Turning Design Limitations Into Award-Winning Print on a Legacy Press
The Challenge
Penn Bakery brought a charming, picnic-style pattern to the table—intended for the interior of their box. The design featured solid fills paired with dashed, screened lines to simulate a gingham or checker pattern. While the concept was visually appealing, the way it was built wasn’t compatible with direct print on corrugated.
To make matters trickier, the printer assigned to this job was working with a very old press—one with known limitations in registration, dot gain, and overall fidelity. If we wanted the design to hold up, we’d have to make changes.
Our Approach
Rather than rewriting the design, we worked with the original creative vision and adapted it for press performance.
Press Simulation & Education: We used our screening software to create a PDF preview showing the designer how their art would likely print on the designated press. It was a reality check—but a helpful one.
Recommended Edits: We proposed changes that would preserve the look and feel of the pattern while making it viable for direct print.
Collaborative Iteration: After a few rounds of discussion and comparison, the client approved our updated version of the pattern.
Design Adaptation: We rebuilt the pattern with correct LPI screening and simplified elements that were unlikely to survive press conditions.
The Results
Interior pattern printed cleanly, even on an outdated press
Box aesthetics enhanced by the updated gingham-inspired design
Client was thrilled—especially given their modest facility and equipment
The packaging won an award at an industry competition for creative execution and adaptability
“They trusted us to adjust their design without losing the feel—and that trust paid off with an award-winning print.”
The Impact
This project proves that great results don’t always require cutting-edge equipment. With a deep understanding of print behavior, a bit of creative give-and-take, and thoughtful client communication, we helped Penn Bakery turn a standard print job into something truly standout.
Designs Don’t Have to Be Rebuilt – Just Rethought
Even with older presses and limited tools, your packaging can shine. We’ll help you preserve your creative intent while optimizing for real-world print performance.
Let’s work together to turn limitations into standout results.