PACKAGING TOOLKIT

PROCESS AND GUIDELINES

Version 1

GR&D
CONTENTS
Revision History ........................................................................................................................................ 4
Reviews ..................................................................................................................................................... 4
Distribution ............................................................................................................................................... 4
Chapter 1....................................................................................................................................................... 5
1.0 Process and guidelines for agencies ....................................................................................................... 5
1.1 Purpose ............................................................................................................................................ 5
1.2 Scope ................................................................................................................................................ 5
1.3 Key steps in packaging toolkit development ................................................................................... 6
2.0 Guidelines for artwork setup .................................................................................................................. 8
3.0 Flat proof content/format and supply .......................................................................................... 14
4.0 File creation guidelines ................................................................................................................. 15
5.0 Artwork Template ......................................................................................................................... 16
Chapter 2 .................................................................................................................................................... 17
6.0 toolkits for development .............................................................................................................. 17
6.1 Purpose .......................................................................................................................................... 17
6.2 Scope .............................................................................................................................................. 17
7.0 Toolkit component specification .................................................................................................. 18
7.1 Packs and Cartons .......................................................................................................................... 18
7.2 Tippings .......................................................................................................................................... 19
7.3 Die Print ......................................................................................................................................... 20
7.4 Inner Bundle (conventional) .......................................................................................................... 20
7.5 Inner Bundle (for Reloc or Maxim, i.e. single opening reloc) ........................................................ 21
7.8 Reloc Label (Conventional, i.e., non-Maxim) ................................................................................. 21
7.9 Reloc Label (Maxim)....................................................................................................................... 22
7.10 Inner Frame.................................................................................................................................... 22
7.11 Films and Tear Tape ....................................................................................................................... 23
7.12 Shipping Cases ............................................................................................................................... 23
8.0 Global Packaging Specification ...................................................................................................... 25
Appendix 1 .................................................................................................................................................. 34
Overview ..................................................................................................................................................... 34
Standardized Naming Convention .............................................................................................................. 34
Abbreviations .............................................................................................................................................. 35
Appendix 2 .................................................................................................................................................. 39

PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 3 OF 39

DOCUMENT HISTORY
Revision History
Revision date Summary of Changes Function Author

06/03/2018 Document creation Brand Packaging Colin Gardner, Celio Goulart

Reviews
Date Role Name Designation

06/03/2018 Author Colin Gardner, Celio Goulart Brand Packaging Manager

07/03/2018 Reviewer Ziaul Karim Head of Strategic Brand Packaging

Reviewer Nathan Thurston Head of Materials

Reviewer Stephen Lewis Head of Structures

Principal Packaging Development

Reviewer Pedro Acosta
Manager

Regional Packaging and Material

Reviewer S Balakumar
Development Manager, APME

Regional Packaging and Material

Reviewer Adoniran Cheddi
Development Manager, AMSSA

Regional Packaging and Material

Reviewer Goodwill Ndolvu
Development Manager, ENA

Reviewer Darrell Vian Group Head of Packaging

Distribution
Name Title

Geometry Global (names and details tbc)

Product Centre Packaging Teams (names and details tbc)
Combustible Packaging Team members
NGP Packaging Team members
Key external development partners (central barrel proof supplier, toolkit
agency)
PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 4 OF 39
CHAPTER 1
1.0 PROCESS AND GUIDELINES FOR AGENCIES
1.1 PURPOSE
This section of the document establishes guidelines for design agencies for creation of artworks, physical
proofs and associated content.

The output from the agencies will be used for technical development of packaging components and
creation of Packaging Toolkits. The toolkits will be used for development of materials for commercial
production at various BAT locations. More details on Toolkits and commercial aspects of packaging can
be found in Section 2 of this document.

Adherence to the guidelines is vital for creation of a robust technical development toolkit (details in
Chapter 2) by packaging developers at BAT.

1.2 SCOPE
The guidelines cover the specification of output to be used for technical packaging development. The
output includes materials, both physical and digital, from design agencies once marketing approval of
designs have been granted.

The document specifies what needs to be provided, how information is to be presented and rules for
digital data, e.g., artworks, images as well physical references, e.g., proofs and progressives.

The document has been created with primary focus on the packaging components and development
process for combustible products. However, the same principles would apply for other categories.

PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 5 OF 39

1.3 KEY STEPS IN PACKAGING TOOLKIT DEVELOPMENT

Brand Packaging Process Flow (visual only)

The Brand Packaging Process Flow, shows the packaging development process from creative concept until
the roll out phase of packaging. Chapter 1 of this document touches upon elements in the agency
development phase of projects.

Brand Packaging
process flow.pdf

Commercial contexts, sourcing strategies and technical capabilities vary across the BAT geographies, so,
it is impractical to provide one set of guidelines that will be suitable commercial packaging development
at all locations. As far as possible the guidelines have been created based on the common denominators
at all locations. However, continued engagement between the design agency and the BAT Brand
Packaging contact from the initial stage of a project is vital to avoid late and costly rework.

It is important that the design agency follows the steps listed below to ensure that creative designs are
consistent with the technical and commercial feasibility.

Step 1: Provide early visibility of print and material features being considered for projects at the concept
exploration stage.
a. Any new print features, materials and combination will need an evaluation for technical
and commercial suitability before progressing to creative design
b. An initial supply base assessment would be necessary as in many instances technical and
commercial solution adopted at one location is not transferrable to another.

Step 2: Have a discussion with Brand Packaging before executing colour exploration, scatter proof and
mock-up production.
PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 6 OF 39
 a. So that comments and suggestions can be offered about features to be tested at the
exercise.
b. Brand Packaging attendance is discretionary at the exercise, and usually will not be
necessary if a prior review is held.

Step 3: Jointly review the artworks or repros of designs to be scatter proofed before the exercise.

