The shape of tomorrow’s technology will be a synergy of what we know and what we imagine.  That’s why DISC commits energy and resources to incorporate new, innovative processes and the latest equipment to advance the art and science of print.

Below feature our current arsenal of equipment that enables us to create Packaging, Mini-flute Packaging & Displays and Printed Label solutions for you.

 

Packaging Group Equipment List

Electronic Prepress

Full service pre-press and desktop services
Fuji Final Proof (digital proofer)
Two (2) 1.3 TB file servers
CIP3 Technology Plate Scanning System
AGFA Avalon N16-50 VLF Thermo platesetter
Full FTP capabilities and state-of-the-art digital workflow

Structural Design

Three (3) CAD/CAM workstations supported by CIMEX software
DATATECH DP53348 sample maker/plotting table with automatic scoring
Artios package design software
Mimaki CF1215 sample maker/plotting table
Mimaki CF2830 sample maker/plotting table

Proofs

Epson Stylus 9900-with X-Rite Spectro Proofer Color Calibration
Kodak Approval Proofing System (including Hexachrome® ink simulation)
Fuji Final Proof System
Extensive sample cutting and mounting capability
Soft proofs and digital rendering
3-dimensional rendering

Quality Control Lab Equipment

Sutherland Rub Tester
Testing oven
Grind gauge
Lansco light
Moisture sword
Grams scale

Sheeters

Two (2) Maxon MSH 350 57” high-speed sheeters with double roll slitters

Ink and Coating Lab

In-plant Ink Lab with full proofing and mixing capabilities

Printing

DISC offers the flexibility and benefits of several print formats.

Digital

Kodak NexPress S3000 press – prints 5 over 5, with in-line coating, on a wide range of substrates (up to 14” x 20”)

Offset Lithography           

6-color, 56” KBA Rapida offset press, with interstation UV and in-line aqueous & UV coating

8-color, 40” Heidelberg 102-CD press with interstation UV, in-line aqueous & UV coating, in-line cold foil stamping capability, and the latest print-on-plastic technology

8-color, 40” Komori LSX841 offset press with in-line inspection system that utilizes high-speed cameras to inspect printed sheets for defects and mark them for operator intervention. The system alerts the press crew to the type of defect and position of the defect on the sheet. The in-line color management system is state of the art and assures color consistency throughout the print run. The press is equipped with two in-line coating units for unique coating applications for both aqueous and UV coating.

Silk Screening

Sakurai 32” x 45” silk screen press, using UV inks and coatings

Embossing, Stamping and Die-cutting

56” Bobst-142CER high-speed die cutter with blanking capability
40” Bobst-103E high-speed die cutter with stripping capability
40” Bobst-103ER high-speed die cutter with blanking capability
Bobst-142 Easy Press Pre-Make Ready System
Bobst-103 Easy Press Pre-Make Ready System
40” Bobst-102 BMA stamping press

Finishing: Windowing, Folding & Gluing

Bobst Expert Fold straight-line folder/gluer with AccuCheck inline carton inspection and Cartonpack Automatic Case Packer
Miehle 28” x 40” UV coater
International 5AU window application machine
42” Kohlman 1050 combination window placement and patcher
Heidelberg Diana Pro 114 folder and gluer
Vega 400 straight-line folder/gluer
International right-angle folder/gluer
International 6FX straight-line folder/gluer
International Speed King straight-line folder/gluer
Bobst Domino 100 straight-line cutter
Bobst Cartonpack GT Automatic Case Packer
Quadrel Labeling Unit
Videojet Inkjet numbering unit

Bindery

45” Jagenberg computerized guillotine cutter
45” Polar Mohr programmable computerized guillotine cutter
62” Polar computerized guillotine cutter
Stahl 4-plate buckle folder
Stahl 6-plate buckle folder
Beseler 15” x 17” shrink wrap packer
Pallet film wrapping

 

Label Group Equipment List

Printing:  Flexography

10-color, 10.75” Nilpeter PB2500 flexo press, with interstation UV, dual-web capabilities, film lamination, turn bar, conveyor/stacker, and Video Web Inspection System

HP Indigo WS6600 Digital Press-prints seven colors with an ABG Omega Digicon Series 2 Module for die cutting and coating over a wide range of substrates (13” wide web).

