Sharp Detail, Solid Coverage, and Seamless Screen Work on Corrugated
The Challenge
Heinen’s needed a premium beverage carrier with full-color coverage, clean reverse copy, and detailed bottle imagery—printed on corrugated board. The challenge? Combining deep solid fills (like the rich brown handle area) with halftone imagery that lived in the highlight and midtone range, all without sacrificing clarity or print integrity.
Our Approach
To hit both coverage and detail on this tight e-flute board, we focused on precise material selection and a balanced flexographic setup:
Plate Selection: A harder durometer polymer provided tighter dot control for clean imagery
Line Screen: Likely a 65-line or higher screen for sharp halftone detail
Backing: Thin, standard cushion backing (no HD foam) to support both solids and screens
Substrate: Premium, tight e-flute corrugated and smooth, strong, and ideal for print performance
Because the substrate was so printer-friendly, we could reduce cushion thickness and go tighter with the plate build and maximizing detail without compromising the solids.
The Results
Rich, clean color coverage with crisp reverse copy
Bottle imagery held up in the highlights and midtones
Successful series execution that led to more projects in the same trend
No press issues or remakes—just consistent performance
“This job really showed off what our materials can do. The plates gave great coverage and still held the screen cleanly. It helped spark a trend at the time.”
Need to Balance Solids and Detail in Your Print Job?
From food and beverage to premium retail packaging, we help you bring high-performing designs to life—even when the details live in the midtones.👉 Let’s start your next project and get every pixel performing on press.