Sheetfed offset printing
High-quality packaging and commercial print produced on individual sheets, including our fast-curing LED-UV process.
Products & capabilities
What we make.
What we make.
What goes into it.
Explore each product area to understand what Formsxpress can produce, the processes we can combine and the information that helps us specify and quote the job properly.
Product range
Start with the finished product.
You do not need to know which press, board grade or finishing process to choose. Tell us what the product must achieve, how many you need, when you need it and the budget you are working within.
Food & consumer packaging
Folding cartons
Printed paperboard cartons, sleeves and inserts engineered for protection, presentation, packing efficiency and retail performance.
What we can produce
- Retail cartons, sleeves, wallets, carriers and product inserts
- Primary-contact and other paper food-packaging applications within the agreed ISO 22000 scope
- Structures for food, beverage, cosmetics, personal care, supplements, household and promotional products
- Short-run samples through to repeat production programmes
What we can handle
- Structural development, dielines, prototypes and packing tests
- Sheetfed LED-UV offset lithography and sheetfed digital printing
- Die-cutting, creasing, perforating, windowing, folding and gluing
- Foiling, embossing, debossing, laminating, coatings and selected special finishes
What shapes the quote
Finished size, board grade, quantity, number of colours, finish, construction, food-contact requirements, packing method and whether a new structure or prototype must be developed.
Premium packaging
Rigid boxes
Hand-finished presentation packaging for premium products, gifting, launches and influencer campaigns—designed and manufactured as a bespoke object, not an ordinary folding carton.
A realistic budget matters
A large custom influencer box is not a sub-R100 product.
A large, one-off or low-quantity handmade rigid box will usually cost well over R1,000 per unit once its size, materials, inserts, finishing, development and hand assembly are taken into account. Complex prototypes and structural design may be quoted separately. This is guidance, not a fixed price: the final cost depends on the approved specification and quantity.
If the available budget is closer to R100 per unit, we can assess whether a simpler folding-carton or corrugated presentation format, produced at a suitable quantity, can achieve the objective more realistically.
What we can develop
- Lift-off lid-and-base boxes, hinged presentation boxes, slipcases and multi-part structures
- Custom paper or printed wraps, premium liners and coordinated internal finishes
- Product platforms, compartments and fitted board, foam or paper-based inserts where suitable
- Foiling, laminating, embossing, debossing and other premium detailing
- Launch kits, gifting packs, sample boxes and premium retail presentation packaging
Why the work is intensive
- The structure is engineered around the actual products, their weight and the way the box must open and present
- Greyboard components and wraps must be accurately cut, aligned, turned in and assembled
- Inserts require their own measurements, material choices, prototypes and fit tests
- Premium papers and finishes often require trials before the final material combination is approved
- Much of the finishing and assembly is skilled handwork, especially on large or low-volume boxes
Design is part of the product
Rigid-box development can include concept interpretation, structural engineering, material selection, CAD work, dielines, blank dummies, printed prototypes, insert development, artwork adaptation and revisions. A prototype is a paid development stage because it requires real design, materials, machine time and hand assembly.
Before requesting a quote
- Supply the product dimensions, weights and arrangement—or the physical products themselves
- State the required quantity and likely repeat quantities
- Share reference images, but explain what you like about them
- List the required inserts, compartments, finishes and delivery deadline
- Provide a realistic total or per-unit budget so we can propose the right construction
What shapes the quote
Overall size, board thickness, wrap material, box style, insert complexity, number of components, decoration, prototype requirements, hand-assembly time, quantity, packing and delivery. Larger size does not increase cost only slightly—it affects material yield, structural strength, handling and labour throughout production.
Transit & retail
Corrugated packaging
Premium corrugated packaging that combines high-quality printed graphics with the strength and practicality of corrugated board.
What we can produce
- Premium e-commerce mailers, product shippers and promotional delivery packs
- Shelf-ready packaging, retail trays, counter units and display structures
- Launch, gifting and sampling packs that need both presentation and protection
- Corrugated sleeves, dividers, spacers, fittings and product inserts
What litho-laminated means
- Your design is printed at high quality onto paper, giving the pack crisp detail and strong colour
- The printed sheet is bonded to corrugated board, adding strength and protection
- This makes it suitable for packaging that must look premium while surviving handling and transport
- We can assist with structural design, prototypes, fit testing and material selection
- Precision die-cutting, creasing, folding, gluing and hand assembly
- Product insertion, campaign kitting and packing where required
What shapes the quote
Internal dimensions, product weight, required strength, printed coverage, construction, inserts, quantity, shipping demands and whether the pack is primarily protective, presentational or both.
Labels
Roll and sheet labels
Digitally printed self-adhesive labels for short and medium runs, multiple versions, variable data and fast-moving product ranges.