Inhouse Ink Lab with Easy Ink Controller System for mixing, matching and inventory control
More than 1,100 dies and 1,000 print cylinders
Over 75 Anilox rollers
Ultrasonic Anilox cleaners
Stratix Examiner Elite Code Verification Unit with printer
X-Rite Spectrodensitometer
Dual-camera Precision Plate Mounting System         

Rewinding and Inspection

Rotoflex VS1330 Slitter / Rewind / Inspection
Arpeco Slitter / Rewind / Inspection
2-web technique table top
Slitter / Rewind / Inspection Stations

Sequential Numbering

Videojet XL high-speed printer
Markem-Imaje 9040 Ink Jet Printing System

Electronic Prepress and Plating (Digital Workflow)

Xante, OpenRIP flexo 7.0 flexo workflow software
Freeform ganging speeds production
Latest Adobe PDF print engine (APPE)
Integrated PANTONE® color libraries
Flexo CTP: Dupont Cyrel “FAST” 1000TD with Esko CD 1 Spark 4835 platesetter (non-solvent based eco-friendly platesetting system)
Kodak Approval Proofing System  
Full FTP capabilities and state-of-the-art digital workflow

 

 

California Design Studio

Located in Culver City California
Full service comp and package develop resources for embossing, stamping, and a myriad of finishes and substrates. Equipment includes:

Kongsberg Plotter/Sample Maker
Artios package design software suite

Graph-Corr

Our Graph Corr facility, located in Dayton, New Jersey, produces mini-flute (B, E, F, and N Flute) for packaging and displays

Bobst Asitrade MPC Laminator (corrugating equipment); Sheet size maximum 63 x 65 and Roll-to-Roll maximum 63 x 72

Bobst SP142 CER Die-cutter; sheet size maximum 55 7/8 x 40 1/8
Bobst EZ Press 142

International – Speed King Folder/Gluer
International- Speed Queen Folder/Gluer

Staude Gladiator Window application unit; window size maximum limit is 24 x 28 and minimum is 2.5 x 1

 

We have your back at DISC.  Every day, we work hard to develop new security solutions that give you superior brand protection and anti-counterfeiting measures as soon as new technologies emerge.

Across the globe, packaging security is being compromised by the dramatic growth of product counterfeiting and grey market diversion of major brands.  It is a significant challenge, costing brand owners in all markets billions of dollars in revenue and eroding consumer confidence every year.

 

NEWS:
Fake Cancer Drug Found in U.S.

The Wall Street Journal reports on fake cancer drugs found in the US. How should hospital and doctors authenticate the product? Look closely at the packaging.
Look at DISC’s PASS program for possible solutions!

http://online.wsj.com/article/SB10001424052970204059804577225640701811020.html

 

 

Our new Package Authentication Security Solutions™ (P.A.S.S.™) is a significant step toward meeting that challenge and strengthening our already rigorous security and quality assurance program.  It represents the culmination of research, prototyping and testing in partnership with leaders in the security industry. P.A.S.S. is a comprehensive program of anti-counterfeiting solutions that provide package protection and authentication to ensure product confidence across your supply chain.  It is a set of technologies, combined in a multi-layered approach that can be customized to meet your unique requirements.

 

How is P.A.S.S. a different approach to the counterfeiting problem?

At DISC, we see packaging having an active role in brand protection by weaponizing it with technology to deter and defeat counterfeiting. While most printers seem to be waiting for customers to come knocking before acting, in the P.A.S.S. program we’ve assembled world-class technology partners to help deliver customized solutions targeting the customers’ authentication and brand protection issues. We started by providing DNA as a blanket protection for all customers, which can be combined with an array of technologies including those listed below:

 

 

LEVEL 1:  SigNature® DNA Taggants for Forensic Authentication

SigNature® DNA, our exclusive core technology for the packaging industry, provides irrefutable forensic evidence of authentication.  Its uniquely sequenced DNA taggants, made from botanical material, are virtually impossible to copy and have been used successfully as markers for forensic evidence by law enforcement around the world.

