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Introduction to Finishing: Converting

Introduction to Finishing: Converting

Converting 101 – Episode Summary

In this foundational episode of The Print University, Pat McGrew and Ryan McAbee explore the essential process of converting—turning flat paper or plastic substrates into 3D, purpose-built products like boxes, pouches, cartons, and envelopes. If you’re creating printing industry training programs for new employees, onboarding finishing operators, or teaching bindery equipment training courses, this is a must-watch course on how materials become finished, usable forms.

The episode demystifies converting across packaging segments:

  • Corrugated Packaging: Thick kraft or white board used for shipping and branded secondary packaging

  • Folding Carton: Lightweight card stock often used for retail packaging and pharmaceuticals

  • Flexible Packaging: Plastic or paper-based pouches with resealable closures and food-safe barriers

  • Envelopes: Die-cut, folded, and glued pieces for direct mail, billing, or specialty marketing

Ryan and Pat cover core converting steps—cutting, creasing, folding, gluing, and die-cutting—plus the tools used (rotary blades, lasers, punch systems). They emphasize the role of dielines, grain direction, substrate compatibility, and structural integrity. Special attention is given to compliance in food, pharma, and chemical packaging, as well as the importance of spout sealing, zipper integration, and digital short-run converting.

The hosts also examine digital innovations in corrugated and folding carton markets, including web-to-pack solutions that let customers design, preview, and order boxes online.

You Will Learn:

  • What converting means across packaging types: corrugated, folding carton, flex pack, and envelopes

  • Key processes: creasing, folding, cutting, gluing, sealing, and dieline design

  • Design challenges: grain direction, glue zones, barcode placement, and weight tolerance

  • How converting varies by substrate and use case—from juice pouches to tech manuals

  • Tools and trends: digital short-run converting, spout sealing, and 3D package previews

Who This Course Is For:

Packaging designers, finishing operators, prepress teams, production managers, and trainers building printing technician certification online, bindery equipment training courses, or lean manufacturing training printing industry

Time to Watch:

Approx. 30 minutes