Introduction

Packaging has more jobs than almost any other piece of design. It must protect the product, survive transport, stand out on a crowded shelf, tell the buyer what is inside, meet legal labelling rules and scan correctly at the till. If it fails at any one of these jobs, the product can be rejected by a retailer, held at customs, damaged in transit or simply ignored by shoppers.

Packaging is also expensive to get wrong. A mistake on a website can be corrected in minutes. A mistake on fifty thousand printed cartons means waste, reprinting and delay, and sometimes a product launch that misses its season.

For brands in Sri Lanka and the UAE, the stakes are especially high. Sri Lanka’s food and agricultural exports, from tea to spices and nuts, compete in demanding international markets. According to the Sri Lanka Export Development Board, tea exports earned about US$1.51 billion in 2025, and spices and essential oils about US$450 million. Many of these products are judged first by their packaging.

This article explains how Dsigngo Group controls packaging quality, from the first structural sketch to the finished carton on the shelf.

Why packaging quality matters

Packaging influences buying decisions directly. In research by Ipsos for the Paper and Packaging Board, 72% of consumers said packaging design plays a significant role in their purchase decisions, and 67% said the packaging material influences what they choose.

Packaging quality affects:

• Sales. Attractive, clear packaging helps a product win attention and trust on the shelf.
• Compliance. Incorrect or missing label information can lead to rejected shipments, fines or product recalls.
• Logistics. Weak packaging leads to damaged goods and returns.
• Operations. Barcodes that do not scan cause problems at warehouses and tills, and some retailers will charge for, or reject, non-compliant items.
• Brand reputation. Damaged, inconsistent or poorly printed packaging makes a brand look unreliable.

The packaging quality process

Our packaging quality process has eight stages. Each one has its own checks, and work only moves forward when those checks are passed.

Stage 1: Packaging brief

We begin by understanding the product and the market. The brief records:

• The product, its size, weight, shape and fragility.
• Whether it is food, cosmetics, apparel, electronics or another category, because each has different requirements.
• How it will be stored, transported and displayed.
• Target markets and languages.
• Retailer or distributor specifications.
• Print quantity, budget and launch date.
• Sustainability goals, such as recyclable materials or reduced plastic.

Stage 2: Structure and dieline

The dieline is the flat technical drawing of the package, showing cut lines, folds, glue areas and panels. A small error in the dieline can mean a box that does not close, a product that rattles or a carton that will not fit a shipping case.

Our checks include:

• Correct internal dimensions for the product, with suitable tolerances.
• Board thickness allowed for in fold and panel sizes.
• Glue flaps and locking tabs that work on the chosen material.
• Efficient layout on the printing sheet, to reduce waste.
• Compatibility with filling and packing methods, whether manual or machine.

We then make physical mock-ups. A real sample, held in the hand with the actual product inside, reveals problems that are invisible on screen.

Stage 3: Material selection

The right material depends on the product, its journey and the brand’s position. Options include folding boxboard, corrugated board, rigid boxes, labels, flexible pouches and non-woven bags.

For food products, materials in contact with the food must be suitable for food contact, and the right barrier is needed against moisture, oxygen and light. Tea, coffee, nuts and spices are particularly sensitive: moisture can spoil them, light can fade them and oxygen can make nuts go rancid.

We also consider:

• Strength and stacking performance for storage and transport.
• Print quality on the chosen surface.
• Finishes such as lamination, varnish, foil and embossing.
• Recyclability and local recycling options.
• Current regulations on plastics and single-use materials in each market.

Stage 4: Artwork and colour

Packaging artwork follows the same colour standards we use for all print work, described in our article on print quality standards. Brand colours are defined for the chosen material, because the same ink looks different on white board, kraft board, film and metallic surfaces.

Packaging artwork has extra checks:

• Artwork placed accurately on the dieline, with bleed and safe zones.
• Text and logos kept clear of folds, glue areas and die-cut edges.
• Key information visible from the front of shelf.
• Legibility of small text, including minimum font sizes where regulations require them.
• Consistency across a product range, so related products are recognisable as a family.

Stage 5: Barcode verification

Barcodes look simple, but they are precise technical objects. A barcode that is too small, printed in the wrong colours, placed over a fold or printed with too much ink spread may not scan.

Retail barcodes follow GS1 standards. Their print quality is graded using ISO/IEC 15416 for linear barcodes, on a scale from 4.0 (grade A) down to 0 (grade F). GS1 sets an overall grade of at least 1.5, which is grade C, as the minimum for retail barcodes. Because quality can vary during a print run, we aim higher than the minimum.