Step 4: Once created and approved by the IBG, produce and supply 5 sets of proof sets
a. Details of proof requirements are outlined in section 3.0 – Flat proof content/format and
supply

Step 5: Supply artworks.

a. It is crucial that the artworks are consistent with the supplied proofs
b. Details of artwork requirements are outlined in section 4
c. Items received in Step 4 and Step 5 will form the basis for subsequent technical
development at BAT.

Step 6: If requested, attend the kick-off meeting for the technical development
d. Artworks are often required to be fine-tuned and construction modified during the kick-
off meeting discussion
e. Agency input might be necessary to understand any trade-offs and compromises that
might be necessary to facilitate production
f. Additional files from the agency, i.e., master images, might be necessary before the
development work.

Step 7: If requested, attend the barrel proofing exercise together with the Packaging Manager.

Step 8: Update, finalise and reissue artwork after the barrel proofing. Brand Packaging will provide the
repro from engraver for the work so that the artwork can be aligned.

Step 9: Create and issue Packaging Guidelines document.

PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 7 OF 39

2.0 GUIDELINES FOR ARTWORK SETUP
The section explains the rules and technical parameters that need to be followed as well as various
production tolerances to be considered in the creation of final artworks to be supplied to BAT.

Note: the guidelines are for design agencies to create artworks for the kicking off the development of
packaging toolkits. Technical artworks created at BAT Product Centres for commercial development will
use the agency files as the basis but will follow the specifics and tolerances as relevant for regional
converters and printers.

2.1 PACKS AND CARTONS

• Unless specifically requested or authorised, artworks must not exceed
10 colours A typical gravure or offset printing line has 10 stations of
which 4 must be reserved for CMYK (used for the Pictorial Health
Warnings) and an additional station for the OP varnish.
• There may be additional commercial or technical requirements in
specific market context which could make fewer colours available for
Colours design. Feedback will be provided once artworks are reviewed.
• Colours used for the Pictorial Health Warnings must not be shared with
any design elements unless it has been discussed and agreed.
• A for all colours used on artworks, a Pantone equivalent or nearest
Pantone match must be provided separately. This will be used for 3d
Renders, visualisation, inserts, printed poly, promotional and
merchandising materials etc.
• Master artworks must be in AI format (more details and version
outlined later in the document).
File Format • Images must be in Tiff or PSD
• Images must be linked and not embedded in the artwork. Files to be
supplied separately.
• All texts must be converted into paths.
• Additional copies of the artwork with live text to be provided.
Fonts • Any bespoke typeface created for a project must be provided as a
separate file (this is required for local amendments to copy, variants,
back of pack stories etc)
• Minimum Bitmap resolution 300 dpi @ 100% scale.
• Minimum 140 lines per cm @ 100% scale.
Image Resolution
• Images which include texts must have a minimum resolution of 400 dpi
@100% scale
• 0.17 mm positive elements (for mechanical engraving excluding PHW
Minimum Line colours)
Thickness • 0.20 mm negative elements (for mechanical engraving excluding PHW
colours)
PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 8 OF 39
 • 0.12 mm positive elements for laser engraving (metallic colours)
• 0.15 mm negative elements for laser engraving (metallic colours)
Note: Smaller values might be possible depending on the engraving
technology but must be checked & confirmed beforehand.
• Priority is given to the printer specification, process standard 0.20 mm.
(Minimum is 0.10 mm in some cases)
• Cut-outs from two non-metallic colours for text elements make the grip
Trapping/Gripping visible and must be avoided. Consider overprint with silver.
• IMPORTANT: Do not put any traps in the artworks. The points above
are for visualising how the final design would print but the actual
trapping would be done by the engraver at the repro stage.
• Minimum size is 80% and the required quite zone of minimum 2.0mm
on both sides of the bar code must be created. Example

Barcodes

Technical Drawing • Artwork must always be produced on the specified profile/Technical

Drawing provided by BAT.
Bleed • 2mm run around of all cut lines.
• Elements like tax stamps, seals, date codes, etc. must be defined on
their own separation.
Additional elements
• These elements must follow a layout or a reference file provided by the
relevant packaging developer at BAT
• If used in the agency artworks, positioning of all technical elements
Technical Elements (Printers Boxes, Cutting Marks, etc.) are to follow the approved BAT
technical layout file.
• All data must be set up in Layers.
• Must have Legend, Profile, Cutting, Varnish and Embossing in separate
Layers.
Layers
• If hot foil is used and has reliefs (emboss, deboss, or both), it must be
shown as a separate layer and must not to be combined with the emboss
layer for the base pack.
• BAT will provide the details of the HW requirements and in most cases,
supply a reference artwork or layout
Health Warnings • The provided Health Warning Templates / PHW Templates must be
used in their original size and placement.
• Pictures must be linked in the AI file, not embedded.

Legend • All information must be included, see the PDF attached Legend
example.
PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 9 OF 39
 • Must include the Emboss/Varnish-Scale at HL= 1:6 / OU= 1:8
Substrate • Substrate must be clearly identified and included in the Legend.
• Emboss
0.40 mm minimum element size
Emboss and deboss 0.10mm minimum distance
Minimum Element • Deboss
Thickness 0.10mm minimum element size
0.40mm minimum distance
• 0.50mm Minimum gap between embossed and debossed elements
• Emboss and deboss elements should be represented in separate
Emboss and debosses - colours.
Layers • Must have Legend, Profile, and Embossing/Debossing in separate
Layers.
• All information must be included, see the PDF attached Legend
Emboss and deboss
example.
Legend
• Must include the Emboss/Varnish-Scale at HL= 1:6 / OU= 1:8