What we can produce
- Product, packaging, promotional, logistics and identification labels
- Suitable paper, film, clear and specialty label materials
- Roll labels for machine or hand application and sheeted labels for practical distribution
- Sequentially numbered, barcoded, QR-coded and personalised labels
- Resin-domed badges, labels and branded components
Current production capability
- Labels are currently produced digitally, allowing economical short runs and rapid version changes
- Variable data, sequential information, barcodes, QR codes and personalisation
- White ink, opaque layers and selected specialty finishes where suitable
- Laminates and varnishes for appearance and added surface protection
- Die-cut shapes, kiss cutting and controlled roll formats
Expanded label capability is coming
A new higher-volume flexographic label press is currently being commissioned. Until commissioning and production approval are complete, the label service described on this site remains digital.
What shapes the quote
Label size and shape, quantity per design, number of versions, substrate, adhesive, exposure to moisture or abrasion, application surface, roll core, winding direction and whether labels are applied by hand or machine.
Specialist label finishing
Resin doming and domed labels
Clear resin doming that gives labels, badges and branded components a raised, glossy three-dimensional finish—using labels printed by Formsxpress or suitable labels supplied by the client.
Two ways to work with us
- Complete domed-label service: we print, cut and resin-dome the labels as one coordinated job
- Doming-only service: you supply suitable printed and cut labels, with the surrounding waste matrix still intact, and we weed them immediately before applying the clear resin dome
- Client-supplied labels may require a sample test before the production run
- We can advise on practical shapes, sizes, spacing and materials before artwork is finalised
What resin doming adds
- A raised, glossy lens that gives colour and graphics greater visual depth
- A premium, tactile finish for product branding and identification
- Added protection from everyday handling, light scuffing and moisture
- A self-adhesive branded component that can be applied to suitable clean, smooth surfaces
Common applications
- Product and equipment branding
- Machinery, appliance and electronics labels
- Badges, nameplates and control-panel branding
- Promotional products, presentation packaging and campaign components
Supplying your own labels
Do not weed client-supplied labels. The surrounding waste matrix must remain intact when the labels are delivered to Formsxpress. Weeding must take place immediately before the resin is applied, so Formsxpress will perform this step as part of the doming process.
Labels should otherwise be clean, flat, accurately cut and supplied on a suitable release liner with consistent spacing. Compatibility depends on the face material, ink or coating, adhesive, liner, shape and edge quality. We will confirm whether testing or production overage is required.
What shapes the quote
Finished label size and shape, quantity, number of designs, whether Formsxpress or the client supplies the labels, material and print finish, resin volume, packing and required date.
Specialist printing
Screen printing
Direct screen printing with UV-cured inks for strong, opaque colour on suitable flat materials, components and specialist applications that are not always practical through conventional paper-printing processes.
Benefits of UV-cured screen inks
- The ink cures rapidly when exposed to ultraviolet light, allowing printed work to move into later production stages without a long air-drying period
- Bold solid colours, dense ink coverage and excellent opacity
- White or opaque print on selected dark, clear or coloured materials
- Strong adhesion and a durable surface when the correct ink and curing conditions are matched to the material
- Useful resistance for regularly handled branding, instructions and identification graphics
Typical applications
- Panels, overlays, boards, decals and flat components
- Display, point-of-sale and promotional elements
- Specialist labels and durable identification graphics
- Selected plastics, papers, boards and other compatible substrates
Why the material matters
UV curing does not make one ink suitable for every surface. Plastics, coated materials and unusual components can behave differently depending on their surface, age, cleanliness and previous treatment. A sample, adhesion test or surface preparation may be required before production.
Tell us about the end use
Flexing, folding, cutting, laminating, outdoor exposure, chemicals, heat and heavy abrasion can all affect the correct ink and construction. These conditions must be specified before quoting so performance can be assessed rather than assumed.
What shapes the quote
Finished size, material, number of colours, ink coverage, quantity, registration tolerance, intended environment, supplied component format, UV-curing and adhesion requirements and whether cutting, laminating or other finishing is needed.
Protection & presentation
Laminating
Protective and decorative films that improve handling, durability and presentation across suitable printed packaging, covers, labels, cards, displays and wide-format graphics.
What laminating can add
- Gloss, matt and selected specialty surface effects
- Added resistance to handling, light scuffing and moisture
- A premium feel for packaging, presentation pieces and covers
- Greater stability and useful life for frequently handled print
Where it is commonly used
- Folding cartons, sleeves, rigid-box wraps and presentation packaging
- Book, catalogue, report and brochure covers
- Cards, menus, folders, labels and promotional pieces
- Posters, display graphics, decals and selected signage
Choosing the right finish
The correct film depends on the material, print process, intended use, required appearance and any later folding, gluing, foiling or die-cutting. We will recommend a compatible construction and testing where the combination is unusual.