Our barcode checklist includes:

• A valid GS1 barcode number registered to the brand owner. Brand owners obtain these through GS1 Sri Lanka or GS1 UAE.
• The correct size, with the minimum quiet zones on either side.
• Dark bars on a light background. Red bars, for example, cannot be read by most scanners.
• Placement on a flat surface, away from folds, seams and curves where possible.
• Bars running in the right direction for the printing process, to reduce distortion.
• Verification of printed samples with a barcode verifier, not just a phone scan.

Stage 6: Labelling compliance

Packaging labels are regulated, especially for food and cosmetics. The rules differ by country, and they change. The checks below are a summary, not legal advice.

Sri Lanka

Food labelling in Sri Lanka is governed by the Food Act and regulations made under it. The Food (Labelling and Advertising) Regulations 2022, published in Gazette Extraordinary No. 2319/40 in February 2023, replace the 2005 regulations. Their implementation has been extended and amended, so the current commencement date and requirements must be checked for each product.

Sri Lanka also has colour-coding rules for sugar levels. The Food (Colour Coding for Sugar Levels – Liquid) Regulations 2022, Gazette No. 2319/42, require sugar content in liquid foods to be shown in a colour-coded label. Labels must also give certain information in Sinhala, Tamil and English.

UAE

In the UAE, food labelling follows the Gulf and UAE standards for labelling of prepackaged foods, based on GSO 9. Labels must be in Arabic, or in Arabic and English, and information in another language must match the Arabic text. Arabic stickers are accepted in some cases. Minimum Arabic information includes the product name, ingredients, country of origin, and storage and usage instructions where they apply.

Our labelling checks

For every label, we check that:

• All mandatory information is present for each target market.
• Text matches the approved regulatory content supplied by the client, word for word.
• Translations are checked by a fluent speaker, including Arabic right-to-left layout.
• Required symbols, logos and colour codes are shown at the correct size.
• Ingredients, allergens, net quantity and dates are in the right place.

The client remains responsible for the accuracy of product information, such as ingredients and nutrition values. Our role is to make sure the approved information is presented correctly and legibly.

Stage 7: Proof and pre-production approval

Before production, clients approve:

• A final PDF proof showing every panel, with all text, barcodes and legal information.
• A colour-accurate proof for brand colours and product photography.
• A printed and assembled sample, where possible, made on the actual material.

Approval is recorded in writing. If anything changes after approval, the changed panel goes back through the checks.

Stage 8: Production inspection

During and after production, finished packaging is inspected for:

• Colour against the approved proof.
• Registration, so colours and finishes line up.
• Cutting, creasing and folding accuracy.
• Gluing strength and alignment.
• Finishes such as foil, embossing and spot UV.
• Barcode grades on samples from the run.
• Correct quantities and packing.

For large runs, inspection is based on sampling. Recognised methods, such as the acceptance sampling plans in ISO 2859-1, help decide how many items to check from each batch.

Testing packaging for the journey

Packaging that looks perfect in the studio still has to survive the real world: loading, stacking, heat, humidity, vibration and handling. This is particularly important for exports from Sri Lanka, where products may travel by sea for weeks in hot, humid conditions.

Depending on the product, testing may include:

• Drop tests, to check that the package protects the product if dropped.
• Compression tests, to check that cartons can be stacked in storage and shipping.
• Humidity tests, to check that the board keeps its strength.
• Seal and leak tests for pouches and bottles.
• Transit trials, where real shipments are checked on arrival.

Recognised test procedures, such as those published by the International Safe Transit Association (ISTA), can be used where a retailer or distributor requires them.

Packaging quality for our own brands

Dsigngo Group also has its own product brands, including Raiden Tea, Raiden Coffee and Udari Nuts & Spices, as well as the clothing brand Duiker. These brands face the same challenges as our clients’ products: protecting sensitive food, presenting well on shelf and meeting labelling rules in different markets.

Working on our own brands gives our team first-hand experience of what packaging must do after it leaves the studio. The lessons we learn about materials, barriers, labels and transport feed directly into the quality standards we apply for clients.

Packaging across product categories

Different products need different checks:

• Tea and coffee. Moisture, aroma and light protection; freshness dates; origin claims and certification marks where the product qualifies for them.
• Nuts and spices. Strong moisture and oxygen barriers; allergen information; clear windows only where the product is protected from light.
• Cosmetics and Ayurveda products. Ingredient lists; usage instructions; batch codes; materials compatible with the product.
• Apparel. Swing tags, care labels, size labels and branded bags that are durable and consistent with the brand.
• Electronics and IT products. Protective inserts, anti-static materials where needed, and clear product information.