This patented and proprietary product, developed by Applied DNA Sciences, is the centerpiece of P.A.S.S., our expanding, integrated packaging security program.  It is versatile, stable and cost-effective, and will not alter the quality of any product.  Combined in ink, varnish, adhesive and textile treatments, it can be detected with a hand-held device and verified in laboratory testing. 

DISC can develop a custom program for you to match the security requirements of your products.

 

LEVEL 2:  Devices for Field Verification

Machine-readable devices – ranging from QR (Quick Response) codes to fluorescent inks & coatings to micro printing – are designed to support security measures for supply chain partners, as well as law enforcement.

Specialized Pigments.  Fluorescent pigments, added to inks and coatings, are invisible to the eye but can be seen using specialized security inspection techniques.  These security features cannot be copied and can be integrated into inks, paper, packaging, and plastics.

Micro Printing. This security technique involves printing very small text, often too small to read with the naked eye and frequently hidden in an inconspicuous, unnoticeable area on the item.  DISC utilizes the latest specialized software to generate unique patterns or text hidden in packaging graphics.
 

QR Code Readers in Smart Phone Applications.  In partnership with Applied DNA Science, product identity using serial numbers and profile data can be entered into a company’s system or in cloud-based Rapidna-QR systems (for automated scanning and/or easy input).  Consumers, retailers, distributors, and other users can access information about the product, facilitating track and trace requirements for verification.

 

LEVEL 3:  Systems for Brand Owner, Retailer & Consumer Confirmation

There are a number of systems that can be used to easily verify a product or brand, most notably human readable codes, holographic images, and tamper-evident structural designs or labels.

Human-readable Identifiers.  Alphanumeric codes imprinted on a package can be read with the naked eye – providing brand owners, retailers, distributors, and consumers the ability to confirm authenticity with the aid of an online database. 

These codes comply with recent FDA guidance for securing the drug supply chain using Standardized Numerical Identification (SNI) for prescription drug packaging.  An SNI should be a serialized National Drug Code (sNDC) that corresponds with the specific drug product and package configuration, combined with a unique serial number from the manufacturer or re-packager of the package. 

DISC’s partner company, Applied DNA Sciences, can generate and provide a registry of codes and a web-based solution for code verification using smart phone applications.

Holographic Security Foils.  Customized holographic foil patterns used to authenticate a product can be incorporated into your packaging by DISC.  Working with our supplier partner Kurz Foil, we can create custom foil patterns or holograms, or use a standard pattern to serve as a unique security marker on your packaging. 

Tamper-evident Structural Design or Label.  We can incorporate design elements in your packaging that can signal evidence of tampering, such as micro-perforations, tamper-evident labels, and structural design devices.

Creating sustainable packaging requires a balanced approach.  We need to weigh the environment, performance expectations, brand, value and cost.

How do we define sustainable packaging?

To create a definition we need to look at the expected role of packaging combined with the generally recognized attributes of sustainable packaging.

The role of packaging

• Preserve and protect the product
• Communicate and educate
• Offers convenience: portion control, single serve, shelf ready, easy to display, transport or store
• Packaging helps sell the product and convey the brand’s image and value

General attributes of sustainable packaging

• Packaging weight and volume has been reduced – source reduction.
• Waste-to-landfill outcomes have been reduced through designed in recyclability, reusability or degradability of the substrate
• Lower environmental impact in terms of resources used as well as emissions to air and water
• Packaging that effectively reduces waste through extending shelf-life and prevents damage or contamination
• Packaging that is able to effectively communicate and engage consumers as to brand attributes and sustainable credentials

Definition

Sustainable Packaging is defined as packaging that achieves its intended role while minimizing resource requirements and maximizing opportunities for recovery, recycling and reuse, and reduce its impact from end-of-life disposal.