2.2 RELOC LABELS

General Print • Normal UV Flexo print.
Specifications • 6 to 9 colours, depending on the base material and design.
• Adobe Illustrator
• Esko Package (Normalised PDF)
• Artpro
Accepted File Format
• Adobe Photoshop
Images in CMYK format.
PSD files with all construction layers.
• All texts must be vectors.
• Minimum font thickness (positive) 0.1mm (in 1 colour only)
• Minimum font thickness (negative) 0.2mm (in 1 colour only)

• Minimum font thickness (negative) 0.24mm (in 4 process colours) – The

use of a key line (0.2 mm) is strongly recommended to avoid blurring.
• Any bespoke typeface created for a project must be provided as a
Fonts separate file (this is required for local amendments to copy, variants, etc.
as required)

PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 10 OF 39

 • Minimum Bitmap resolution 300 dpi @ 100% scale.
Image Resolution
• Minimum 140 lines per cm @ 100% scale.
• Minimum line thickness (positive) 0.1mm (in 1 colour only)
Minimum Line • Minimum line thickness (negative) 0.2mm (in 1 colour only)
Thickness • Minimum line thickness (negative) 0.24mm (in 4 process colours) – The
use of a bildboarder (0.2 mm) is strongly recommended.
• Minimum font / line thickness (silkscreen / tactile varnish) 0.3 mm
Special varnishes • Maximum font / line thickness (silkscreen / tactile varnish) 0.9 mm
• Minimum font / line thickness (gloss varnish) 0.3mm
• Process standard 0.20 mm.
Trapping/Gripping • IMPORTANT: Do not put any traps in the artworks. The point above is
for you to be able to visualise how the final design would print but the
actual trapping would be done by the engraver at the repro stage.

Technical Drawing • Artwork must always be produced on the specified profile/Technical

Drawing.
• 2mm bleed for all cut lines.
• 1.5mm text free area from all cut lines.

Bleed & Text Security

Areas

Screening Rule • 175 to 200 lines per inch.

• Minimum printing dot: 8%.
Printing Dot
• Maximum printing dot: 100%.
Colours • Each colour must have its own separation.
• All data must be set up in Layers.
Layers
• Must have Legend, Profile, Cutting and Varnish in separate Layers.

2.3 TIPPING
Print Stations • Normal Gravure printing process with 4 colour stations.
Accepted File Format • Must be in Illustrator/Art Pro.
• All texts must be converted into paths.
Fonts
• Must not use free fonts.

PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 11 OF 39

 • Any bespoke typeface created for a project must be provided as a
separate file (this is required for local amendments to copy, variants, etc.
as required)

Image Resolution • Bitmaps must not be used. If an image or icon is necessary, it must be
used as a vector.
• 0.20 mm positive elements (for mechanical engraving excluding PHW
colours)
Minimum Line • 0.25 mm negative elements (for mechanical engraving excluding PHW
Thickness colours)
Note: these values are different from paperboard printing as tipping is
printed on uncoated material.
• Priority is given to the printer specification, process standard 0.20 mm.
• Cut-outs from two non-metallic colours for text elements make the grip
visible and must be avoided. Consider overprint with silver.
Trapping/Gripping
• IMPORTANT: Do not put any traps in the artworks. The points above
are for you to be able to visualise how the final design would print but
the actual trapping would be done by the engraver at the repro stage.
• Artwork must always be produced on the specified profile/Technical
Drawing.
Technical Drawing
• The design must follow the specified logo repeat distance compatible
with the stick dimensions.
• Discrete design elements (brand logos, icons, devices, etc.) must be
pulled back by at least 0.8mm from tipping edges. Wallpaper patterns or
Slitting Tolerance solid colour is acceptable.
• If a printed band is placed at the edge of the tipping it must have a
thickness of minimum 1.0 mm but ideally such designs should be
avoided.
• Each colour must have its own separation.
• The colours must never be specified in RGB.
Colours
• Only colours from the BAT approved Tipping Colour Catalogue will be
accepted. No other colours – no exceptions.
• All data must be set up in Layers.
Layers
• Must have Legend, Profile, Colours in separate Layers.
Substrate • Tipping is always printed on an uncoated, white base material

2.4 INNER BUNDLE (TRADITIONAL)

Colours • Typically, 1 but no more than 2 colours.
• Usually artworks are not necessary for single solid colour jobs. If a
Accepted File Format pattern or multiple colours are used the file must be supplied in
Illustrator/Art Pro.
Minimum Line • Minimum line thickness (positive) 0.1mm (in 1 colour only).
Thickness Minimum line thickness (negative) 0.2mm (in 1 colour only).

PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 12 OF 39

 • Each colour must have its own separation.
• The colours must never be specified in RGB.
Colours
• The colours must be defined either in terms of Pantone reference or
pack elements (e.g. Matching to the top panel of the pack).
• The base material is silver foil, so the result will always have a metallic
Substrate finish. It can be slightly matt or bright depending on the side of the foil
used. This must be specified.

2.5 INNER BUNDLE (FOR RELOC)

• Typically, 1 but no more than 2 colours
• If 2 colours are used, one should be a solid background and another to
Colours create a wallpaper pattern, non-registered to the first colour. Although,
depending on the supplier, registered colours are possible but must be
checked beforehand.
• Solid colour reverse printing is possible if necessary.
• Usually artworks are not necessary for single solid colour jobs. If a
Accepted File Format pattern or multiple colours are used the file must be supplied in
Illustrator
Minimum Line • Minimum line thickness (positive) 0.1mm (in 1 colour only).
Thickness • Minimum line thickness (negative) 0.2mm (in 1 colour only).
• Each colour must have its own separation.
• The colours must never be specified in RGB.
Colours
• The colours must be defined either in terms of Pantone reference or
pack elements (e.g. Matching to the top panel of the pack).
• The base material is silver foil, so the result will always have a metallic
Substrate finish. It can be slightly matt or bright depending on the side of the foil
used. This must be specified.

PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 13 OF 39

3.0 FLAT PROOF CONTENT/FORMAT AND
SUPPLY
After approval of print test results and approval of 360’s from Brands, physical proofs are to be submitted
to the respective Packaging developer. This section describes the requirements of how the proofs are to
be created and supplied.

• Printed in offset. digital proofs may be acceptable for some components with prior agreement with
the Packaging Manager.
• On the right substrate if feasible. If not, on a substrate agreed with the Packaging Manager
• Substrate with pre-printed gravure silver primer may be used to simulate metallic finishes. Any other
form of simulation, e.g., dull hot foil for metallic inks must be agreed beforehand.
• The print must contain the complete artwork with all panels of the packaging component.
• Colour bars and tint blocks must for part of the printed proof. Tint blocks to contain blocks at 5%, 10%
to 100% in increments of 10%. A comments box to be included in the proof providing a basic
description and details of any deviation from the guidelines.
• All print proofs must be accompanied by progressives i.e., individual colours printed on their own on
the substrate
• Unless agreed otherwise, 5 sets of composite proofs and progressives are to be supplied.

Progressive proofs

PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 14 OF 39

4.0 FILE CREATION GUIDELINES
The artwork files must be created, named and issued as per the guidelines in this section.

Body of the artwork

• placed to the left of the information panel
• at 100% scale, single up
• on correct profile drawing (to be obtained from the Packaging Manager)
• on correct Health Warning layout, unless instructed otherwise
• showing necessary dimensions as requested, e.g., capsule position or band thickness on tippings

Information panel
It needs to contain the following information in the order below:
• Brand name > Project name > Market and variant
• Creation date > Version
• Artwork creator
• Profile reference
• Substrate referring Matrix board category
• Colour sequence including varnishes
• Thumbnails for additional features, i.e. emboss, deboss, hot foil
• Scale factor used for thumbnails
• Caption for thumbnails
• Statement of compliance with guidelines, detailing any deviation

PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 15 OF 39

5.0 ARTWORK TEMPLATE
The agency is to create a master template. To facilitate the artwork review, all artworks must be
developed on the same template.

File naming

The file names must follow the guidelines in Appendix 2 – (Naming Convention for BAT Packaging Files)

Format
All BAT packaging files are to be provided in the following formats
- Composite PDF (with layers preserved)
- Adobe Illustrator (with CS6 compatibility on), all texts converted to paths
- Adobe Illustrator (with CS6 compatibility on), all texts kept live

Images must be linked, not embedded, and supplied separately in the same parent folder

Artwork template
PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 16 OF 39
CHAPTER 2
6.0 TOOLKITS FOR DEVELOPMENT

6.1 PURPOSE
The section of the document provides an outline of the components that will be contained in the
packaging toolkits released to the BAT packaging teams based in Product Centres.

6.2 SCOPE
For ranges developed for global deployment, a Full Global Toolkit will be developed, compiled and
released by the relevant Brand Packaging Manager. While every effort will be made to ensure the toolkit
is released as a single package covering all components, sometimes it would be unavoidable to release it
in multiple modules. This is often due to longer lead time in developing complex packaging components,
i.e., special inner bundle embossing, a tipping design requiring a print trial etc. In such circumstances, the
number of modules will be kept as few as possible.

For designs and ranges that are bespoke for a single market or ring-fenced for a market cluster without a
global roll-out potential, the package will take the form of a Market Specific Toolkit contain the necessary
agency artworks, color targets, progressive proofs and additional guidance for the development to be
managed by the packaging teams at the Product Centers.

As with the previous section of the document, this section has been created with primary focus on the
development process and packaging components process for combustible products. However, the same
principles would apply for other categories.

PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 17 OF 39

7.0 TOOLKIT COMPONENT SPECIFICATION
Below is a brief description of the contents of a Full Global Toolkit. Table 1 at the end of the section
contains a summary. It also lists the items provide for Market Specific Toolkits.

7.1 PACKS AND CARTONS

Master Artworks

• The files will be based on the pilot market regulatory specifics. If designs for additional regulatory
scenarios are needed, additional master files will be supplied.
• The artworks will be created using the global profile drawing for the format. Ideally the RPCs
should follow the same profile drawing after checking with the factory. However, due to various
technical reasons, acquisitions etc. sometimes slightly different profile for the same format exists
at different factories. If it is unavoidable to use a locally modified profile, the RPCs will have to
adapt artworks to the required profile.
• A mini-brand standards document will be provided with Global ranges. This document would
contain a summary all the necessary technical details, HW guidelines and other design adaptation
guidelines.

Master images

• If images are used on the design, they will be supplied as separate image files in TIF, PSD or EPS
format at a resolution of 300 dpi or higher.
• Master images of HWs will not be provided. In some cases, a low-resolution place holder will be
included but the RPCs will have swap them images at the right size, placement and resolution.

Colour Targets

• Will be included in the toolkit in the form of approved barrel proof sheets for a gravure workflow.
If range is meant for a single market with the RPCs leading the development, physical mock-ups
or agency prints with progressive proofs will be provided.
• These targets are to be used as the reference for matching the inks if necessary, as well as for PQ
and the first print signoff.
• In the unlikely event, if the agency proof is on a dissimilar substrate, ink draw-downs on the right
substrate from a global ink supplier will be shared if requested. This is unlikely for FMC’s where
the agency will use a similar substrate but is possible in future, particularly, if a NGP or THP device
packaging is to be ported on to a FMC-style packaging or substrate.

PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 18 OF 39

Supporting Information

• Substrate details – the Matrix board category will be the default. However, specific supplier’s
grade used for the global development will be included as reference. The RPCS need to define the
specific supplier’s grade to use based on the regional destination board portfolio.
• Ink technical datasheet – the datasheet for the inks matched by Brand Packaging and used for
global barrel proofing will be included. The same will be supplied for offset work flows if managed
by Brand Packaging.
• Repro and cylinder specifications (for gravure projects)– will be included based on the
specification used for the barrel proofing. If the Region uses a different engraver, they are
encouraged to carry out a trial or repeat the proofing using this specification as a guideline.
• Embosses and debosses – typically the supplied proofs will be embossed and debossed.
• ‘Watch-outs’ and specific testing requirement – will be communicated if relevant in the
accompanying GPS document.
• PSC documents – The Annex 3 self-certification will be supplied for any new inks used for the
barrel proofing. These will be on an ink level; therefore, the converter will still have to provide the
Annex 3 compliance certificate for the finished packaging components supplied to the factory.

7.2 TIPPINGS
Master Artworks

• Will be supplied in AI and layered PDF format.

• The design will follow the logo repeat distance appropriate for the cigarette format as the Core
Chassis
• If a different logo repeat is to be used due to non-standard cigarette dimensions, the RPC will
have to adapt the design to the required repeat.
Colour Targets

• Unless there is a specific business requirement, all colours used on the design will be referenced
against the BAT Tipping Colour Catalogue and will be indicated by their CS reference numbers.
• Due to special requirements, if there are colours or coatings used in the design that are outside
of the catalogue, a suitable visual reference may be provided. If no such visual exists, an ink
drawdown on the right substrate from a tipping supplier will be included.
• For cork or cork-on-white designs, colours will be indicated by the S-series references used within
BAT.
Supporting Information
• Substrate details – will be stated as tipping base paper performance grade (TBPxx) for both cork
and white tipping base papers.
• PSC minute number (and any stipulation) – if new components (e.g.., a coating or off-catalogue
inks) are used, a PS ingredients evaluation from one of the tipping suppliers will be submitted by
Brand Packaging and the minute number provided. If the region uses a different supplier or
substitutes the material, a submission to PSC is to be made by the RPC. As these submissions and
evaluations will be done on an ink or varnish level, a final submission will be necessary for the
finished tipping design before commercial production.
• Further guidance can be found in the BAT Tipping Design and Technical Guidelines

PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 19 OF 39

7.3 DIE PRINT
Master Artworks

• Will be provided in AI and PDF formats.

• Die designs require optimization at the manufacturer before producing the die. For Global designs,
the optimization will be carried out and drawing supplied by Brand Packaging. A regional review
will be necessary with the supplier if a different die manufacturer is used.

Colour Targets

• All colours used on the design will be indicated by the CS references numbers from the ‘BAT colour
reference catalogue for cigarette die prints’
• Due to stringent toxicological requirements, no new die colour will be developed or used in
designs.

7.4 INNER BUNDLE (CONVENTIONAL)

Master Artworks

• Will be provided in AI and PDF formats for printed designs

• If unprinted or of a single solid colour without any design artwork, the specification will be stated
in the accompanying GPS.

Colour Targets

• A visual reference or a Pantone number will be provided. If the development has already taken
place with the supplier for the pilot market, the internal code used by the supplier will be provided
as well.

Emboss details

• If an embossed design is used, the elements will appear as a separate layer in the master artwork.
For a special type of embosses i.e., Boegli Entero, waffle, Vividus etc, an associated Boegli drawing
and reference number will be included. The factory will have to make sure the final rollers are
compatible with the packing line used for production.
• For overall pin-up design, the pin pitch will be stated in the accompanying GPS.

Supporting information

• Substrate details – material type, thickness and grammage will be stated in the accompanying
GPS.
• Emboss specification – technical specification including pin pitch plus any additional information
required for the packing line, i.e. 3-roller system or Boegli Vividus kit will be stated in the GPS.

PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 20 OF 39

7.5 INNER BUNDLE (FOR RELOC OR MAXIM, I.E. SINGLE OPENING RELOC)
Master Artworks

• Will be provided in AI and PDF formats for printed designs

• If unprinted or of a single solid colour without any design artwork, the specification will be stated
in the accompanying GPS.
• The artwork will follow the global profile drawing for the format. If a local or regional profile is
used (which typically varies by eye-mark sizes), the artwork need to be adjusted by the RPC in
consultation with the factory.

Colour Targets

• A visual reference or a Pantone number will be provided. If the development has already taken
place with the supplier for the pilot market, the internal code used by the supplier will be provided
as well.

Emboss details (currently unavailable in BAT but the technology is being considered for future)

• If an embossed design is used, the elements will appear as a separate layer in the master artwork.
For a special type of embosses i.e., Boegli Entero, waffle, Vividus etc, an associated Boegli drawing
and reference number will be included.

7.8 RELOC LABEL (CONVENTIONAL, I.E., NON-MAXIM)

Master Artworks

• Will be provided in AI and PDF formats for printed designs

• The artwork will follow the global profile drawing for the format. If a local or regional profile is
used (which is typically due to formats from acquisitions, i.e., IndoSlims), the artworks need to be
adjusted by the RPC in consultation with the factory.

Colour Targets

• Visual references or a Pantone numbers will be provided. If the development has already taken
place with the supplier for the pilot market, the internal code used by the supplier will be provided
as well.
• In some cases, if the design has been proofed and signed off by Brand Packaging as it is sometimes
the case for cross-regional sourcing, the toolkit will contain approved physical references.

PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 21 OF 39

7.9 RELOC LABEL (MAXIM)
Master Artworks

• Will be provided in AI and PDF formats. The artwork will follow the global profile drawing for the
format. No local adaptation is permitted at this point.

Colour Targets

• Not required by individual projects. Currently the labels are non-Branded, printed in silver and
black for eye marks regardless of format.

