1. Start with the finished size, not the file size
The first step is to work from the finished product size. Measure the area that will carry the foil mark on the actual card, carton or sleeve, then allow for trim, fold lines and any glue flaps that must stay clear. A die ordered from the wrong reference point can shift the logo too close to an edge or sit across a crease, which causes trouble at press-up.
For packaging jobs, note whether the foil is going on the top panel, front face, flap or wrap-around area. For cards, confirm if the mark must sit inside a border, centred on a panel or aligned to a printed element. If you are working across several pack sizes, send each size separately instead of assuming one die will suit all of them.
- Measure the live area in millimetres
- Allow for trim, folds and glue areas
- Confirm the exact position on the finished item
- Send each size variation as a separate order
2. Prepare artwork the way the die maker needs it
Clean artwork saves time in the workshop and gives a sharper result on press. Supply a vector file where possible, with the foil area clearly marked in one solid colour. Thin lines, tiny text and over-complicated detail may look fine on screen but can disappear once the die is heated and pressed into stock.
Keep the artwork at the correct size and make sure all fonts are outlined or converted before sending. If there are fine borders, check that they are thick enough for the stock and finish you are using. Uncoated board, textured paper and laminated packaging all behave differently, so a detail that works on one job may need adjustment on another.
- Use vector artwork where possible
- Outline all fonts before supply
- Mark only the foil area clearly
- Avoid hairline rules and tiny copy
- Note if the stock is coated, uncoated or textured
3. Check the die type and mounting method before ordering
Not every die fits every press or job setup. Before you place the order, confirm the press model, the mounting method and the size of the die plate or chase area. The mounting detail matters because a die that is too large, too small or drilled incorrectly can delay production and cost extra fitting time.
If your job uses multiple logos, a repeat pattern or a long strip, ask whether the die should be made as one piece or split into sections. For short runs or variable work, the mounting system may need extra support to keep pressure even across the form. In Johannesburg and surrounding areas, many customers also plan around power cuts, so it is worth checking whether the job needs a warmed-up machine window and enough time for setup before load-shedding hits.
- Confirm the press model and mounting setup
- Check the usable plate or chase size
- Decide if the die should be single piece or split
- Allow time for warm-up and setup windows
4. Match the die to the stock and foil finish
The stock and foil choice affect how the die should be made and used. Heavy board, soft paper, coated carton and laminated sleeves each need different pressure, heat and dwell time. If the die is ordered without this information, the finished mark may look patchy, over-pressed or incomplete.
Give the supplier a clear note on the material thickness, any coating or varnish, and whether the job will be run indoors or in humid conditions. Coastal moisture can change how stock behaves, while winter dryness in Gauteng can affect static and registration. If the job must hold a deep solid area, say so early because that may change the die layout and the foil recommendation.
5. Confirm mounting marks, registration and orientation
Before a die is cut, confirm how it will sit on the job. Mark top, bottom and front edges clearly on your artwork or reference sheet so there is no confusion during mounting. If the design must line up with print, embossing or die-cutting, give the exact registration points and say which element is the main reference.
Small errors at this stage can create waste on the press, especially where the foil sits close to a window, cut-out or fold. It helps to send a simple drawing with measurements from the nearest edge and a note on the reading direction. That small bit of extra detail often saves a second make-up run.
- Mark top, bottom and front edges
- Give exact registration points
- Note the reading direction
- Show distances from the nearest edge
- State if the die must align with print or cut lines
6. Use this final checklist before you place the order
A complete order usually moves faster through the workshop and onto the press. Before sending it off, check that every measurement, file and note is correct. If you are ordering for a client, ask them to sign off the size and position in writing so there is no uncertainty later.
FoilPress works with card and packaging businesses across Industria West, Roodepoort, Randburg, Midrand, Sandton and Germiston, and we also supply nationwide. If you need help with a new setup, our team can assist with die mounting, foil matching, heater calibration and pressure setup so the die performs properly from the start.
- Finished size confirmed in millimetres
- Artwork supplied clean and in the right format
- Material and finish noted clearly
- Mounting method and press type confirmed
- Registration points and orientation checked
- Client sign-off saved before production
For direct help, send a message through our contact form with your artwork, measurements and any press details you already have. A few minutes spent checking the order now can save hours on press later, especially on tight packaging runs.
