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Operations of a PSP: Packaging Converters

Operations of a PSP: Packaging Converters

Operations of Packaging Converters – Episode Summary

In this manufacturing-focused episode of The Print University, Ryan McAbee and Pat McGrew dive into the intricate operations of packaging converters—facilities that turn raw substrates into boxes, cartons, labels, and flexible pouches. For those in printing industry training programs for new employees, or organizations developing outsourced training for print production staff, this episode delivers an in-depth look at how packaging PSPs integrate materials science, supply chain management, and production automation.

The conversation begins with the two main segments: folding cartons and corrugated packaging. These environments convert paper-based substrates into structural packaging using processes like corrugation, die-cutting, creasing, gluing, and printing. Some converters even manufacture the substrate themselves or integrate printing with box formation in a single line.

Ryan and Pat also highlight the rise of web-to-pack operations—smaller, agile converters catering to short-run, highly customized orders with just-in-time production and digital printing. These converters increasingly rely on ERP and MES software for planning, material inventory, and execution. Hybrid equipment configurations are common, blending analog (flexo, offset) with digital inkjet and advanced die-cutting.

Flexible packaging and label production add further complexity with multilayer film structures, resealable components, and caustic-resistant linings. These converters must factor in material chemistry, environmental conditions, and end-use durability. With growing demand for sustainable packaging, converters are innovating with recycled content and new substrates like plant-based paper.

Whether serving CPG giants or indie ecommerce sellers, packaging converters are essential, evolving, and increasingly high-tech.

You Will Learn:

  • Packaging formats: folding carton, corrugated, flexible packaging, and labels

  • Equipment configurations: in-line converting, hybrid print, automation, robotics

  • Tools: ERP and MES software for scheduling, inventory, and job execution

  • Trends: web-to-pack, sustainability, box-on-demand, and digital print innovation

  • Supply chain complexity: paper making, materials science, recycled content, and fulfillment integration

Who This Course Is For:

Packaging operators, production planners, workflow managers, label and flexo teams, and executives pursuing lean manufacturing training printing industry or evaluating digital printing press training and MIS software training for print production

Time to Watch:

Approx. 26 minutes