Tip-on (Affixing) Specifications and Requirements “Tip-on” and “Affixing” are common terms used to describe the process of applying an adhesive (fugitive or permanent) to a carrier (e.g. promotional sell sheet, backer or insertion card) for placement of sample or trial size packets (packettes) or similar items. This involves affixing an item to a backing substrate (or "carrier") using either a fugitive (also called removable) or permanent glue. Fugitive glue allows the items to be removed by the end user without tearing either the attachment or the carrier. In addition, we’ll use the terms single-fill packet to describe a single product filled in an individual packet, and multi-fill to describe sealed side-byside fills of what are often two or more products as illustrated below
Advanced planning for any sampling program is important to its successful completion. To help prevent what are often avoidable issues and problems, we recommend involving us as early as possible in the planning process. Below are DISC’s standard specifications and requirements for the affixing of packets (packettes) to paperboard carriers. Packet (Packette) Specifications and Requirements DISC will make every effort to provide the most cost effective options when quoting affixing services. In general, short run and odd sized packets will be quoted using our hand assembly operations. Below are general requirements for automated affixing.
The minimum overall dimensions for single-fill packets to use our standard automated affixing lines is generally 3” in length and 1 ½” in width and are rectangular in shape.
Maximum dimensions are determined based on volume and the pillowing effect of the fill material; however in general the size is limited to 10” in length and 8” in width. ALL non-standard size, die-cut shaped and multi-fill packets must be reviewed to determine if automated affixing is possible. DISC reserves the right to request samples for testing prior to quoting. If automated affixing is not possible, DISC will provide a quote using our handassembly operation. The liquid fill of your packets should be accurately regulated and controlled so the liquid remains the same measurement throughout the production run. This will limit the variation in the bulking of the packet and improve control and speed of affixing. The packets must be “soldier packed” in cartons for ease of unpacking. A soldier packed configuration requires that all packets are inserted on the same edge and are front facing in a uniform configuration, which helps assure that in affixing the packets will consistently face in the proper direction. If more than one deck or row of packets is placed into a carton, then each must be segregated using appropriate paperboard separations. (See illustration below)
Packets must be loaded in their cartons to assure they do not curl or stick together, or significantly crimp, crush or otherwise damage the sealed edges. If this occurs, they may require additional handling or may not be suitable for automated affixing and could require hand application, which will be priced accordingly. During automated affixing, packets will be subjected to compression. The customer represents that packets supplied have been adequately compression tested to withstand pressures routinely applied during standard magazine bindery operations. NOTE: LEAKING OR BURST PACKETS WILL REQUIRE MACHINE STOPAGES AND CLEANUP THAT WILL BE CHARGED BACK TO THE CUSTOMER AT OUR STANDARD MACHINE RATES. Prior to commencing affixing operations DISC will advise you on sample requirements for production testing and timing of receipt. DISC reserves the right to refuse non-conforming customer supplied packets. NOTE: LOOSE PACKED ITEMS WILL INCUR ADDITIONAL HANDLING CHARGES.
Delivery Specifications (Incoming Materials) We request “Advanced Shipping Notification” for all materials at least 24-hours in advance. Such notification should include any special batch coding or lot numbers as well as the Case Label information. Having this information in advance will help ensure proper receipt of your materials. Incoming materials must include the following information: Case Label
Company Name and Address Packet Client (Your Customer) - Optional Product or Project Name, or Identifier Identification Codes Batch Codes (if required) Units per Case (Any cases with less than standard counts must be marked “Partial Quantity”) Pallet Label Company Name and Address Packet Client (Your Customer) - Optional Product or Project Name, or Identifier Purchase Order Number Identification Codes Units per Case Cases per Pallet Total Pallet Quantity Pallet Number (e.g. 1 of 10, 2 of 10, etc.) DISC’s standard incoming inspection protocol focuses on the requirements for affixing and is not meant to detect any defects or errors related to the packets or products provided. Proper lot, batch or product identifiers; proper packet printing and fill materials are the customer’s responsibility and DISC is not liable for any such errors or defects. Carrier Specifications As noted above the carrier is the promotional sell sheet, backer, folder, or insertion card to which the packet is affixed. For automated affixing the carrier must fall within the following specification tolerances: Minimum Flat Size 3 x 4 Maximum Flat Size 10 x 12
Carrier Specifications (continued) Minimum Thickness 100lb cover weight stock or paperboard equivalent Maximum Thickness 24Pt. Paperboard Items outside these specifications will be quoted using our hand-affixing operation.
Carriers that are folded or have unique die cuts or configurations are subject to review prior to quoting and may not be suitable for automation. Pay attention to placement tolerances: When designing your carrier, leave a small margin between your copy and the placement target. Although attaching placement is accurate, it is a high-speed process that involves some variation. Most applications have a placement tolerance of 1/8" to 3/16", so leave at least 3/16" clearance around your target placement area to be sure adjacent copy isn't obscured. Positioning must be a minimum of ¾”from the edges of the card. NOTE: FOR MAGAZINE INSERTS PLEASE CHECK WITH THE PRINTER FOR THEIR INSERTION REQUIRMENTS. Please detail print specifications including any spot colors, stamping, coatings and any perforation requirements. Specify adhesive requirements including type of adhesive and glue pattern requirements.
Shipping Specifications (Outbound Materials) Client agrees to provide DISC with pack-out specifications prior to quoting. This will include: Corrugated Case Requirements Case Quantity Pallet Quantity and any special pallet requirements Unique Pallet, Pallet Strapping, Edge Corner or Pallet Wrapping Requirements Special Handing or Marking Requirements Case Label Pallet Label If the above information is not available at time of quoting than additional charges may be required. Special Reporting Any special reporting, including count reconciliation, batch control or other specialized reports must be requested at time of quotation. Requirements not stated in advance may require additional charges.