7.10 INNER FRAME

Master Artworks

• Will be provided in AI and PDF formats for printed designs

• If unprinted or of a single solid colour without any design artwork, the specification will be stated
in the accompanying GPS.
• The artwork will follow the global profile drawing for the format. If a local or regional profile is
used (which typically varies by eye-mark details for registered designs, the artwork need to be
adjusted by the RPC in consultation with the factory.

Colour Targets

• In most cases the colour will need to be matched against a specific element of the pack which will
be stated in the accompanying GPS. For other instances, a visual reference or a Pantone number
will be provided.
• If the development has already taken place with the supplier for the pilot market, the internal
code used by the supplier will be provided.

Supporting information

• Substrate details – the Matrix board category will be the default. The RPCS need to define the
specific supplier’s grade to use based on the regional destination board portfolio.
• The other supporting details, particularly for a printed and registered designs, will be similar to
those of the packs and cartons.

PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 22 OF 39

7.11 FILMS AND TEAR TAPE
• Generic details, thickness and width will be provide

7.12 SHIPPING CASES

• The global standard for Shipping Cases is generic and unprinted. Branded designs, if required, are
to be developed by the end market directly working with the RPCs. Ideally these should be single
colour designs.

Table 1: Composition of toolkits

Contents: Single market or

Component Design element Contents: Full global toolkit
regional toolkit
Pilot market, generic 0% HW
Pilot market variants plus HW
Artworks artworks and HW adaptation
adaptation guidelines
guidelines
Images Yes, if used Yes, if used
Layered pdf based on Pilot
Repro
market variants
Packs and Agency proofs, flats and
Colour targets Barrel proofs
cartons progressives
Substrate Matrix board category Matrix board category
Profile BAT drawing BAT drawing
Technical datasheet and
Inks
sequence
Cylinders Engraving specification
Guidelines Mini Brand Standards As required
Artworks Full range Single market variants
Tipping catalogue reference Tipping catalogue reference
Colour targets
numbers numbers
Tipping Substrate Performance grade (TBPxx) Performance grade (TBPxx)
Dimensions and logo repeat Dimensions and logo repeat
Profile
information information
Guidelines Mini Brand Standards
Artworks Full range Pilot market variants
Die print colour reference Die print colour reference
Colour targets
Die print number number
Supplier Boegli drawing and design
reference reference
Inner bundle
Artworks Full range, if relevant Pilot market variants, if relevant
(incl reloc)

PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 23 OF 39

 Visual reference or pantone
Visual reference or pantone
Colour targets numbers, approved physical
numbers
reference if available
Profile BAT profile drawing BAT profile drawing

Type, thickness, grammage, Type, thickness, grammage,

Substrate
lamination direction lamination direction

Emboss Boegli emboss drawing

Supplier Matched drawdowns and lab
reference codes
Guidelines Mini Brand Standard
Artworks Full range Single market variants
Repro If relevant and necessary
Visual reference or pantone
Reloc label Colour targets numbers, approved physical Visual reference or pantone code
reference if available
Profile BAT profile drawing BAT profile drawing
Guidelines Mini Brand Standard

Artworks Full range Single market variants, if relevant

Visual reference or pantone

Colour targets numbers, approved physical Visual reference or pantone code
Inner frame reference if available
Substrate Matrix board category Matrix board category
Profile BAT profile drawing BAT profile drawing
Guidelines Mini Brand Standards
Material Generic details Generic details
Films and TOS
Dimensions Thickness, width Thickness, width
Generally, none. In some
cases, a single colour
Shipping Case Artwork
illustration may be provided
for regional adaptation.

PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 24 OF 39

8.0 GLOBAL PACKAGING SPECIFICATION
The Global Packaging Specification (GPS), is the document where the technical specifications of the
packaging components will be summarized in a table. The document is to be used in conjunction with the
physical samples, digital data, and guidance or mini-Brand Standards for commercial development of
packaging for regional deployment.

Additionally, the GPS will be useful for the Manufacturing and Quality teams at factories to understand
the material specifics and ascertain any testing or qualification requirements. The same will be used by
NPI for requesting creation of new material SKUs.

The example below shows the structure of a GPS with illustrative data.

Packaging GPS (illustrative data in italics)

Brand Dunhill

Range Sensations

Project Name Optimus

Market(s) GTR Aspac

GPS Version 1.0

First release date 13/10/2017

Creator Michael Zoeller

Overview

Attribute Value Visuals Notes

Pack format KS BE 20s

Collation 7-6-7

Stick format KS 83mm

Tipping Cork on white

range visual
Die Print No
if available
Reloc No

Maxim No

Inner frame type Shaped and registered

Inner bundle type Foil with embossed logo

PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 25 OF 39

 Outer Carton

Shipping Case type Unbranded

Pack assembly drawing reference D124-999A

Component - Tipping

Attribute Value Visuals Notes

Number of SKUs 3

SKU identifier or variant name, if

Coloured band red, green, blue
applicable

Type Cork on white

Cork part
Shade reference S518
reference

Base paper TBP11

Single length 32mm

Logo repeat 24.50mm

base cork, top

Number of colours (excluding lip
3 cork, band
release)
colour

Flexo, if
required, needs
Print process Gravure
to be developed
regionally

Distance of the capsule icon 1 (if RPC to reconfirm

8mm
confirmed) before tooling

Distance of the capsule icon 2 (if RPC to reconfirm

15mm
confirmed) before tooling

Special features range visual

Sweetened Yes if available

Sensate No

Hot foiled No

Embossed No

Pre-perforated No

PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 26 OF 39

 Development Partner

Commercial Supplier (if known) Region to select

Component - Die print

Attribute Value Visuals Notes

Number of designs 1

Number of colours per design 1

Shade reference CS5901

Distance from tipping edge (1st

3mm
die)

Distance from tipping edge (2nd

n/a
die)