What shapes the quote
Finished size, sheet or roll format, quantity, one- or two-sided application, film type, surface finish, later production processes, handling environment and required date.
Retail activation
Displays and point-of-sale
Retail structures and campaign components designed to attract attention, carry product and arrive ready for practical rollout.
What we can produce
- Counter units, floor-standing displays and product presentation stands
- Shelf strips, wobblers, shelf talkers, header cards and promotional signage
- Launch displays, sample dispensers and campaign-specific structures
- Multi-component retail kits for store, branch or national distribution
From concept to rollout
- Structural development, prototypes and product-load testing
- Paperboard, corrugated and rigid display materials selected for the required life
- Printing, laminating, die-cutting, CNC routing and digital contour cutting
- Assembly instructions, flat packing, kitting, labelling and distribution support
What shapes the quote
Display footprint, product weight, required lifespan, number of components, material, finish, quantity, whether it ships flat or assembled and how many destinations must receive the campaign.
Wide format
Signage and graphics
Large-format graphics for retail, events, interiors, promotions and signage, printed onto rolls, boards and selected objects.
What we can produce
- Printed boards, posters, banners, decals, wallpaper and window graphics
- Retail graphics, event branding, wayfinding and promotional panels
- Cut lettering, shaped graphics and display components
- Short-run branded items, display parts and prototypes on suitable rigid materials
What we can do
- Print flexible graphics up to 1.6 metres wide for banners, decals, window graphics and similar applications
- Print directly onto suitable boards and rigid materials instead of always mounting a separate print
- Print onto selected objects and materials up to 50 mm thick
- Use white ink on clear, coloured and selected non-white materials where suitable
- CNC routing, laser cutting and digital contour cutting
- Laminating and selected protective finishes based on use and environment
What shapes the quote
Finished dimensions, flexible or rigid material, material thickness, indoor or outdoor use, expected lifespan, viewing distance, cutting complexity, quantity and whether installation hardware or site work is required.
Marketing
Commercial print
Everything from premium brochures and reports to high-volume forms and repeat operational print, using the production route best suited to the job.
What we can produce
- Brochures, annual reports, catalogues, calendars, inserts and direct mail
- Presentation folders, inserts, stationery and corporate collateral
- Cards, invitations, vouchers, promotional pieces and campaign sets
- Business forms, transactional documents and other high-volume repeat print
- Versioned, personalised and variable-data print
How we choose the production route
- Sheetfed offset: individual sheets printed at high quality for brochures, reports, packaging, covers and premium marketing material
- LED-UV sheetfed offset: immediately dry print, strong colour and faster movement into finishing
- Web and continuous printing: paper is fed from a roll, making it practical for long runs, business forms and repeat operational work
- Digital printing: suited to shorter runs, multiple versions, personalisation and fast changes
Finishing and fulfilment
Folding, binding, die-cutting, foiling, embossing, coating, laminating, collation, insertion, packing and distribution can be integrated into the production route where required.
What shapes the quote
Finished format or page count, quantity, number of versions, paper, print colours, binding and finishing, personalisation, packing, delivery points and required date. We will decide whether sheetfed, web/continuous or digital production offers the best result and value.
Publishing
Books and publications
Bound documents and publications planned around page count, reading life, opening behaviour, run length and distribution.
What we can produce
- Books, manuals, catalogues, reports, workbooks and training material
- Short-run publications and longer repeat production runs
- Sectioned, tabbed, versioned or personalised documents
- Presentation editions and durable reference material
Binding and finishing
- Saddle stitching for suitable lower-page-count work
- Perfect binding, wire binding and selected sewn or case-bound formats
- Laminated, varnished or specialty covers
- Folding, gathering, trimming, drilling, tabbing and packing
What shapes the quote
Trim size, page count, colour split, paper, cover, binding, quantity, number of versions, supplied artwork quality, packing and delivery requirements.
Data-driven print
Forms and variable data
Operational print that carries changing information accurately—from sequential numbers and barcodes to personalised content and traceable documents.
What we can produce
- Business forms, waybills, pads, books and practical operational documents
- Sequential numbering, barcodes, QR codes and unique identifiers
- Personalised letters, statements, certificates, vouchers and direct mail
- Versioned documents for departments, branches, regions or customer groups
Data and production controls
- Data review, field mapping and proofing before production
- Digital production for changing content and shorter targeted runs
- Collation, perforating, drilling, padding, binding and packing
- Number-range and version planning based on the agreed specification
What shapes the quote
Finished format, number of parts or pages, quantity, data complexity, number ranges, barcode or QR requirements, paper, finishing, packing and how cleanly the supplied data is structured.