At DISC we work with clients, suppliers and stakeholders to ensure that we strike a balance of business and eco-friendly objectives to develop packaging systems that will be sustainable for future generations.

For more information on how we can help you review your packaging and improve its sustainability and minimize it environmental impact please contact your sales representative or John Rebecchi, Senior Vice President

DISCover Green Program

Our DISCover Green Program was developed to provide sustainable packaging solutions. The mission statement of this program – “Moving Eco-Consciousness into Action” – is one that we take seriously and literally, and we have the “green” credentials to prove it.

We have been an FSC Chain-of-Custody supplier and an EPA Green Power Partner since 2007, reflecting our commitment to use renewable materials and energy responsibly. We seek out ways to give you “greener” options – from adding energy-efficient in-line cold foil stamping andDISCover Green Paper, to creating re-usable shippers for clients like LNK International to reduce your carbon footprint.

We are your partner in a step-by-step process to discover new environmentally-friendly possibilities – with a fresh spin on the traditional R’s of sustainable packaging:  Rethink / Resize / Reconstruct.

Step 1:  Define Your Objectives.  The objectives of your environmental strategy become our roadmap to a successful eco-design program for you.  We begin with source reduction options, finding ways to right-size your packaging or decrease energy requirements.  We replace non-sustainable materials with recycled, recyclable or certified choices.

Step 2:  Create Packaging that Matches Those Objectives.  It does not stop with choosing “greener” materials and processes.  We evaluate product and package lifecycles, distribution and sales channels, and potential consumer value perception.  

Step 3:  Measure the Results.  At the end of the day, we want to know that what we do makes a difference.  Our Eco-Resource Coordinator and design team work with you to meet your objectives – and then prove it by calculating the metrics that demonstrate the eco-effectiveness of the packaging we design for you.

DISCover Green Paper

Paper Made with Sustainability in Mind

An exclusive DISC offering, DISCover Green Paper is a tree-free, energy-efficient alternative to conventional wood-fiber based paper.  It is made from readily available calcium carbonate mineral powder and small amounts of plastic resin used as a binding agent. 

Compared with conventional paper, it uses a third less energy, zero water and no chlorine during the manufacturing process and emits 50% less CO2, resulting in a low carbon footprint. It is recyclable when collected with #2 plastic packaging waste.

DISCover Green is a bright white paper with good printability and excellent color contrast that will bring your graphics to life.

At DISC, Packaging Innovation is at the core of our business objectives.  As we look to the next generation of packaging solutions, we embrace the exciting challenges and opportunities on the horizon.  Emerging technologies, innovative manufacturing processes, and advancements in printing & packaging equipment will converge to change the face of packaging and fuel future growth.

This year, we have invested in innovative processes and package enhancements, like the two cited below, as well as new DNA-based security solutions.   We look forward to sharing more exciting developments in the near future.

In-Line Cold Foil Stamping

DISC is excited to be one of the first packaging companies to offer in-line cold foil stamping as an innovative alternative to hot foil stamping and foil board applications.  This value-added technology gives designers – yours and ours – a dynamic and versatile tool to take packaging graphics to a whole new level. The effect of overprinting translucent inks onto spot or overall silver foil is stunning. 

We have retrofitted the two front units of our 8-color Heidelberg press to accommodate in-line cold foil stamping.  As a result, we can print up to 6 ink colors or a combination of inks and coatings onto foil in a one-pass operation.  The foil, available in solid, patterned or holographic silver, can be embossed to provide even more graphic possibilities.

Other benefits of this innovative operation are numerous:  high performance, efficient manufacturing, cost-effectiveness (no expensive stamping dies!), shorter set-up times, and no need to inventory foil colors.  And, in addition, this technology is energy efficient and decidedly “green”-only 1500 watts of electricity are needed as compared with 22-25,000 watts for hot foil stamping equipment.

This new packaging innovation from DISC will greatly enhance the look of your brand.

