1. Start With the Purpose of the Scratch Panel
Before you approve artwork, decide exactly what the scratch area must do. Some panels reveal a prize code, others hide a promo message, and some are used to trigger a claim or verification step. The purpose changes the size, opacity and security level needed for the print.
For packaging in Durban, Johannesburg or Cape Town, it also helps to think about the journey from the converter to the shelf. A scratch panel on a carton that moves through hot depots, coastal humidity or cold store conditions must stay intact until the customer is ready to use it.
- Define the message hidden under the panel.
- Set the amount of force needed to scratch it off.
- Choose whether it should be one-time reveal or a repeated check.
- Confirm if the panel must carry security features as well as promo copy.
2. Place the Panel Where It Can Be Seen and Used Properly
Good placement is about visibility, handling and the user’s hand movement. If the panel is too close to a fold, glue line or seal, it may crack during forming or be damaged in transit. If it sits in a busy graphic area, consumers may miss it or scratch the wrong section.
Keep enough clear space around the panel so the scratch action is obvious. On folding cartons, leave room away from creases and tuck flaps. On pouches or wrap labels, avoid areas that flex hard during filling, sealing or sleeving. For wide packs, place the panel where a shopper can hold the pack steady with one hand while scratching with the other.
- Avoid folds, score lines and heat-seal zones.
- Keep away from varnish changes that may affect adhesion.
- Do not place over fine text or critical barcodes.
- Make the panel easy to find without crowding the main artwork.
3. Specify the Scratch Build and Surface Under It
The panel is only as good as the layers underneath it. The surface under the scratch area must be smooth, clean and compatible with the coating system. If the substrate sheds dust or the overprint has poor bond, the panel can lift at the edges before use.
For promotional packaging, the build usually needs a base layer, the hidden print and a scratch-off top layer. The hidden copy must remain readable after scratch removal and should be tested for contrast on the actual substrate, not just on a sample sheet. On recycled board or textured stocks, extra care is needed because surface porosity can change the finish.
- Confirm substrate type and finish before print starts.
- Check coating compatibility with the scratch layer.
- Allow for the right drying or curing window.
- Test hidden text, codes or symbols on the final material.
4. Decide How Hard the Panel Should Be to Scratch
Scratch force matters. If it is too soft, the panel may scuff in packing, stacking or transport. If it is too hard, customers struggle to open it and may give up. The correct threshold should suit the item, the campaign and the expected age group or user profile.
Threshold tuning is best done with real samples and not guesswork. A panel for a premium promotion may need a firmer feel, while a fast retail redemption can use a lighter scratch. Keep the result consistent across batches so one carton does not feel different from the next.
- Test the scratch feel with at least 3 sample levels.
- Check for accidental removal after rubbing by hand or carton-to-carton contact.
- Assess whether coins, fingernails or plastic tools are the intended scratch method.
- Record the final threshold for repeat production.
5. Run Trials Before Full Production
A trial batch saves time, money and rework. It shows whether the panel prints cleanly, scratches evenly and stays secure after packing. In South Africa, a trial is also useful because distribution conditions can change from inland dry air to coastal moisture and back again.
During trials, check the panel on press, after cutting or creasing, and again after packing. If the job is going to Pinetown, Prospecton or further inland, ask what the transit and storage conditions will be. That helps you spot failures before thousands of packs leave the floor.
- Inspect edge lift, cracking and flaking.
- Confirm the panel survives rub resistance checks.
- Check adhesion after folding, gluing and final packing.
- Keep a retain sample from each approved batch.
6. Build Security Into the Scratch Panel if Needed
If the panel is being used to reveal a code, verify a product or protect a promotion, security details should be planned from the start. That can include a specific pattern under the scratch area, a unique reveal layout, or verification features that make copying more difficult.
Security features should still be practical for the converter. The artwork, coating and hidden print must all work together so the panel can be produced at scale without slowing line speed. When security and promotion sit on the same pack, the layout must stay clear enough for staff and consumers to use without confusion.
- Set the security level before artwork release.
- Use a repeatable reveal format for customer support.
- Keep the hidden content separate from open promotional copy.
- Document the approved pattern, code range and batch reference.
7. Final Production Checklist for Scratch Panels
Before release to production, go through a simple sign-off. This reduces disputes, reprints and confusion on the line. It also helps when the same pack is being run again months later and the team needs a clear reference.
For converters supplying nationwide, keep the record with the artwork, approved sample and batch notes. That makes it easier to repeat the job for Jacobs, Durban South, Johannesburg or Cape Town runs without guessing.
- Panel position approved on final artwork.
- Scratch force tested and signed off.
- Hidden content legible after removal.
- Adhesion, rub and curing checks completed.
- Retain sample stored with batch notes.
- Press startup support noted if the job needs a live setup.
When a scratch panel is specified carefully, it does more than create a reveal. It keeps the pack usable, supports the promotion and gives the brand a cleaner result on the shelf.
