing 70 kg or less. Fixed drop heights and a single compression test; fast and cost-effective.
• ISTA 2A — Partial simulation for 70 kg or less. Adds vibration and a second drop sequence on top of the 1A baseline.
• ISTA 3A — General simulation for packaged products weighing 150 lb (70 kg) or less moving through parcel delivery systems. Covers package categories and hazards including atmospheric preconditioning, shock and vibration; widely used for ecommerce shipping.
• ISTA 3E — Unitized loads: products identical, packages identical, one consistent shipping unit. Simulates the vibration and shock a full unit load experiences in truck or rail distribution.

Common hazards each standard checks

• Drop or impact — free fall onto a hard surface, corner / edge / face orientation
• Vibration — transport shaking and resonant frequency response
• Compression / stacking — strength of the box or pouch under stacked loads

How we apply these to custom packaging

Our structural design is fully compliant with ISTA 3A drop test standards. When you specify the shipping channel and target bar code / serialized carton requirements, we engineer the structure, insert and closure to the relevant procedure, then send a production-intent sample for a test run or third-party report.

Related guides: ISTA 3A, Mailer Boxes and Damage Prevention · Packaging Testing Standards: ISTA, Drop & Compression

Buyer-Guide Pages

• Factory Capability
• Sample Process
• Artwork Guidelines
• MOQ Policy
• Shipping & Packing
• Buyer FAQ