Magnetic Closure

DISC’s new automated magnetic closure application system recently made a successful debut in the market.  This patent-pending innovation is a unique re-closable mechanism and a revolutionary alternative to the standard Velcro® hook-and-pile fastener or fugitive glue currently used to fasten packaging. 

The application process is a simple one in which magnets and related receptors are registered and embedded in the package at the point of closure, such as the flaps of a book-style carton.   Because it is simple and discreet, the magnet does not intrude on packaging art.  In addition, consumers can easily open and close the package as they browse at retail, without damaging the carton. 

It’s all done automatically.  The device, mounted to a conventional folder-gluer, replaces a 3-step hand application to apply the magnet, receptor and final gluing with an in-line one-step operation.  It is an affordable, reliable choice that accelerates the manufacturing process.

The new DISC automated magnetic closure has already been successfully incorporated in packaging for a software language series, and other companies are taking a serious look at it.

Marketers of certain products, particularly in high-end Beauty, Consumer and Entertainment categories, demand complex Special Packaging Solutions that convey value, power, prestige, and excitement.  DISC excels in this area.  We are adept at creating custom-designed carriers, rigid box sets, set-up boxes, and unique structures that showcase our clients’ best work.

Special Packaging is an art form that has evolved over the years.  It began with dramatic packaging for music compilations and blockbuster movies and is now part of the sales strategy for a myriad of products in all markets.  Strong design focus, multiple components and materials, unique closures, and attention to detail are essential elements for success -- whether we are creating a unique setting for an expensive designer fragrance, a prestige brandy gift set or a multi-disc TV series or video game.

Sourcing

The components and materials needed for outstanding Special Packaging are often not the typical nuts & bolts you find on the shelf.  It takes time and experience to source the right ingredients to bring a unique concept to life.  The DISC Special Packaging team knows how and where to look.  We have strategic resources, both domestically and internationally, for a broad range of materials and embellishments – from metal hinges and closures, to thermoform inserts, to ribbons and bows.

Project Management

The key to a successfully executed Special Packaging Solution – delivered on time and on budget – is careful project management.  That’s why we tackle each one as a team – made up of designers and packaging engineers, account executives and CSRs, and experts in manufacturing, QA and purchasing. 

We keep you informed using our “Project Management Dashboard Report” that alerts you to critical dates and project requirements. Our objective is to make sure we meet your objectives in every way we can.

When the NEO Blu-ray disc package grabbed the attention of major film studios last year it demonstrated how innovative ideas can change the marketing strategy of an entire industry. Now DISC introduces the application of NEO to the beauty market by transforming its aesthetic appeal and structural integrity for use as a folding carton. The NEO cartons incorporate DISC’s patent pending process that utilizes a composite of APET plastic and Silver Mylar lamination, which is combined with a cut score to create an exceptionally square edged carton. We are also launching NEO-lite, an o-sleeve version for standard DVD and Blu-ray cases. Other markets we’re focused on include vinyl record jackets, CDs and video games.

In the 37 years since the introduction of the Digital Disc for delivery of various media there has never been a package that brought together performance, graphic excellence, superior quality and sheer beauty in a single form, until now.  

Consider NEO. Sleek, clean, immensely satisfying to handle and touch, guardian of the contents within. Unobtrusively functional from closure to disc retention, lacking any unnecessary embellishment to detract from graphic panels that might have come straight from the silver screen, NEO speaks to you, an object of desire.

Physical Media Packaging for a Digital World

About NEO™

The NEO package is a dynamic, patent pending Blu-ray™ disc package that is a visually stunning and sleek alternative to traditional special packaging.  Designed for collector-level Blu-ray disc products, it answers the call for new, advanced, contemporary packaging for multi-disc film, video game and music compilation releases. NEO’s frameless, hyper-glossy art panels provide a seamless presentation ground for title graphics. The current package is designed to hold two discs in embedded printed cavities using a unique retention method that is at once robust and unobtrusive. Three and four disc versions of the NEO package will be available in late Q1 2014. 

