Design and print
Product insert printing
Product inserts are the cards and leaflets packed with an order: thank-you notes, set-up instructions, care guides, discount codes for a next purchase or information a customer needs to use the product safely. Once an insert has been designed, printing it well is a practical job. It has to fit the packaging without bending, be printed on paper that survives handling, be ordered in quantities that match how many parcels you send, and stay current as products, offers and web addresses change. Some businesses need several versions for different products, which affects how print runs are planned.
This page covers sizing, paper and folds, quantities, versions, QR codes, proofs and storage. For designing insert content, see the product insert design pages. Printing can be included in a LetGetGrow quotation, with specifications, quantities, production arrangements and delivery agreed for each project, or files can be prepared for your own printer. Delivery and distribution of printed items can also be arranged through our team or suitable partners.
Illustrative diagram
- Measure
- Artwork
- Proof
- Pack
Size it to the packaging
Measure the inside of the box or mailer and the space left once the product is in. An insert that is slightly too large bends or gets crushed; one that is too small can slip under the product unseen. Common paper sizes such as A6 or DL often fit, but confirm exact dimensions with your printer and test a cut piece of paper in a packed order.
Insert formats
| Format | Suits | Print note |
|---|---|---|
| Single card | Thank-you, discount code | Heavier stock feels considered |
| Folded leaflet | Instructions, care guides | Fold type affects page order |
| Small booklet | Detailed set-up | Stapled, page count in multiples of four |
| Sticker or label | Short note on the box | Different material and printer |
Paper and finish
Inserts are handled, bent in transit and sometimes kept for reference. Choose a weight that holds its shape. Uncoated paper is easier to write on, which matters if you add handwritten notes; coated paper shows photos more vividly. Ask the printer for samples.
Quantities and order volume
Work out how many inserts you use in a month or quarter, then choose a print run that lasts a sensible period without leaving boxes of outdated cards. Discount codes, web addresses and product details change, and a large run of inserts with an expired offer is waste.
Managing versions
Planning
- One insert per product or one shared insert
- Which versions change most often
Identification
- A small code on each version
- Stored separately when packing
Updates
- Date or version noted on the file
- Old stock removed when replaced
QR codes and links
A QR code can lead to set-up videos, care guides or a review page. Link it to a page you control, so the destination can change without reprinting. Test it from the printed proof with several phones.
From design to packed orders
Measure
Packaging and fit.
Output: Insert size
Artwork
To the printer's specification.
Output: Print-ready files
Proof
Details, links, codes.
Output: Approved proof
Print
Run sized to orders.
Output: Inserts
Pack
Right version in each box.
Output: Orders sent
Example: inserts for three products
Illustrative example — not a client case study
Situation: An online shop sells three gadgets, each needing set-up instructions.
- A shared thank-you card is printed in a larger run; each gadget gets its own instruction card in a smaller run.
- Each version carries a small product code so packers pick the right one.
- Cards are sized to slide in beside the product without bending, tested in packed boxes.
What this shows: Packers could pick the right insert quickly, with little waste. This example is illustrative.
Safety and required information
Some products must come with specific instructions or warnings. The business is responsible for deciding what these are, with its adviser; the insert printing simply needs to reproduce them accurately and legibly.
Storage
Store inserts flat and dry near the packing area, labelled by version, so the right one is to hand.
Print method and run length
Printers use different methods for short and long runs. Digital printing suits smaller quantities and frequent changes; other methods can be cheaper per piece for large runs of an unchanging insert. Ask your printer which suits your volume, and whether colour will match between methods if you switch later.
Fitting into the packing routine
Place inserts where packers can reach them without slowing down. Decide whether the insert goes on top of the product, under it or in a sleeve, so customers see it at the right moment. A short packing note for staff avoids inconsistency.
Colour consistency
If inserts sit next to printed packaging, ask the printer to match key brand colours, and compare a printed proof with your packaging under the same light.
Questions about product insert printing
What size should an insert be?
Sized to your packaging; test a sample in a packed order.
Which paper suits inserts?
A weight that holds its shape; uncoated if you write on them.
How many inserts should we print?
Enough for a sensible period before details change.
How do we manage versions?
Code each version and store separately.
Should we use QR codes?
Yes, linked to pages you control.
Who prints inserts?
Insert runs can be included in our quotation and delivered to your packing address, or printed by your own printer.
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Ask about Product insert printing
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