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Differentiation and Inspiration: Value Added Packaging


The members of the PrintCity Allianz plus many partners have been sharing knowledge on value added packaging to show what is now possible and give inspiration.

The focus of the broad initiative are the demands and requests from brand owners and designers to initiate open discussions around the benefit of innovative VAP techniques:

  • Increased brand awareness from customers because of new or combined VAP techniques
  • Effective differentiation of innovate products in all consumer market segments
  • New opportunities to develop and position brand in the market place

Benefit for designers & creatives, brand owners and converters:

  • Highly creative sample box portfolio to give inspiration
  • Broad range of options and techniques
  • Full ‘how to do it’ tutorials explaining the VAP techniques used
  • Shared VAP process knowledge + access to innovative suppliers & process knowledge in one location

More information on VAPack and sets of sample boxes can be requested from each participating project member or by contacting

PrintCity members:

Eltosch (UV driers), Leonhard Kurz (hot and cold-foils), Merck (pigments / Iriodin®), MetsäBoard (board), Océ (digital printing), Sappi Fine Paper Europe (board) and WEILBURGER Graphics (coatings and flexo inks),

Project partners:

AR Carton (3D design), Esko (3D design tools and visualisation), Folien Company (laminating films), Gallus (inline printing presses and finishing machines), Gietz (embossing machines), Hinderer+Mühlich (embossing dies), Marbach (cutting dies), Reproflex (flexo plates), Reproservice (prepress data preparation), Saueressig (gravure cylinders), Sun Chemical (gravure inks) and Zeller+Gmelin (cold-foil adhesives and food-safe UV flexo inks).


Actual Project: Real Life Samples


Based on an innovative 3D design, 2 sweets packages have been created - each in 2 variations.

These 4 folding boxes have been completely produced inline with only one machine run – from roll to fully decorated and cut box.

All the experience gained in the process, from the design stage to the used material and the production, has again been summarised in a Tutorial.

Efficient inline production

The samples were produced on a Gallus ICS 670 in Weiden.

The modular machine used for this purpose was equipped with 5 flexo modules, a cold-foil module and a hot-foil stamping module, inline cutter, inline die-cutting and embossing station, inline waste stripping station, and delivery unit.

Two different designs for food-safe packagings for chocolate with a high degree of finishing were each produced in two different finishing versions, as mixed forms on two different substrates.

In each case, a holographic cold-foil, two different hot-foils, two pigment coatings, UV gloss and haptic soft dispersion coatings were applied in a single pass, with various blind embossing, die-cutting and creasing steps also being performed at the same time.

"Inline production gives you incredible dependability when it comes to technical realisation: the finished blank is ready after die-cutting and can be tested in accordance with the requirements – by the tape test, for example," says Dieter Widmann, Production Manager at Gallus. "In addition to which, the modular structure of the Gallus ICS 670 makes for a very safe investment, because the machine configuration can be adapted to suit the needs of the market and the user."

Added Value” through Real Life approach

From the very beginning, the entire development process was characterised by close coordination with everyone involved in the value chain: designers, printers and folding-carton manufacturers, and suppliers. Only if these different skills work together effectively can such good results be obtained."

The Value Added Packaging sample portfolio


In the first project of the Value Added Packaging initiative 5 different designs with a high degree of finishing were produced in 5 different finishing versions each.

They were produced inline on a sheetfed offset press, with offline screen printing, hotfoil stamping, embossing, debossing and cut & crease.

The tutorials summarize all the experience gained in the whole process, from the design stage to the used material and the production.

Die complete folder with all 25 different samples has been preseted the first time at drupa 2012.


Sample #2.2

VAPack Sample Portfolio


Sample #5.5

VAPack Members and Partners