The NEO package includes a revolutionary lithographic material, PixelChrome, ™ a patent pending design that incorporates highly reflective substrates in a multi-layer composite – much more consistent with smart phone technology than traditional plastic disc cases – to produce packaging with unprecedented finish. A major functional component to safeguard the contents is the hidden magnet that maintains a secure, yet soft closure.   

In the highly competitive personal care industry getting consumers to try your products can be challenging. Sample or trial size packets are a convenient and cost effective way to get in front of the consumer. At DISC we’ve made managing printing promotional sheets and affixing or tippingon packets easier with one-stop-shopping. Our 30+ years of printing and packaging experience combined with high-speed automated affixing simplifies managing a sampling program.

• Full service printing and converting capabilities
• Automated and highly accurate glue application and tip-on of packets
• Multiple lines for high volume projects
• Dedicated project management staff and computerized production tracking assures accurate and timely reporting to meet your requirements
• Experienced with the insertion requirements of national magazines and luxury retailer promotions

DISC provides an extensive array of assembly and fulfillment services to support our customer’s requirements for turnkey services. This next step allows our customers to issue a single purchase order encompassing folding cartons, labels, product pack-out assembly and fulfillment, so that DISC is a one-stop-shop for all these products and services.

Services Include:

• Packaging and Assembly
• Hand gluing
• Displays
• Kitting
• Labeling
• Source tagging
• Automated application of pouches and packets
• Inkjet coding
• Secured Facility and Inventory

DISC’s finishing and converting capabilities top off our line-up for the packaging and labeling products we manufacture.  We take great care to ensure that the final steps in our process – windowing, folding & gluing and bindery requirements – reflect the same quality and attention to detail you are accustomed to receiving from us. 

Windowing

There are certain products that consumers like to see before they commit to a purchase.  It may be a new cosmetic or personal care item or a premium toy that promotes a children's movie.  Marketers in our client companies turn to DISC to augment their packaging with various see-through windows that do the job without endangering the contents of the package.

To that end, we can design windowing in a number of styles:

• Rigid windows made of 7 mil to 25 mil plastic film
• Panoramic windows that wrap around the front and sides of a package
• Cello or “patch” windows in a variety of sizes
• Windows embellished with decorative treatments like foil, printing or specialized coatings
• A variety of materials, including APET, PVC, PET, RPET, and PLA

Folding, Gluing, Bindery

The final steps in the production of a folding carton or special package are often the most critical.  Performed to perfection, they help to ensure product integrity as well as functionality.  DISC offers a range of folding and gluing options to match the construction, configuration and requirements of the packaging we produce. 

Some projects also require fulfillment operations.  We have the capabilities to apply source tags for electronic article surveillance in-line for consumer product packaging.  Coupons and promotional cards can be placed directly on packaging prior to gluing or wrapping them for shipment.

Our bindery is staffed with expert craftspeople trained in the latest computer-based cutters, folders, and specialty die-cutting equipment to meet any and all requirements.  We take the utmost care with these last steps so that our clients are satisfied enough with our final creations to come back for more.

DISC has an impressive palette of decorative effects that create excitement, value and brand differentiation.  These graphic treatments are part of the in-house services that we provide to companies in all markets.  Some are applied in-line during our printing operation.  Others are part of separate specialized processes.

Our current choices in decorative effects include:

Special Inks, Coatings & Substrates

Embossing and Foil Stamping

Special FXs

Precision Die-Cutting

 

Special Inks, Coatings & Substrates

 

A variety of sensory effects are achievable just by changing one or more elements in the mix.

 

New ink formulas add luster, sheen, mood, and extra “pop” – pearlescent, metallic, fluorescent, glow-in-the-dark, heat and photo-sensitive, scented, custom pigments – the list goes on

Unique coatings provide a variety of aesthetic experiences:

Luminous pearlescent appearance

Smooth and subtle DISC “Soft Feel” suppleness

Gritty or sandpaper-rough textures

Reticulating patterns

Water drop and blood splatter coating liquidity

Shimmery glitter and sparkle 

Special substrates with their own individual stamp give packaging new life:

Foil or mylar-laminated board in various colors and patterns – from fine textured to geometrics to holography

Simulated leather and fabric coated board

Clear, translucent and solid plastics

Eco-friendly options like DISCover Green Paper

Novelty paper and board

Embossing and Foil Stamping

These 3-D effects can be used alone or in combination to create upscale sophistication or clever playfulness.