Common packaging failures and how we prevent them

Most packaging problems we are asked to fix fall into a few familiar groups. Each one is prevented by a specific check in our process.

An example: launching a spice range in two markets

Here is an illustrative example of the full process. It does not describe a specific client.

A Sri Lankan spice producer plans a range of six ground spices in resealable pouches, for supermarkets in Sri Lanka and the UAE.

• Brief. The packaging team records pouch sizes, fill weights, shelf life, the retailers’ requirements and both markets’ labelling rules.
• Structure and material. A pouch with a strong moisture and aroma barrier, a resealable zip and a hang hole is selected. Samples are filled and sealed to test fit and closure.
• Artwork. A shared design system keeps the six products recognisable as one range, with a different colour for each spice. Brand colours are proofed on the actual film.
• Barcodes. Each product has its own GS1 number. Barcodes are placed on a flat panel, away from the seal.
• Labelling. The Sri Lankan version includes the required information in Sinhala, Tamil and English. The UAE version is bilingual Arabic and English, with the Arabic text checked by a fluent reviewer.
• Approval and production. The client approves printed samples, and production samples are checked for colour, seal quality and barcode grade before delivery.

The result is a range that looks consistent on shelf, meets the rules of both markets and protects the product through its shelf life.

A packaging quality checklist for brand owners

Before approving any packaging for production, ask:

1. Has a physical mock-up been tested with the real product?
2. Is the material right for the product, its journey and its shelf life?
3. Do brand colours match the approved standard on this material?
4. Does all mandatory label information meet the rules of each target market?
5. Have translations been checked by a fluent speaker?
6. Has the barcode been verified to at least the GS1 minimum grade?
7. Has a printed and assembled sample been approved?
8. How will production be inspected, and what happens if a batch fails?

Frequently asked questions

Do you design and print packaging?

Yes. Product packaging design and print is one of Dsigngo Group’s in-house services, covering labels, product boxes, branding and 3D showroom design. We manage the process from concept to production.

Can you help us meet UAE labelling rules for Sri Lankan products?

We can design bilingual Arabic and English labels and check that the approved information is presented correctly. The exact regulatory content should be confirmed with the relevant authority or a regulatory adviser.

What barcode grade should we aim for?

GS1 sets grade C (1.5) as the retail minimum. We recommend aiming for grade B or better on printed samples, so normal variation during printing does not push barcodes below the minimum.

Can we make small packaging runs?

Yes. Digital printing is suitable for short runs, test markets and seasonal products. For large volumes, offset printing is usually more cost-effective. There is no fixed minimum order quantity; quantities are discussed and agreed for each order.

How can we make our packaging more sustainable?

Options include choosing recyclable mono-materials, reducing unnecessary layers, right-sizing packages and using certified paper-based materials. Sustainability choices must still protect the product, because a damaged product wastes far more resources than its packaging.

Conclusion

Packaging quality is the result of many small, careful checks: the right structure, the right material, accurate colour, readable barcodes, compliant labels, approved samples and inspected production. When all of these come together, packaging protects your product, wins attention on the shelf and passes through supply chains without problems.

That is the standard Dsigngo Group applies to packaging for clients and for the group’s own brands.

Planning new packaging or a redesign? Talk to our packaging team before you finalise the structure and artwork.

Start a Packaging Project

Sources

• Sri Lanka Export Development Board, 2025 export earnings for tea and for spices and essential oils, as reported by Daily FT.
• Ipsos for the Paper and Packaging Board, consumer survey on packaging, as reported by Packaging Gateway.
• GS1, barcode verification guidance; ISO/IEC 15416 barcode print quality grading.
• Sri Lanka Food (Labelling and Advertising) Regulations 2022, Gazette Extraordinary No. 2319/40; Food (Colour Coding for Sugar Levels – Liquid) Regulations 2022, Gazette No. 2319/42; USDA Foreign Agricultural Service summaries.
• GSO 9 and UAE labelling requirements, as summarised by the US International Trade Administration’s UAE Country Commercial Guide.
• ISO 2859-1, sampling procedures for inspection by attributes.
• International Safe Transit Association (ISTA), test procedures.

Check each regulation and figure against the original source before publishing.