Frequently Asked Questions

General

Etching is the process of hand engraving or carving glass via sandblasting, followed by hand painting. Screen printing requires specialty print machines specifically designed to handle bottles. When screen printing, thermal-plastic inks are applied via squeegee and screens before being fired in a high temperature Lehr for at least 2-3 hours to permanently fuse paint to the glass.

No, we also work on glass containers for beer and spirits, gourmet food products, olive oil, cannabis, and water bottles.

In both screen printing and etching, a typical lead time is 3-4 months (from initial contact). Our process starts with artwork development, followed by pre-production sampling through complete production run. This timeline can fluctuate based on overall quantity of bottles and/or complexity of a project.

Screen print: 250 (12 pack) cases for 375ml – 750ml in size, single varietal.

Screen printed large formats (1.5L and 3L): for large formats we reference bottles instead of cases when determining quantities. We require a minimum of 120 bottles for 1.5Ls and 3Ls. Please be aware that the number of colors allowed could change our minimum requirements.

Etching: we have no minimums in custom etching.

Dressing: we have no minimums required for dressing and fulfillment.

Yes, but ONLY in the months of September and October.

Yes! We would love to have you in. Appointments are required. You can tour both screen printing and etching, as well as our showroom.

No, but we can receive full shiners Tax Paid.

Screen printed bottles are 100% recyclable. The paint gets melted down with and into the glass when being repurposed. Etched bottles are 100% recyclable after the paint has been removed which can very easily be stripped off the bottle with water and pressure. Screen printed and etched bottles are also perfect for upcycling; you can repurpose them for candles, water bottles or vases. We have even seen them turned into chandeliers!

We partner with vendors who participate in sustainable practices to ensure we are actively mindful of our carbon footprint as a company. The minimal waste generated by our production operation is almost 100% recyclable. We recycle pallet wrap, damaged boxes, and glass containers, as well as recycle or reuse wooden pallets. If we experience a quality control issue (misprint), paint is hand scraped from the un-fired ware and re-printed. In the rare case of a misprinted run that has already gone through the Lehr, the entirety of the product, glass, & cardboard case, is recycled.

Screen Printing

GLASS bottles and other cylindrical glass vessels typically intended to contain liquid.

Apparel, decanters, metal, plastic, wood, wine stems, and glassware.

We use high fire thermal plastic inks.

We currently have 8 machines: 3 fully automatic, and 5 semi-automatic machines along with 3 complete production lines.

Yes, with required minimums and design limitations.

No, we do not provide spray or frosted coatings of any kind.

Yes, but there are limitations regarding certain treatments.

No, we need empty bottles so they can be fired through Lehrs at 1180 degrees for permanent adhesion.

In screen print, numbering may only be done with a singular repeating statement on each bottle specific to the color layer it applies to.

Examples of numbering sequences or statements for screen printing:

  • 1 of 1,000 bottles made/produced
  • Only 350 cases produced
  • 1 of 350 bottles made
  • Limited production
  • Only 3 barrels produced.

In etching, individual numbering is possible for any number of bottles. Etching allows us to produce individual masks for numbers or specialty custom text making numbering sequences possible. For example: 1 of 100,

Etching

We use a combination of specialty process enamel paints for fine detail and intricate paint work. For large areas requiring consistent and even coverage, we use various spray paint brands and often make our custom spray paints that are applied via airbrushing.

Etching is a cold process, which allows us to work on a full product. This is because there is no heat application at any point in the process. Our etch studio is also temperature controlled allowing us to work on bottles any time of day. We will work on full bottles up to 6L in size. All sizes above 6L need to be brought to us empty due to liability and safety concerns.

Yes, we do. We reserve this for full products we work on in etching. We do not offer unlimited or indefinite cold storage.

No, they do not ever scan properly, if at all. If you require a barcode for an etched bottle, we strongly encourage you to plan on applying a barcode sticker.

Color

We can screen print up to 7 colors. We have the ability to print more but typically we use a repeating color already being utilized in the design.

We love playing with colors! Yes, we can create custom colors and we try to color match to the best of our ability. We will also create custom mixes to achieve specific textures or effects.

We offer metallic paints that are faux gold but look much different and are not as brilliant. They contain raw mica, which is natural sparkle/shimmer. We also provide true precious metal inks: 22 Carat gold, white gold/platinum, and copper.

Precious metal inks are expensive because they contain true precious metals (gold, platinum, copper). The price of our gold fluctuates with the market. Our precious materials can range from 7-12% of actual precious metal. Added cost also depends on how much is used based on design.