 

Graphics emphasized with embossing or de-bossing

Blind embossing on a solid or unprinted ground

Multi-level and deep sculpted embossing

Combination embossing and foil stamping effects

Hot foil stamping in a variety of foil leaf metallics and colors as well as transparent foil

Innovative in-line cold foil stamping – a thin, silver foil leaf overprinted with up to 6 ink colors or a combination of inks and coating – a NEW versatile, cost-effective option from DISC

Special FXs

Some unique decorative effects are in a class all their own.

Lenticular Graphics add visual impact, fun and excitement in unusual ways.  Created by the combination of digital images with specially designed plastic lenticular lens, they fool the eye and engage the imagination with unique animation.

3-D illusions of distance, depth and motion

Flip – two or more images flip back and forth to provide before & after or cause & effect

Morphing – two or more unrelated images gradually transform into one another

Zoom – objects seem to move from foreground to background

Light & Sound bring a package to life and add an element of surprise.  L.E.D. light and sound chips can be applied to the inside of a package as an attention grabber or a security feature.

Precision Die-Cutting

Our highly skilled craftspeople are adept at applying sharp die-cut windows and intricately “carved” design motifs when the situation calls for it.   We have the most advanced, automated technology available to ensure accuracy, consistency and quality controls every step of the way.

Folding Cartons

Folding cartons are unquestionably the most versatile form of packaging used to market products in all categories.  At DISC, we offer our clients the advantage of that versatility plus choices – in materials, carton styles and structural details well before the presses roll. 

Our design and production teams have extensive experience with a library of standard tube or tray-style cartons and optical disc templates, as well as customized structures, to match your product’s requirements.  With the right combination of size and style, clever closures and detailed windowing or die-cuts, they can transform any folding carton into a unique package perfect for the materials and graphics you have chosen.

We have an equal facility with a variety of grades and calipers of substrates, including: 

• Paperboard – SBS, SUS, CCNB, TMP, and others in all available calipers
• Special paper in heavy-weight cover stock
• Foil and mylar-laminated board
• Mini-flute and micro-flute container board – E, F and N-flute
• Plastic, including PVC, PET, RPET, PLA, polypropylene, and others

Whether we are developing a hexagon-shaped carton to launch a fragrance, or a standard DVD slipcase and O-card for a new movie release – we take the same meticulous approach to packaging production.

Labels           

DISC offers the experience, expertise and resources needed to produce high-quality labels for many of our clients.  Our Quality Management System, with its emphasis on meeting the FDA’s regulations for current Good Manufacturing Practices (cGMPs) and ISO 9001:2008 standards, ensures that we meet the strict requirements for labels used in the OTC and Private Label healthcare and food industries. 

Our Flexo printing process is the ideal medium to produce full-color pressure-sensitive labels and stickers, extended content labels, instant redeemable coupons, and other labeling products on paper, paperboard and plastic substrates. 

When Orange, Green and Violet (OGV) inks are added to traditional Cyan, Magenta, Yellow and Black (CMYK), the result is a significantly “extended” color gamut and the ability to achieve more rich and vibrant colors when printing. Compared to CMYK process printing alone, the PANTONE EXTENDED GAMUT Coated guide allows you to match approximately 90% of all PANTONE Spot Colors. Experience the difference: teals, corals, lavenders – so many combinations of oranges, greens and violets – all become less “dirty” and more true.

How does the PANTONE EXTENDED GAMUT Coated guide speak to you?

Designers and Brand Owners – Enjoy greater color accuracy and closer PANTONE Spot Color matches than with CMYK, fewer rounds of approval, lower printing costs, faster go-to-market time and HIGHER satisfaction.