Drawing reference DD9999 range visual Boegli drawing

if available
Development Partner

Commercial supplier (if known) text

Component - Pack

Attribute Value Visuals Notes

Number of SKUs 3

SKU identifier or variant name, if

Mist, Frost, Boost
applicable

Format KS BE 20s

Profile ref D134-999C

Glue pattern drawing ref

range visual
Base board Matrix Class A
if available
Base board used for development Promina Style 15 pt

Print process Gravure

Total number of colours and

10
varnishes (including PHW)

Special features

Hot foil Yes Kurz MTS 512

PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 27 OF 39

 Special varnishes Yes UV tactile

Serial or unique QR code No

Windows patching No

Gravure up to embossing,
Conversion steps sheeting, off line hot foiling,
offline creasing and cutting

Special requirements n/a

Engraver (if known) Janoschka

Ethanol-free
Ink supplier (if known) Siegwerk
formulation

Development Partner

Converter (if known) Amcor Korea

Component - Outer

Attribute Value Visuals Notes

Number of SKUs 3

SKU identifier or variant name, if Colour of logo, printed variant

Red, green, blue
applicable name

Format Standard 200s

Profile ref D134-666D

Glue pattern drawing ref

Base board Matrix Class A + transmet

Base board used for development Promina Style 13 pt range visual

if available
Print process Flexo and UV offset

Total number of colours and

10
varnishes (including PHW)

Special features

Hot foil No

Dual cure soft

Special varnishes Yes
touch

Serial or unique QR code Yes on Panel D

PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 28 OF 39

 Windows patching No

Flexo (HW), sheeting, offset,

Conversion steps
offline serial coding

Special requirements n/a

Engraver (if known) n/a

Ink supplier (if known) Huber (flexo), Siegwerk (offset)

Development Partner

Converter (if known) Region to select

Component - Reloc Label

Attribute Value Visuals Notes

Number of SKUs 3

SKU identifier or variant name, if

Colour of tab Red, green, blue
applicable

Profile ref D134-111A

Base material (bottom) White BOPP

Base material (top) Clear BOPP Matt finish

Print process UV Flexo, silkscreen

Number of colours incl varnishes 5

Special features
range visual
Special varnishes Tactile
if available
Serial or unique QR code No

Others No

Conversion steps UV Flexo, offline silkscreen, cutting

Substantial tactile varnish

Special requirements coverage. A pre-MQS trial is
recommended.

Supplier
Tool maker (if known) Not known
managed

Supplier
Ink supplier (if known) Not known
managed

PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 29 OF 39

 Development Partner

Converter (if available) CCL Thailand

Component - Reloc Inner Bundle

Attribute Value Visuals Notes

Number of SKUs 1

SKU identifier or variant name, if

n/a
applicable

Profile ref D134-001X

Top film 20-micron BOPP

Bottom film 20-micron BOPP

Aluminium layer 9 microns dullside out

Print process Flexo

Number of colours including eye

3
mark range visual
if available
Special features n/a

Conversion steps Printing, laminating, slitting

Eye mark colours need to be

Special requirements confirmed with the factory. A trial
might be necessary.

Supplier
Tool maker (if known) Not known
managed

Ink supplier (if known) Sun Chemical

Development Partner

Converter (if known) Parkside Malaysia

Component - Standard Inner Bundle

Attribute Value Visuals Notes

Number of SKUs 3

SKU identifier or variant name, if range visual

Red, green, silver
applicable if available

Profile ref D134-123J

PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 30 OF 39

 Base material 6 micron foil over 25 gsm tissue Foil dullside out

Print process Gravure

Number of colours (excluding any 1 solid and 1

special coating, e.g. NC for 2 wallpaper
printability) overprint

Conversion steps Printing, laminating, slitting

Boegli drawing reference DD2201

Special requirements n/a

Supplier
Tool maker (if known) Not known
managed

Supplier
Ink supplier (if known) Not known
managed

Development Partner

Converter (if known) Vaassen

Component - Standard Inner Frame

Attribute Value Visuals Notes

Number of SKUs 3

SKU identifier or variant name, if

Red, green, silver
applicable

Registered or standard Registered

Shaped or standard Shaped

Profile ref D134-101A Focke

Base material Matrix Class B range visual

if available
Print process Gravure

Number of colours including

varnishes (but excluding any Eye mark in
3
special coating, e.g. NC for black
printability)

Conversion steps Printing, slitting

Special requirements n/a

PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 31 OF 39

 Supplier
Tool maker (if known) Not known
managed

Ink supplier (if known) Sun Chemical

Development Partner

Converter (if known) New Toyo

Component - Pack film

Attribute Value Visuals Notes

Clear or Printed Clear Existing material

Profile ref

Number of SKUs 1

SKU identifier or variant name, if range visual

n/a
applicable if available

Material BOPP

Thickness 20 microns

Coated or uncoated Coated

Component - Outer film

Attribute Value Visuals Notes

Clear or Printed Clear Existing material

Profile ref

Number of SKUs 1

(if multiple )SKU identifier / variant range visual

n/a
name if applicable if available

Type BOPP

Thickness 20 microns

Coated or uncoated Uncoated

Component - Tear Tapes

Attribute Value Visuals Notes

Pack TOS - Clear or Printed Clear Existing material

PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 32 OF 39

 Pack TOS - Number of SKUs 1

Pack TOS - Width 1.6mm

range visual
Outer TOS - Clear or Printed Printed with BAT corporate design Existing material
if available
Outer TOS - Number of SKUs 1

Outer TOS - Width 1.6mm

Component - Shipping Case

Attribute Value Visuals Notes

Generic or branded Branded

Number of colours 1

Base material Kraft corrugated

range visual
if available Local, RPC to
Content TBC
manage

Local, RPC to
Drawing reference TBC
manage

PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 33 OF 39

APPENDIX 1
Naming Convention for BAT Packaging artwork files

OVERVIEW
The purpose of this appendix is to provide a standardized naming convention across all packaging files
supplied by external agencies to the BAT Central Packaging team.

