Design Resources

Templates and Design Guidelines

Our Process

SonderPak will digitally print your art on high-quality flexible packaging substrates in CMYK, often referred to as 4-color process or 4CP. This will all happen on our state-of-the-art HP Indigo digital presses. The printed packaging will then go through the lamination process, which will add a visual element and protective layer to your design. 

Our presses are calibrated to G7 Gracol standards to get each and every package to match as closely as possible. If color is a personal obsession (which we completely relate to), please explore our proof options.

  • HP Indigo 20000 Digital Roll-Fed Flexible Packaging Press
  • Karlville Pack Ready Lamination System
  • Karlville KS-DSUP-400 Flexible Pouching Machine

Our lineup of proven flexible packaging equipment and digital processes are designed to deliver the highest quality flexible packaging, with the following benefits to you:

  • Fast setups for high SKU counts, frequent copy and art changes, and rapid changeovers
  • Variable printing capabilities for variable art or content
  • Simple lot/exp updates without the need to reproof
  • The ability to accommodate a wide array of sizes
  • High capacity volume for short runs and low minimum order quantities
  • No plate costs
  • Sustainable processes and solutions
  • Available pre-made open top and zipper sachets, zip-seal and CRSF closures, gusseted stand-up pouches and bags, and many other options

Helpful Links


Design Recommendations

Please keep in mind that closely following the recommendations below will speed up the time required to approve and produce your printed packaging. We appreciate your attention to detail!

  • Set colors to CMYK – no RGB, Pantone, spot, book or lab colors
  • Embed all images and assets that are linked
  • Convert text to outlines
  • Hide / turn off direction layer
  • Save Adobe PDF preset “High Quality Print” with document bleed settings on or set at 0.5 in
  • Tolerances: View Our Print Tolerance Guidelines document and the design templates for details

Using Templates

  1. Open with Adobe Illustrator (version CC or later preferred)
  2. Review the directions layer for instructions and tolerances
  3. Turn off directions layer before saving
  4. Design artwork on art layer only
  5. Leave "Nosco" swatches (in folder), as is. Do not use them in your design
  6. Save document as described in "directions" layer
  7. 80% minimum UPC and QR codes with quiet zone according to design tolerances
  8. All QR and UPC codes should be 100% black (K, not CMYK)

Downloadable Art File Design Templates aka Dielines

Reference Dimensions Template Style
210272 3.5" x 3.5" Fold-Over 2-Side-Sealed Sachets
210377 3.5" x 4.00" Fold-Over 2-Side-Sealed Sachets
210376 3.5" x 5.25" Fold-Over 2-Side-Sealed Sachets
210384 4.00" x 4.00" Fold-Over 2-Side-Sealed Sachets
210386 4.00" x 5.00" Fold-Over 2-Side-Sealed Sachets

All dimensions shown in inches W x H. W=pouch width, H=pouch height

Reference Dimensions Template Style
210385 4.50" x 5.25" x 0.0" Regular Zipper Pouch
210390 4.50" x 5.25" x 2.0" Gusseted Stand-Up Zipper Pouch
210387 5.00" x 7.00" x 2.5" Gusseted Stand-Up Zipper Pouch
211309 5.50" x 8.00" x 2.5" Gusseted Stand-Up Zipper Pouch
210471 6.00" x 7.00" x 2.0" Gusseted Stand-Up Zipper Pouch
210470 7.00" x 8.00" x 3.0" Gusseted Stand-Up Zipper Pouch
211096 7.00" x 11.75" x 5.0" Gusseted Stand-Up Zipper Pouch
211436 7.50" x 9.00" x 3.0" Gusseted Stand-Up Zipper Pouch
210391 8.00" x 5.50" x 3.0" Gusseted Stand-Up Zipper Pouch

All dimensions shown in inches W x H x G. W=pouch width, H=pouch height, G=total length across gusset

Reference Dimensions Template Style
210395 4.50" x 6.00" x 0.0" CRSF Regular Zipper Pouch
210393 4.50" x 6.00" 2.0" CRSF Gusseted Stand-Up Zip Pouch
210396 5.00" x 7.00" x 2.0" CRSF Gusseted Stand-Up Zip Pouch
210397 6.00" x 7.50" x 2.5" CRSF Gusseted Stand-Up Zip Pouch
210394 7.50" x 8.50" x 3.0" CRSF Gusseted Stand-Up Zip Pouch

All dimensions shown in inches W x H x G. W=pouch width, H=pouch height, G=total length across gusset


Material Specifications