Shampoo Sachet Roll Film for Four Product Designs: An Integrated Gravure Printing and Lamination Project
Year:
2026
Service:
Prepress · Gravure · Lamination
Industry:
Flexible Packaging
Size:
HUAYN provided prepress coordination, gravure cylinder preparation, printing, lamination, and dispatch coordination for four shampoo sachet designs. The project used a PET/VMPET/PE structure with a total thickness of 80 μm and supplied unfilled, continuously printed laminated roll film for the customer’s subsequent sachet forming, filling, and heat sealing. All four variants were produced and dispatched.
Project Overview and Supply Scope
Item | Project Scope |
|---|---|
Project type | Custom printed laminated roll film |
Application | Shampoo sachet packaging for personal care products |
Product variants | Four separate designs |
Material structure | PET/VMPET/PE, 80 μm total thickness |
Printing and conversion | Gravure printing followed by lamination |
Cylinder configuration | Four sets of seven cylinders, 28 cylinders in total |
Supplied format | Continuous printed laminated roll film, identified by design; no preformed sachets or filling services |
Cylinder management | Retained by HUAYN for assessment before potential repeat production |
Customer identity, branded artwork, and other commercially sensitive details are withheld. The thickness and cylinder configuration describe this project and do not represent a standard specification for every order.
Project Background and Customer Requirements
The four shampoo packaging designs each had distinct visual characteristics. They needed to balance brand recognition, text detail, and subsequent packaging conversion within a limited sachet layout. The project focused on four requirements:
Coordinate production and dispatch across all four designs while preserving their differences and managing the series’ color appearance.
Keep small text, fine lines, and gradients recognizable within a limited print area.
Distinguish roll-film supply from subsequent forming and filling, with clear dimensional and material requirements.
Provide one team to coordinate artwork, cylinder preparation, printing, lamination, and dispatch information.
Helping the Customer Define Production Specifications
HUAYN broke the packaging requirements into artwork, dimensions, materials, and quantities by design. The team guided the customer through providing and checking these details, then carried the agreed information into cylinder preparation, production, and dispatch.
Information to Provide or Confirm | How HUAYN Guided the Discussion | Basis for Execution |
|---|---|---|
Packaging application and supplied format | Clarified the shampoo sachet application and distinguished continuous rollstock from preformed sachets | Scope of the unfilled roll-film order |
Artwork and printing requirements | Reviewed each design, printing colors, and its cylinder set | Artwork and tooling arrangements by variant |
Packaging dimensions | Distinguished single-face dimensions from the combined front-and-back unfolded dimensions and recorded revisions | Shared dimensional definitions and revised specifications |
Material structure and thickness | Discussed material combinations and thickness requirements | PET/VMPET/PE construction at 80 μm total thickness |
Planned quantity by variant | Allocated the order across the four designs and checked quantities | Production allocation and actual-quantity reconciliation |
Receiving and identification requirements | Confirmed receiving arrangements, shipping marks, and variant identification | Packing information and handover arrangements |
The dimensional revision is a concrete example. HUAYN clarified single-face and unfolded dimensions, then recorded the correction in a supplementary agreement so artwork preparation, cylinder making, and production used consistent specifications. Customer inputs, technical decisions, and execution documents were connected through that process.
PET/VMPET/PE Material Structure
The three-layer construction assigned print support, barrier, and heat-sealing functions to different materials:
Material Layer | Main Role in the Structure |
|---|---|
PET | Print carrier, dimensional stability, and mechanical support |
VMPET | Light shielding and barrier functions from the metallized layer |
PE | Inner layer for subsequent heat sealing |
Barrier performance, seal performance, and product compatibility should be evaluated against the actual shampoo formulation, equipment conditions, and customer filling trials. The material names alone do not establish suitability for every product.
Prepress Files and Color References
Preparing four designs together required translating their appearance into executable production files.
Layout and specification checks: Incorporated the artwork, dimensional revisions, and agreed print requirements into the production layout.
Separations, overprint, and trapping: Used ESKO ArtPro+ for color separation, overprint settings, trapping, and preflight. Trapping introduces a controlled overlap between adjacent colors to reduce visible gaps caused by small registration variations.
File preflight: Checked fonts, image resolution, bleed, and barcode placement, with required adjustments submitted for confirmation before production.
Proofing and color comparison: Used GMG ColorProof digital proofs as color references and performed the agreed ΔE comparisons. Measurement methods and acceptance tolerances followed the project requirements.
Any CGATS measurement data or other color records must be agreed within the project scope and confirmed as available; they are not default deliverables for every order. Explore HUAYN’s packaging design and prepress services.