Glass

50ml up to 3L bottles.

375ml up to 27L.

1-5% depending on complexity of design and volume of production run.

Yes, but we require large minimums and custom tooling fees apply.

We carry a limited stock of large format bottles primarily 3Ls, 5Ls, and 6Ls intended for custom etching. We do not supply glass for screen print.

No, we do not currently accept bulk glass.

Dressing & Fulfillment

Blackening is the process of coating the inside of a bottle using a specific type of paint to give the illusion of it being “full”. This process is often done when producing display bottles that are never intended to be filled. You cannot fill a bottle that has been blackened due to the chemical nature of the paint.

We can do full dip, half dip, dripped wax, dollops, as well as emboss/deboss wax stamping.

Yes, we are happy to assist with shipping logistics as requested. We have a handful of preferred carriers we work with.

Yes, we can provide individual shippers for 1.5L bottles up to 27L bottles.

Design

Yes, our Art Department is led by one Art Director and four accompanying Production Artists.

We provide custom design services for both screen print and etching, including custom illustration and artwork. We have three different design service packages ranging in price depending on scope of project. We are happy to work with you on redesign as well, particularly when converting from paper to screen print or helping introduce screen printed labels into your portfolio.

Yes, frequently and often! We are happy to work alongside your designer or design team to help achieve your packaging vision.

Yes, we can create TTB files. We will NOT submit them on your behalf; however, we will provide you with the necessary files for successful submission.

Sampling

We provide a pre-production sample, which becomes your “press check”. Pre-production sampling is optional and not all projects require this process.

Yes, once we have a project and pricing commitment.

Yes, on a case-by-case basis. Artwork development and sampling fees will be charged prior to work being started.

Design FAQs

YES to all. We can print UPC and QR codes in a variety of different colors, not restricting you to traditional black and white coloring. Barcodes printed in white ink on a flint (clear bottle) will still scan.

Ensuring that all spot colors are on separate layers of the art file. We can only print one color per layer.

NO. Bergin’s paints are not CMYK and do not use the same pigments as traditional media. We can create custom paint mixes to get as close as possible to your suggested color call outs.

Trapping is the practice of overlapping the edges of objects to improve registration in printing. In some cases, we use knockouts to glass surface as our trap color creating space between two objects.

Vector art is graphic artwork that consists of points, lines, curves, and shapes based on mathematic formulas. Unlike raster images, vector art can be scaled up or down without loss of image resolution.

Not all raster images (JPEGs) are appropriate for screen printing or etching. All raster images must be reviewed by our art team to assess printability/etch ability before committing to the project. When submitting, all text and logos included in your art files must be vector art.

Screen Print: Yes, in screen print we are limited to one color per screen. We can do a max of 7 colors on a single package.

Etch: No, in etching we can use several different paints to achieve your vision.

Bergin will adjust art as necessary to ensure design is produced beautifully and accurately. It is on a rare occasion we receive artwork that is either print or etch ready without needing modification on our end. If significant changes are required, we will discuss with you or your designer first.

We need your updates 30-45 days ahead of your scheduled print date. Please try to consolidate ALL updates and changes together when submitting. Any time a new change is requested, new art files must be created and resubmitted for formal art approval.

If you have PMS colors called out, we can match them as closely as possible to the Ink Colors we have or we can send you a swatch bottle with available ink colors on it. Please note, some colors may require longer lead time to order from our suppliers. Selecting colors in advance is recommended.

CMYK and RGB color references are not accepted.

Please provide a physical example of your paper label if we are attempting to color match.

The best format is an Adobe Illustrator (ai.) packaged vector file with live text. That way we have all accompanying links and fonts. Otherwise, an ai. file or pdf. of all the artwork and typography vectorized and outlined will work.

Each new piece of art is discussed with the Etch and Paint Department for any necessary modifications to ensure a successful etch job. Important details that are too small, or lines that are too thin risk getting blown out during the sandblasting phase, so a digital artist will thicken up and enlarge details to meet minimum specs for a successful job. All modifications will be submitted to the client for approval before proceeding. A good rule of thumb is having all linework no smaller than .75 pt. to 1 pt. in thickness.

There are limitations in etching the shoulders or entire surface of a bottle. Burgundy bottles are easier to decorate when it comes to shoulder work but would require a bottle inspection before committing to shoulder decoration.

All artwork on the Etch Approval Form represents the stencil masks that the Etch Department will use to sandblast the art onto the bottle and is not a representation of the final product. However, all new art will require specific color callouts and/or a paper label to reference for color matching.