The guidelines that follow set out:

• the standardized naming convention

• the list of agreed abbreviations

It is the responsibility of the external agency teams to ensure adherence of this naming convention across
all files supplied to the BAT Central Packaging team.

The BAT Central Packaging team reserves the right to reject files based on the naming convention not
being correctly applied, at the relevant Brand Packaging Manager’s discretion. Reviews of adherence to
the naming convention will be carried out by the BAT Central Packaging team on a quarterly basis.

STANDARDIZED NAMING CONVENTION

The following agreed standardized naming convention should be applied across all Packaging Files:

• Brand_Range_Format_Pack Type_SKU_Component_Market_Intelliversion

Part Description
Brand Denotes the Global Drive Brand
Range Denotes the Design or Product Range as given by the IBG
Format Denotes the Cigarette Format and length
Pack Type Denotes the characterizing features of the Hinge Lid’s Corners/Edges
SKU Denotes the Product ID as given by the IBG
Component Denotes the Packaging Component
Market Denotes the End Market, if applicable
Intelliversion Denotes the Intelliversion number of the file

PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 34 OF 39

IntelliVersion

The IntelliVersion is a two-digit version number system, denoting both approved BAT version number (first
digit) and unapproved internal Agency version number (second digit).

Prior to approval, a file’s first IntelliVersion number will read 0-1, increasing to 0-2 for internal amends
loops and BAT feedback etc. Once a file has received BAT approval, the IntelliVersion will read 1-0.

If that approved file then requires subsequent amends, the next IntelliVersion would read 1-1, increasing
to 1-2 for internal amends loops and BAT feedback etc. Once that file has received BAT approval, the
IntelliVersion would read 2-0.

In summary, approved published files will show a 0 as the second digit; work in progression files will show
any other numerical digit as the second digit.

In context:

Hinge Lid (HL)

• DH_Brand Code_DS 83_SQ_4mg_HL_Russia_v1-0

Inner Bundle (IB)

• RM_Brand Code_INT 94_All SKUs_IB_Ukraine_v0-1

Inner Frame (IF)

• PM_Value Trad_SKS 99_BE_All SKUs_IF_UK_v3-0

Outer (OU)

• VR_Brand Code_KS 83 XL_SQ_6mg_OU_Spain_v1-4

Tipping (TP)

• KE_Core White_FC 94_10mg_TP_Iraq_v0-3

• VG_La Cigarette_SS 99_All SKUs_TP_Poland_v2-0

Other

• LS_Smooth Series_DL 90_Packaging Guidelines_v2-0

For components which aren’t determined by Pack Type (characterizing features of the HL), this may be
omitted, i.e. Inner Bundle, Tipping. For components which may go across multiple SKUs, i.e. Tipping, Inner
Bundle, Inner Frame, the SKU descriptor may read “All SKUs”.

ABBREVIATIONS
Brand

DH Dunhill

PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 35 OF 39

 KE Kent
LS Lucky Strike
PM Pall Mall
RM Rothmans
VG Vogue
VR Viceroy

Format

DL 90 Demi Long 90mm

DS 83 Demi Slim 83mm
FC 90 Slims (Fine Cut) 90mm
FC 94 Slims (Fine Cut) 94mm
INT 94 International 94mm
KS 83* King Size 83mm
KSSS 83 King Size Super Slim 83mm
LG 79 Long 79mm
SKS 99 Super King Size 99mm
SS 90 Super Slim 90mm
SS 99 Super Slim 99mm

*For the KS format, if generating files for a pack size other than the standard 20s pack, please also give
further detail:

KS 83 6+X King Size 83mm 6+X stick count

KS 83 25s King Size 83mm 25 stick count
KS 83 XL King Size 83mm 30 stick count
KS 83 XXL King Size 83mm 40 stick count

Pack Type

BE Bevel Edge HL
CL Click Pack SQ
CP Champs Pack (aka Octagonal)
DB Double Bundle Square HL

PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 36 OF 39

 FB Flap Box
FW Flow Wrap Pack
HC Hard Cup
IK Shaped Lid (KS Shaped Lid Exposed IF)
LD Lady Lighter Round Front HL
LP Latin Pack
MB Metal Box
OB Oval Box
OF Round Corner Front Left HL
OT Open Top Box
PU Push Button HL
RC Round Corner HL
RF Round Corner Front HL
RW Wave Round Corner Front HL
SB Shoulder Box (Laube)
SC Soft Cup
SF Side Opening HL
SH Sliding HL
SHL Short Lid
SL Straight Lid
SQ Square Corner HL
SSL Shell & Slide
SX Springbox HL
TB Tin Box
TE Two Bevel Edge HL
TL Top Less
TN Tin
TT Twin Ten HL
WA Reloc Square Corner HL
WC Wallet Round Front HL

PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 37 OF 39

 WE Reloc Bevel Edge HL
WS Wallet Square Corner HL
XS X Pack Square Corner HL

Component

HL Hinge Lid (Pack)

IB Inner Bundle
IF Inner Frame
INS Insert
OU Outer
PF Printed Film
SH Shipper
SL Reloc Seal
TP Tipping

PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 38 OF 39

APPENDIX 2
Mini Brand Standard

Full global toolkits will contain a mini brand standard which would provide additional guidance for local
adaptations. The mini Brand Standard will not replace the GPS and need to use in conjunction with the
GPS, supplied artworks and other data to create artworks for deployment.

The visual show a few page extracts from such a document.

Extracts from the mini brand standard

PACKAGING TOOLKIT – PROCESS AND GUIDELINES PAGE 39 OF 39