Promotional
Custom sticky notes
Useful branded pads configured as a practical promotional product, campaign component or internal business tool.
What can be specified
- Custom pad sizes and shapes within production limits
- Sheet count per pad and total number of pads
- Paper colour, printed colours and branding area
- Adhesive position or edge based on how the note will be used
- Optional covers, backers or presentation packaging where suitable
Common applications
- Corporate gifts, conference packs and campaign giveaways
- Desk tools, planning aids and internal communication
- Retail, pharmaceutical, financial-services and educational promotions
- Branded components within larger kits or presentation packs
What shapes the quote
Pad dimensions, number of sheets, number of pads, paper colour, print colours, adhesive edge, covers or backers, packing and delivery date. “Post-it” is a registered 3M trademark; Formsxpress supplies custom-printed sticky notes.
Development
Prototypes and samples
Physical development and colour-matching work used to test structure, fit, presentation, materials and production decisions before committing to a full run.
What we can develop
- Structural concepts, CAD dielines and plain white dummies
- Printed mock-ups and presentation samples
- Fit tests for products, inserts and packing arrangements
- Colour test samples on the intended material before full production where appropriate
- Custom ink mixing and precise colour matching carried out in-house
- Selected production samples from the intended manufacturing route
What a prototype proves
- Whether the physical dimensions and tolerances are correct
- How the product is inserted, protected, displayed and removed
- Whether the structure assembles and performs as intended
- Where artwork, folds, joins, closures and finishes will appear
- Whether the target brand or spot colour can be matched accurately on the selected substrate
- Which changes are required before production approval
Precise colour matching
We can mix inks in-house and produce a small colour test—known as a drawdown—on the intended material before full production. This is particularly valuable for brand-critical colours, packaging ranges and repeat work where consistency matters.
Development is chargeable work
A custom prototype is not a free miniature production run. It can require structural design, CAD work, material, printing, cutting, machine setup, hand assembly and revision time. The development charge depends on complexity and is separate from—or incorporated into—the production quote as agreed.
Fulfilment
Assembly, kitting and packing
The final manual and logistical work that turns separate printed components and supplied products into complete, correctly packed campaign or retail units.
What we can handle
- Collation, insertion, labelling, folding, gluing and hand assembly
- Campaign, launch, gifting, sample and point-of-sale kits
- Shrink-wrapping, bagging, bundling and selected protective packing
- Combining printed items with approved customer-supplied components
- Quality checks against the agreed bill of materials and packing sequence
Storage and distribution support
- Carton labelling and preparation by destination or branch
- Warehousing and call-off supply where agreed
- Multi-destination campaign packing and distribution coordination
- Repeat kit assembly using an approved master specification
What shapes the quote
Number of components, assembly sequence, handling time, supplied-product condition, quality-control requirements, packing materials, storage duration, number of destinations and delivery schedule.
Offset leadership
First locally into LED-UV offset.
Formsxpress was the first local adopter of LED-UV offset lithography, combining the consistency and economy of sheetfed offset with instant, lower-energy curing.
Immediately drySheets can move to finishing sooner, shortening the critical path.
Crisp and consistentSharp dots, strong colour and reduced marking or set-off.
More material choiceExcellent performance on premium uncoated, synthetic and non-absorbent stocks.
Cleaner productionNo spray powder, less heat and lower energy demand than conventional UV curing.
Production systems
One route through multiple processes.
We choose the production method around the product, quantity, quality, timing and budget—then keep printing, finishing, assembly and packing connected under one roof.
Web and continuous printing
Roll-fed production for long runs, business forms and repeat operational print where speed and consistency matter.
Digital print and labels
Short runs, multiple versions, variable data, personalisation, prototypes and our current roll and sheet label production.
Wide format and direct-to-board
Large flexible graphics plus direct printing onto suitable boards, rigid materials and selected objects.
Cutting and conversion
Die-cutting, CNC routing, laser cutting, digital contour cutting and kiss cutting.
Screen printing and specialist print
Opaque colour, direct printing and functional graphics on suitable panels, overlays, boards, labels and flat components.
Finishing and fulfilment
Laminating, UV/IR coating, foiling, embossing, gluing, binding, resin doming, assembly and packing.
Food safety
ISO 22000:2018
Certified for the manufacturing, die-cutting and printing of paper packaging for use in the food industry, with approval for primary-contact paper food-packaging applications subject to the agreed job specification.
View certificate
Start with the product
We will define the route.
Tell us what the finished product must do, the quantity, timing and budget. Our estimating and production teams will recommend the most practical route.
Specify a job