HELL Engraving and Management of Four Cylinder Sets
The project used seamless steel cylinder bases, copper-layer preparation, polishing, and German HELL electromechanical engraving to translate separated artwork into gravure cells. These processes provided the printing-form foundation for small text, fine lines, tonal gradations, and ink transfer.
HelioKlischograph is HELL’s engraving-machine series; HelioDisk supports engraving job preparation and parameter management. Engraving files underwent technical checks before production. The four sets, totaling 28 cylinders, were prepared to consistent project requirements and linked to their respective artworks.
HUAYN retained the cylinders. Potential repeat orders still require a review of artwork versions, specifications, and cylinder condition. Applicable cylinder warranty terms are governed by the order agreement. Learn more about gravure cylinder manufacturing.
ELS Gravure Printing and Lamination
The project used electronic line shaft (ELS) gravure printing. Press setup accounted for the material, print repeat, web tension, and color reference. Color and registration were checked throughout printing and adjusted within the approved production requirements.
Lamination management covered the material combination, process, and curing requirements, with bond strength, appearance, and odor checks according to the order. Revised single-face and unfolded dimensions were carried into the production files to align the artwork with the intended sachet faces.
These process controls support subsequent packaging conversion; they do not replace forming, filling, and sealing trials on the customer’s actual equipment. See HUAYN’s flexible packaging printing and manufacturing services.
Quality Checks and Dispatch Coordination
The agreed checks were completed before dispatch, with records prepared according to the order requirements. HUAYN reconciled actual quantities against the production plan, documented the agreed adjustment in a supplementary agreement, and updated the packing information.
The four variants were packed on separate pallets with reinforced stretch wrapping. The packing list retained the variant-to-pallet relationship. A common carton-marking scheme was coordinated, with the receiving party assigned to apply the labels and provide photographs after arrival at the designated handover point. The arrangement was intended to reduce label damage or loss during the preceding transport leg.
Project Challenges and Responses
Challenge | Project Response |
|---|---|
Coordinating color across four distinct designs | ArtPro+ separations, GMG proofs, and agreed ΔE comparisons linked to consistent cylinder-preparation requirements |
Preserving detail within a small print area | Prepress checks for small text, fine lines, and gradients, combined with HELL gravure-cell preparation |
Translating dimensions into sachet artwork placement | Distinguished single-face and unfolded dimensions, documented the correction, and updated production files |
Keeping multiple variants identifiable during dispatch | Separate pallets, variant-level packing records, and a coordinated shipping-label scheme |
Retaining a consistent artwork basis for potential reruns | Store the cylinders and review artwork, specifications, cylinder condition, and color references before a new order |
Project Timing and Current Status
From the specification revision to dispatch, the project spanned 11 working days under China’s official holiday and adjusted workday calendar. The period crossed the Mid-Autumn Festival and National Day holidays, with dispatch completed during the National Day holiday.
All four variants were produced and packed. HUAYN coordinated the packing list, label files, and transport updates. Feedback from the customer’s subsequent forming, filling, and sealing operations will inform future improvements and potential repeat orders. This case reports production completion and dispatch; receiving-label arrangements and subsequent end-use validation are not presented as completed results.
Integrated Coordination Across the Project
HUAYN provided one point of coordination for prepress, cylinder preparation, printing, lamination, and dispatch. The project connected artwork versions, process requirements, and variant-level packing information. Its value lay in turning customer requirements into executable specifications and maintaining consistency across files, tooling, production, and shipment records, alongside the individual technical processes.
Common Questions About This Project
Was the product supplied as finished shampoo sachets? No. HUAYN supplied unfilled continuous printed laminated roll film. Shampoo contents, preformed sachets, and filling services were outside this supply scope.
Can another shampoo project use the same structure? It requires a separate assessment. PET/VMPET/PE at 80 μm was this project’s specification. A new project should be reviewed against its formulation, fill volume, equipment, and use conditions.
Can the cylinders be used for a repeat order? Their suitability can be assessed after checking artwork, specifications, and cylinder condition. Retaining the cylinders does not mean a repeat order has already been placed.
Configure Shampoo Sachet Roll Film and Request a Quote
Planning similar packaging? Configure printed rollstock for shampoo sachets and request a quote. Start with your available artwork, product application, target dimensions, and expected quantity for each design.
Include any known material requirements, filling conditions, and destination. Film width, print repeat, unwind direction, core specification, and packaging-machine details can be supplied where available; unresolved items can be clarified through technical discussion. You can also explore HUAYN’s packaging formats or contact HUAYN to discuss the supply scope.
