Tolerances

In print and packaging, tolerances are the small, acceptable amounts of variation that can happen during the printing or cutting process. Because machines aren’t perfect, things like color, alignment, size, and cutting can shift slightly. Tolerances tell printers how much movement is allowed before something is considered an error.

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For example, a box might have a tolerance of ±1 mm for cutting, meaning it can be 1 mm bigger or smaller and still be okay.

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Why it matters

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Tolerances make it clear what is “acceptable” and what isn’t. They help prevent mistakes, reduce waste, and ensure all finished products look consistent, even across large print runs.

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Tolerance Help With:

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• Consistency: Helps keep all prints looking the same
• Quality control: Clear limits make it easier to spot real errors
• Efficiency: Reduces reprints and waste
• Better communication: Ensures design teams and printers stay aligned on expectations

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Use Cases in Print and Packaging:

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• Cutting and trimming: Small variations in box or label size
• Color printing: Slight differences in shade across a print run
• Registration: How much misalignment between colors is acceptable
• Finishing: Tolerances for folds, glue areas, and creases on cartons

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Tolerances set the acceptable limits for small variations in printing and cutting, helping keep packaging accurate, consistent, and high-quality.

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