The leading edge equipment found in DISC’s printing systems form the basis of a strategy to produce your packaging and labels to perfection.  We refine and reinvest in advanced technologies to ensure that we have the right configuration to meet your needs.  Our press room is populated with diverse press formats and specialized capabilities to embellish the final product. 

Our current press formats include:

• Offset Lithography
• Flexography
• Digital Printing
• Silk Screening

Offset Lithography           

The Litho process captures the color subtleties and sharp detailing of product packaging.  Our multi-color offset presses can accommodate different substrates in various widths as well as a range of inks and coatings – whether you need standard 4-color process or multi-color printing in a single pass.  You also benefit from our extensive experience as an authorized PANTONE® Hexachrome™ Printer.

Flexography

The Flexo process is the ideal medium for high-volume labels that demand high print quality and brilliant hues.  Our 10-color narrow web presses provide fast delivery of labels on paper, paperboard and plastic substrates.

Digital Printing

DISC added Digital Printing to accommodate clients who need low-cost, low-volume printing for quick turnaround projects.  It is especially good for P.O.P. packaging, redeemable coupons, and print-on-demand projects.

Silk Screening

The silk screen process enables us to apply spot coatings and UV inks to printed projects that need extra-added punch.

All of our printing systems can accommodate a range of inks and coatings designed to enhance and protect your packaging.  Process, UV, and special Pantone® or Hexachrome™ inks deliver exciting splashes of color.  Aqueous (water-based) and UV coatings – in overall coverage or spot matte/gloss combos – provide scuff and scratch resistance and essential finishing touches.  In addition, a wide range of decorative effects is continually expanded to enrich your packaging experience with DISC.

Any operation takes good preparation and management to be a success.  The DISC digital workflow system is no exception.  Our electronic prepress and proofing capabilities are designed to work simply, quickly and efficiently…so that what you want is what you see in the finished package.

The DISC prepress technical team works diligently to ensure that your package graphics reflect accurate color match, sharp images and precise quality.  The same is true for the production of proofs and prototypes for your approval.  While traditional proofing was a trial-and-error process that only simulated the desired effect, today’s technology allows us to create proofs that are true reflections of the final product.

We have the right tools and teams in place to go beyond your expectations.   

The DISC design group is a resource for inspiring ideas and award-winning packaging that benefit companies in every market we serve.  This talented team of structural package designers, graphic artists and packaging engineers understands the power of design to sell.  They work closely with your marketing and creative teams to brainstorm and develop the right packaging solutions for you.

Our holistic approach integrates several key criteria of good package design.  It reflects a balance of strong brand identity, perceived value, efficient costs, powerful performance, security safeguards, and environmental concerns.  We know how to translate this approach into proactive design, using the array of creative and manufacturing resources we have at our disposal.

To ensure that you get what you expect, our designers give you a preview.  We routinely produce accurate, production-quality prototypes and comps that you can examine and test drive before you ever commit to production.

At DISC, design comes F.I.R.S.T.

Function

Your packaging must function well at all levels.  It must protect, promote and inform throughout its lifecycle.  Our job is to make that happen by meeting your objectives and turning the package into the proverbial “silent salesperson.”

Image

The image of your brand is its most powerful asset.  Our designers see to it that your product is easily identified and has a dynamic shelf presence that sets it apart from your competition.

Resources

Our design team seeks out new resources and tools to create stunning design-centered packaging that is cost-effective.  From eco-friendly inks, coatings and substrates to new packaging embellishments, we start with the best to achieve the best for you.

Structure

We routinely transform standard tube and tray-style cartons and optical disc templates into cleverstructures that meet the size, shape and aesthetic requirements of your product.  And, we make sure that the package is strong enough to withstand any environmental or shipping demands.

Total Package Experience

We take a 360° view of each and every package that goes through our design process. It must reflect a total package experience, meeting your criteria for creativity, marketing savvy, production quality, and economies of scale.  Ultimately, the package must connect with the consumer and sell the brand.

It all starts with good package design.