Production processes

PREPRESS

Prepress is a term used in the printing and publishing sectors for the procedures and processes that occur between the creation of the print layout and the final formation of the package.
The prepress procedure, which includes graphic projects, is called desktop publishing. Desktop publishing includes processes such as creating a cutting design, assembling graphics into the cutting design, typographical composition, copying and editing, making prepress markings, adjusting prepress color, prototyping, modifying, creating printing plates and creating cutting dies.

ALV BOXES uses the latest technologies that meet the prepress needs of its customers and reflect the latest developments in the industry. Top-of-the-line software for photo reproduction, such as Illustrator, Photoshop, Adobe InDesign, Adobe Acrobat and CorelDRAW. A cutting-edge plotter is available to customers to provide rapid feedback on their prototyping needs.

After the work has been submitted to the client for approval, all work and approvals are initiated under the supervision of our quality team with detailed work from our prepress departments.

Cutting-edge technology CTP devices are used to prepare the printing plates necessary for maximum print quality. We can create printing plates with a resolution of up to 2,400 DPI, so you can get even the finest details in your print.

HIGH DEFINITION OFFSET PRINTING

ALV BOX uses the most cutting-edge printing systems to guarantee high production capacity and the best definition. We start from the paper rolls and this allows us to be efficient and flexible on the dimensions of the printing sheets.
With printing, there are different finishes that we can offer:

SILVER or GOLD foil

Finishing that highlights the case in the eyes of the consumer. The creative visual effects help convey the message that the brand wants to convey using this finish.

Paint

Treatment applicable on all or, optionally, only on a part of the surface of the cardboard, made to prevent the surface of the cardboard without scratching it, moistening it, protecting it from sunlight and friction. We can offer water-based matt dispersion paint and water-based gloss dispersion paint solutions needed to protect your packages.

OPP (cellophane) coating

Requirement for boxes that are shipped long distances, kept/used in exhaust environments, exposed to sunlight for a long time, prone to scratches during logistics. The cardboard of such packaging must be carefully selected and coated with OPP toincrease the resistance of the packagingto external factors. OPP can be matte, glossy OPP or metallized OPP (metallic OPP) for various classes of board.

Metallic OPP and UV based printing

Companies and brands aim to collaborate with packaging companies to increase the appeal of canned packaging every day. Gold/Metallic OPP and UV printing are widely preferred to achieve high quality and exclusive look. In reality, gold/metallic OPP is like a thin barrier film (layer) that gives a unique and superior look to the product by improving the decorative and aesthetic properties of the packaging and with UV printing, with a shiny and bright metallic.
It has various advantages, such as a bright and shiny metallic appearance on the shelf, resistance against scratches, tears and other external factors.
The UV inks are environmentally friendly, contain no solvents and have a carbon footprint nearly equal to zero.

Embossing and engraving

Embossing is embossed printing. Two clichés are used during the production of embossing. When using the cliché, a bulge forms on the printing surface. The cardboard is placed between the male cliché found in the printing press and the female cliché found in the die-cutting machine. The bulging cliché puts pressure on the other cliché and the paper is embossed. Embossing can be combined with gold foil or silver foil.

AFTER PRESS

The processes that follow printing can be multiple:

Lamination

By using lamination with different options such as E-groove, B-groove, EB-groove and CB-groove, the strength of the box increases and it is easier to transport.

Cutting and Folding

Folding-gluer machines allow you to fold cardboard in a wide range, quickly and automatically. They are modular and can be adopted according to the folding-gluing needs of our customers. We process many different boxes simultaneously and achieve a high production capacity. We use various applications depending on the type of box or case, such as tear-off tape or double-sided tape. The variants are different, such as crash locks, to 1-2-3 style boxes, to manually assembled boxes, most frequently used in the e- commerce, A-box type boxes, 4 or 6 glued boxes, preferred by pastry shops and bakeries, conical boxes and boxes for medicines.

Acetate window

Having a window in the box allows you to display the product to the customer without losing the sturdiness of the packaging. In addition, the acetate window or OPP window allows the customer and store staff to easily locate the products when arranging the shelves.

Thread stitch

Wire stitch technologies, used to join together boxes made of two pieces or to join one side of the box, are especially preferred in large boxes. Thanks to the sewing machines, grouped into single head and double head, it is possible to provide wire stitching according to customer needs.

Packaging and shipping

The packaging and shipping solutions for the cases are numerous and designed to ensure that the products are not damaged after having passed all the quality control processes.

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Standard and Customized Processing

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