You are ordering cardboard packaging for the first time and in the offer description you see two items that you do not understand: „creasing” and possibly „die for die-cutting”. One is included in the price, the other is a separate implementation fee. To understand why it works this way and what you are actually paying for, you need to know what these two processes are and when each of them is needed.
What is paperboard creasing and why does every box need it
Creasing is the process of pressing precise fold lines onto the surface of a sheet of cardboard or paperboard. These lines—known as crease lines or simply creases—designate the places where the cardboard will be folded during packaging formation. Without creasing, the fold of corrugated cardboard would look imprecise, and the material would crack or wrinkle along the fold or along the line closest to the flute instead of bending evenly and repeatably.
The key is that scoring does not cut the material – it only presses it along a line without damaging the structure of the outer layers of the cardboard. As a result, once folded, the packaging retains its strength and aesthetics at the edges, and every folded series looks the same.
Creasing of paper and cardboard is performed on a creasing machine (and sometimes directly on the corrugator) equipped with special tools – creasing rules or knives – which press lines into the sheet. At TEK-PAK, we use creasing machines adapted for working with corrugated cardboard of various thicknesses, from light 3-layer to heavier 5-layer. Creasing can also be performed on a die-cutter, simultaneously with the cutting (die-cutting) process.
Every flap carton – that is, a standard transport box with top and bottom flaps – is created through a combination of creasing and cutting. Creasing alone only allows for „creating” corners and fold lines – to achieve the full form, cuts (slots) are also needed along the places where the box will fold spatially, and in the case of a classic flap box, additionally a gluing tab, which is also formed by cutting rather than creasing. The die-cutting and creasing machine performs both operations simultaneously, resulting in a flat, blank box ready for shipping and assembly by the packer.
What is cardboard die-cutting and when is it necessary
Die-cutting – also known as cutting or punching – is the process of cutting a sheet of cardboard into a specific shape using a special tool called a die. For simple flap boxes, cutting takes place directly on the machine without using a die – a die is only needed for more complex shapes. Unlike creasing, die-cutting physically cuts through the material along and across the designed contours.
Cardboard die-cutting is essential wherever the shape of the packaging goes beyond a simple rectangle cut on slotter machines rather than a guillotine. This applies to die-cut packaging with irregular shapes, packaging with cutouts in the flaps or walls, trays and displays with cut-out holes, packaging with perforation for easy opening, as well as any forms that cannot be achieved through straight-line cutting alone.
A cardboard die is a tool made of plywood containing metal blades that map out the shape of the packaging. One die corresponds to one packaging design and is a reusable element – it is manufactured for the needs of a specific form and can be used multiple times for the same packaging pattern. The cost of the die is included in the cost of implementing a new die-cut design and is a one-time fee, amortized over subsequent orders, or incurred once upon the first production run, depending on the arrangement.
Creasing, cutting and die-cutting – when each is needed
This is a practical question, because the cost of implementation and the order fulfillment time depend on the answer.
In practice, we deal with three processes: creasing (see above), cutting, and die-cutting. Cutting applies to slotted boxes and simple structures produced linearly on slotter or casemaker machines – without the use of a cutting die. Die-cutting is required wherever cutting lines have different orientations and the design requires holes, perforations, hand grips, or tray-type structures. In practice, creasing and cutting cover the entire segment of FEFCO 0201, 0203 and similar slotted boxes – by far the most popular category of transport packaging.
Die-cutting becomes necessary when the project requires:
- cutting along a complex contour (irregular shape, rounded corners, cutouts)
- holes in the walls or flaps of the packaging (e.g., product display window, carrying handle)
- perforations that facilitate opening (dotted cut line, e.g., in SRP packaging)
- custom structural packaging, trays, and displays of any geometry
In short: every packaging requires creasing and cutting – this is the basis of production. A cutting die and die-cutting are needed only when the packaging has any cut-out opening, custom outline, or perforation.
Cardboard cutting die – what is it and how much does it cost
A cardboard die is a special production tool made individually for each packaging project that requires die-cutting. It consists of a plywood board in which grooves are cut according to the design, and then metal cutting blades and creasing rules are hammered in. The entire assembly, mounted in a die-cutting machine, cuts and creases cardboard sheets with high precision and in a short time.
The cost of the die depends on its complexity – the number of contours, the length of the cutting lines, the presence of creasing, and potential perforation elements. A typical die for a moderately complex die-cut packaging is a one-time cost incurred only upon the first order of a given project. For subsequent runs with the same project, the die is already ready and does not generate additional costs – provided its technical condition allows for it.
Important practical information: the cardboard cutting die has a limited service life. With high production runs, the blades dull over time and require reconditioning or replacement. At TEK-PAK, we store customers' cutting dies between orders and notify them when they need to be refurbished before it affects production quality.
How creasing and die-cutting work in the ordering process
When ordering standard-sized regular slotted cartons, the entire production process is in most cases based on creasing and cutting without a die. For very small dimensions, however, making a die may be necessary. There is no one-time tool fee, the lead time is shorter, and the minimum order quantity can be lower. This is why regular slotted cartons are the most cost-effective type of cardboard packaging.
When ordering die-cut packaging, trays, displays, and other custom forms, the initial quotation includes a „die” (or "cutting die") item. This is a one-time setup cost, after which subsequent orders of the same design are cheaper. When planning your budget, it is worth noting that the cost of the die usually amortizes after a few production runs.
If you do not know whether your project requires a die-cut, simply send a drawing or description of the packaging – at the quotation stage, we will clearly specify which process is needed and what that means for the cost and lead time.
You can find more about the die-cutting process itself at TEK-PAK on the website die-cutting. If you are interested in the range of packaging that requires a die-cut, you can find the details on the website die-cut packaging. For projects requiring both creasing and complex die-cutting, we handle them comprehensively – from design to the finished packaging delivered to your warehouse.
Do you want to check if your project requires a die-cut and how much the implementation costs? Use free quote – we respond within 24 hours.
Frequently asked questions about die-cutting and creasing
What is the difference between die-cutting and creasing? Creasing in short: pressing a fold line into cardboard without cutting it – prepares the material to be folded into packaging. Die-cutting on the other hand: cutting cardboard into a specific shape using a die, necessary for custom shapes, holes, and perforations. Both processes are often used together: die-cutting cuts the outline, creasing marks the fold lines.
Does every cardboard packaging require die-cutting? No. Standard slotted boxes with a rectangular outline (e.g., FEFCO 0201) are produced exclusively on slotting or slotting-creasing machines, without a die. Die-cutting is only required for custom shapes, holes in the walls, opening perforations, and any forms going beyond a simple rectangle.
What is a cardboard die and do I need to buy one? A die is a production tool manufactured individually for the design of packaging requiring die-cutting. Its cost is included in the quote for the first order of a given design and is a one-time fee. For subsequent runs with the same design, the die is already ready – you do not incur this cost again.
How long does it take to produce packaging that requires a die-cut? For a project requiring a new cutting die, the lead time is typically 10 to 14 business days from design approval, which includes the time to make the die and any potential prototype. For repeat orders using an existing die, the lead time is shorter and similar to that of standard slotted boxes.
Does scoring weaken cardboard? Properly executed creasing does not weaken the structure of the cardboard – quite the opposite, it prevents uncontrolled cracking of the material when bending. Creasing machines adjust the pressing force to the thickness and grammage of the cardboard, thanks to which the fold lines are precise and the outer layers of the material remain
