Industry Trends

The One Berry Global Ordering Mistake That Cost Me $1,400 (And How to Avoid It)

The Short Answer: You Probably Need to Check the Artwork File Type

If you're ordering custom printed packaging from a large supplier like Berry Global, the single biggest preventable mistake is submitting artwork in the wrong file format or resolution. It's not about the design being "wrong"—it's about the technical specs being incompatible with their high-volume, automated pre-press systems. I learned this the hard way, and it cost my company $1,400 and a week's delay.

I'm a procurement manager handling custom packaging orders for about six years now. I've personally made (and documented) a dozen significant mistakes, totaling roughly $8,500 in wasted budget and delays. Now I maintain our team's 12-point pre-submission checklist to prevent others from repeating my errors. This checklist has caught 47 potential errors in the past 18 months alone.

Why This Mistake Is So Common (And Costly)

It took me three years and maybe 150 orders to understand that with global-scale suppliers, the relationship isn't just buyer-to-seller; it's your file hitting their fully automated, zero-tolerance pre-flight check system. A human might glance at a .JPG and think, "Looks fine." Their system sees it and kicks it back instantly.

In September 2022, I submitted artwork for a run of rigid containers. The design was perfect. I'd used the correct Pantone colors, the dielines were right… but the files were high-res .JPGs instead of vector .PDFs or .EPS files. I knew I should convert them, but we were rushing, and I thought, "What are the odds their system can't handle a JPG? It's 2022." Well, the odds caught up with me.

"The result came back: 'Artwork rejected. File type not suitable for high-volume print.' 5,000 units, $1,400 in setup fees, straight to the digital trash. That's when I learned that for Berry Global's Bowling Green, KY, plant—and likely others—their automation requires specific, print-ready vector formats to ensure consistency across millions of impressions."

The mistake wasn't just the $1,400. It was the 7-day production delay while we re-processed the files, which pushed back our client's product launch. That's the real cost: budget plus timeline.

The Not-So-Obvious Detail Most People Miss

Here's the counterintuitive part: sometimes, a lower-resolution proof from your designer is actually the red flag. If your designer sends you a beautiful, crisp .PDF proof, that's great for approval. But you must ask: "Is this the final, print-ready, vector-based artwork file you'll submit, or is this just a proof render?" I've seen teams approve a proof, then the designer submits a completely different (and often raster-based) file to the manufacturer. The proof looked perfect, so no one double-checks the submitted file. That mismatch is where the $1,400 mistakes live.

The 5-Minute Pre-Submission Checklist (Born From That $1,400 Error)

After that third major artwork rejection in Q1 2023, I created this checklist. It takes 5 minutes. It has saved us an estimated $8,000 in potential rework.

1. File Format & Type:
Is it a vector file (.PDF/X, .EPS, .AI)? If it's a raster file (.JPG, .PNG, .TIFF), is it at a minimum of 300 DPI at final print size? (For Berry Global's processes, vector is almost always required for anything beyond a simple, small logo).

2. Color Mode:
Is the color mode CMYK (for process printing) or are specific Pantone PMS colors called out and used correctly? RGB artwork will shift color dramatically when printed.

3. Dieline & Bleed:
Is the artwork correctly aligned to the supplier-provided dieline (the template showing cut lines)? Is there a minimum of 1/8" (0.125") bleed extending beyond the cut line?

4. Fonts & Text:
Are all fonts outlined/embedded? If not, you must include the font files. Missing fonts default to something like Courier, which… isn't great for branding.

5. Final, Silly Check:
Open the actual file you're about to attach to the order. Does it look right? I once approved a file named "Final_Art_v3.pdf," but the attachment was accidentally "Final_Art_v2.pdf." A $450 mistake.

5 minutes of verification beats 5 days of correction and $1,400 in fees. Every single time.

When This Advice Doesn't Apply (And What to Do Instead)

This checklist is built for custom printed orders—think flexible packaging with your logo, or branded rigid containers. It's been my experience with those. If you're ordering standard, non-printed items—like stock aluminum cans or generic plastic bottles—the artwork check is irrelevant. Your focus shifts to material specs (e.g., 3004 H19 aluminum alloy vs. 3104 H19) and closure compatibility.

Also, if you're working with a very small, local printer instead of a Berry Global-scale operation, their flexibility might be different. They might be able to manually fix a low-res file. But you're paying for that manual labor in higher unit costs or longer lead times. The principle remains: providing print-ready files is always the most efficient path.

Finally, a note on sustainability claims, since it's a big topic in packaging. Per FTC Green Guides, claims like "recyclable" must be substantiated. If your Berry Global rep says a material is "widely recyclable," ask for the documentation. Don't just take marketing copy and put it on your box. That's a compliance pitfall waiting to happen.

In my opinion, the extra five minutes with this checklist is the cheapest insurance you can buy for a packaging order. It forces you to slow down at the one point where a small error creates a massive, costly ripple effect. I had to waste $1,400 to learn that. You don't.