In packaging dies the sample is the last — and cheapest — point to catch an error before the production run. A badly managed approval process does the opposite: it turns the error into an “approved” one. This guide covers what the sample must prove, the approval checklist, and how revisions are tied to records.

The sample proves three things: dimensions, folding, locking

The first sample is tested in its use scenario, not on a desk: the box is folded, the locks are engaged, and where possible the real product goes inside. Even with correct dimensions, a lock tab that fights back or a lid that resists folding means the die is not ready for approval.

The sample must be cut from the production material. The folding behaviour of a sample cut from 300 gsm board says nothing about 450 gsm or corrugated stock.

  • The sample is folded, locked and, where possible, tested filled.
  • The sample material must match the production material exactly.
  • A sample with correct dimensions but failing function is not approved.

The approval checklist: a five-item tour

Before approval, five items are checked in order: inner dimensions (does the product actually fit), print cracking along the folds, lock tightness, edge cleanliness, and unwanted crease or rubber marks on the surface. Each item is written down as “pass / revise”.

Both sides should run the tour: the workshop looks with production eyes, the customer with product and filling-line eyes. Overlaying the two checklists puts the approval decision on solid ground.

  • Inner size, cracking, locks, edge cleanliness, marks: five items in order.
  • Each item gets a written “pass / revise” result.
  • Workshop and customer checklists are evaluated together.

Revisions go on record: new file name, one active version

When a revision is decided, the change is never left verbal: what changes, from which dimension to which, and why — all in one written message. The drawing is saved under a new revision number (R1, R2…) and the old version is marked cancelled; two active files at once is the most common cause of producing the wrong die.

A revision after production starts has a different price: a cut board and bent rules cannot be undone. That is why the revision window closes at sample approval.

  • Revision requests state the dimension, the change and the reason in writing.
  • Every revision gets a new file name; the old version is marked cancelled.
  • Sample approval is the moment the revision window closes.

Keep the approved sample: the reference for repeat runs

One approved sample stays at the workshop and one with the customer, both physically labelled with the file number. If a dispute appears on a reorder six months later, the reference is that sample — neither memory nor a photo replaces the approved box in hand.

The same discipline continues digitally: the approved drawing, material details and sample photos are archived in one folder under the file number. Repeat production opens only from that record.

  • The approved sample is labelled and kept physically on both sides.
  • Approved drawing + material + photos live in one archived folder.
  • Reorders are opened only from the approved record.

Quote details we clarify together

When the file, material, quantity and deadline are clear, the quote conversation moves faster and with less back-and-forth.

  • Current revision file
  • Material and quantity details
  • Critical dimensions or production notes
  • Deadline expectation and delivery preference