Order Receipt and Requirement Analysis
Input: Customer order (including product type, quantity, material, process requirements, delivery date, etc.).
Key Actions: Confirm the specific parameters of the puzzle: number of pieces (e.g., 500 pieces, 1000 pieces), dimensions (e.g., 300mm × 200mm), material (white core board, blue core board, grey board).
Verify any special customer requirements: eco-friendly inks (e.g., soy-based ink), scratch-resistant coating, etc.
Design and File Confirmation
Design Stage:The original image needs to be divided into puzzle pieces (commonly used software: Adobe Illustrator / ArtiosCAD), ensuring that the edges have “interlocking tabs and blanks” structures.
File Review:Check file resolution (≥300 dpi), color mode (CMYK), bleed (3 mm), and die-cut marks (such as registration marks and color bars).
Proofing confirmation (digital proof / traditional proof): lock the file after receiving the customer’s signed approval.
Material Procurement and Inspection
Material Selection:Grey board, blue cord board (900–1200 g/m²), white cardboard (250–400 g/m², high smoothness, less prone to edge bursting during die-cutting).
Inspection Standards:Paper: Test gram mage, thickness, smoothness (≥300 s), and pH value (neutral to prevent deformation).
Auxiliary materials: Ink (light fastness ≥ grade 7), glue (eco-friendly type, such as EVA glue / hot-melt adhesive), film materials (PET / PP film, transparency ≥90%).
Pre-Press Processing (Proofing and Sample Approval)
Digital Proofing: Use Epson / Haoyin large-format printers to produce proof samples, check color difference (ΔE ≤ 1.5), pattern accuracy (no jagged edges), and die-cut mark positions.
First Sheet Printing: Run 50–100 sheets on the printing press, check registration accuracy (±0.1 mm), ink uniformity (no missing prints or smudges), and drying performance (ink curing rate ≥ 95%).
Customer Sample Approval: Once approved by the customer, the proof will serve as the sole reference standard for mass production.
Printing Process
Material Preparation: Grey- back whiteboard paper (250–400 g), white cardboard (190–400 g), coated art paper (157–250 g).
Printing Method: Most puzzles use four-color offset printing (CMYK) for large solid areas (e.g., backgrounds); partial designs can be printed with screen printing / spot UV coating (to add a 3D effect), or spot color printing (per Pantone color codes).
Special Techniques: Hot stamping (gold/silver) using special stamping plates, temperature 120–220 °C; embossing (depth 0.05–0.1 mm) to enhance texture.
Quality Requirements: Minimal color variation, precise registration, no dirt or blemishes.
Surface Finishing
Varnishing: Gloss varnish, matte varnish, semi-matte varnish, soft-touch film, UV varnish.
Lamination: Matte lamination, gloss lamination, soft-touch film, anti-scratch film, other special effects (e.g., glitter, brushed finish).
Embossing: Adds tactile texture, improves grip, reduces glare.
Mounting Process
Mounting: Laminate printed and film-coated art paper onto greyboard using glue.
Glue: Hot-melt adhesive or eco-friendly white latex glue.
Requirements: Smooth adhesion with no lifted corners, bubbles, or wrinkles.
Pressing: Use a pressing machine to ensure stronger bonding.
Die-Cutting Process
Mechanical Die-Cutting: Use flat-bed die-cutting machines (fast speed, suitable for mass production); cutting dies must be custom-made based on puzzle piece shapes.
Hydraulic Die-Cutting: For complex shapes (e.g., irregular puzzles), and for high-density puzzles with 500–1000+ pieces.
Waste Removal & Sorting: Remove excess die-cut edges (automatic waste stripper + manual assistance), check puzzle piece edges for roughness (trim if necessary).
Sort puzzle pieces by code (to prevent mixing), and randomly test 5% for fitting smoothness.
Assembly & Packaging
Puzzle Assembly: Place puzzle pieces into color boxes according to design requirements (boxes must be die-cut and glued; glue must be eco-friendly). Include a puzzle instruction card inside (with difficulty level and theme information).
Packaging Requirements: Reinforce outer cartons (corrugated box, compression strength ≥ 800 N), include moisture-proof bags inside (moisture absorption rate ≤ 10%), and stack no higher than 1.5 m (to prevent crushing).
Finished Product Inspection & Shipping
Inspection Items:
Appearance: No printing color difference (ΔE ≤ 1.5), die-cut burrs ≤ 0.1 mm, no missing accessories.
Function: Puzzle pieces fit tightly (separation force ≥ 5 N), board game components assemble firmly (cards insert/remove smoothly without sticking).
Safety: Paper/plastic materials comply with EN71 (EU toy safety standard), heavy metals in inks (lead/cadmium) ≤ 90 ppm.
Shipping Process: Batch number management (traceable to production date, equipment, and operator), choose climate-controlled trucks (temperature 20–25 °C, humidity 45–55%), avoid direct sunlight and rain exposure.
Key Considerations When Choosing the Best Puzzle Manufacturer
When selecting a wholesale puzzle manufacturer or custom puzzle manufacturer, consider the following:
Quality: Sharp printing, vibrant colors, and precise interlocking fit.
Materials: Eco-friendly, internationally certified, thick and durable boards.
Production Capability: Advanced equipment, stable lead times, and large-scale manufacturing.
Customization: Flexible sizes, piece counts, and packaging options.
Quality Control: Strict inspection processes and low missing-piece rates.
Experience & Reputation: Proven success with global clients.
Why Choose Ningbo Hobon Printing Co., Ltd.
As one of China’s trusted puzzle manufacturers with over 20 years of experience, we offer:
20+ Years of Expertise: Printing, jigsaw puzzle, and board game production, with deep knowledge of international market standards.
One-Stop Service: From design and printing to packaging and shipping.
High Cost-Performance: Own factory for competitive pricing without compromising quality.
Diverse Product Range: Paper puzzles, children’s puzzles, specialty-shaped puzzles, and board game components.
Strict Quality Control: Full inspection + sampling ensures extremely low defect and missing-piece rates.
Reliable Quality & On-Time Delivery: Flexible customization with responsive customer support.
Export Expertise: Familiar with packaging laws and requirements in different countries. Partnering with Ningbo Hobon Printing means choosing a reliable jigsaw puzzle manufacturer that delivers quality, efficiency, and peace of mind—every time.
