Litho lamination combines the strength and protective properties of corrugated board with the high-quality graphics of offset printing. A separately printed paper sheet is bonded to the surface of corrugated board, creating packaging that can deliver detailed images, fine text, smooth colour transitions and a premium appearance while retaining the structural advantages of corrugated packaging.
At Pack & Roll, we use litho lamination for packaging where visual presentation is just as important as protection. It is particularly suitable for premium consumer goods, electronics, beverages, gift products, retail packaging and other applications where the package forms an important part of the customer’s first impression.
Offset Print Quality on Corrugated Board
Direct printing on corrugated board is suitable for many packaging applications, particularly when simple graphics, logos or product information are required. Litho lamination offers another option when the design calls for finer detail or more demanding visual reproduction.
The artwork is first printed by offset lithography onto a smooth paper sheet. Because printing takes place on a flat, high-quality surface rather than directly on corrugated board, the process is well suited to detailed graphics, photographs, fine typography and controlled colour reproduction. The printed sheet is then laminated onto the corrugated substrate to create the finished board construction.
Pack & Roll works with specialist printing partners to produce the individually printed top sheets required for each project. Depending on the design, these sheets can be supplied with gloss or matt finishes, varnishes or suitable surface films before being laminated to the corrugated board.
The Litho Lamination Process
Once the printed sheets arrive at our facility, they are bonded to corrugated board using a laminating machine and water-based dispersion adhesive. Accurate bonding is essential because the printed artwork must remain correctly positioned for subsequent converting operations such as die-cutting and creasing.
After lamination, the sheets are allowed to rest for approximately 24–48 hours before further processing. This stabilisation period allows the laminated construction to settle before it moves to the next production stage. At Pack & Roll, litho-laminated sheets are typically converted into finished packaging using flatbed die cutting, which enables precise cutting and creasing of complex box shapes.
Premium Appearance with Structural Strength
The key advantage of litho-laminated packaging is that it brings together two different capabilities: high-quality printed graphics and the strength of corrugated board.
Corrugated board itself consists of one or more fluted paper layers bonded between liners. This construction provides rigidity and resistance while remaining relatively lightweight, making it suitable for protective packaging. By adding an offset-printed outer sheet, the same structural packaging can also act as a strong visual communication surface. This makes litho-laminated corrugated packaging particularly useful for:
- premium retail boxes;
- consumer electronics packaging;
- wine and beverage packaging;
- gift and speciality products;
- branded e-commerce packaging;
- promotional packs and displays.
The final packaging can therefore protect the product throughout handling and distribution while also presenting the brand professionally at the point of sale or during unboxing.
Designed for Further Converting
Litho lamination is normally one stage within a broader packaging production process. Once the laminated sheets are ready, they can be die-cut, creased, folded and glued depending on the required box construction. Corrugated converting commonly combines these operations according to the customer’s packaging specification.
For custom packaging projects, Pack & Roll can support the complete process from structural design and prototype production through litho lamination, flatbed die cutting and final converting. This helps ensure that the graphics, structure and production method are developed as one integrated packaging solution.
Litho Lamination from Pack & Roll
Pack & Roll has been manufacturing corrugated packaging since 1996. Our litho lamination service is intended for customers who need more than a conventional transport box and want to combine reliable corrugated construction with high-quality printed presentation.
Whether you already have finished artwork and a packaging specification or need support developing a complete custom solution, we can help turn the concept into production-ready packaging. Send us your packaging dimensions, required quantity, artwork requirements and intended application, and we will help you determine whether litho-laminated corrugated packaging is the right solution for your product.