Decoding Packaging Converting Methods: A Detailed Look at Pros, Cons and What to Expect

Flexible packaging converting is an intricate process that combines technology, innovation and design to create functional results aligned with industry trends and consumer demands. 

Printing is a critical part of this process, as it brings the packaging to life through branding, product details and visual appeal. Each method, from flexography to digital printing, has unique advantages, making the choice of printing technology pivotal to the final product's success.

What Is Packaging Converting?

Packaging converting is the process of transforming raw materials into finished packaging products that are ready for use in various industries. It involves multiple stages, including raw material preparation, printing, cutting, folding and assembly, to create functional and visually appealing packaging solutions. 

Converting is a critical step in the packaging supply chain and is vital to ensuring products are protected, preserved and marketed effectively. Key components of the converting process in packaging include:

• Material selection: Converting starts with raw materials like paper or cardboard. The choice depends on the packaging's intended purpose, such as durability or environmental considerations. At DIYpack, we use environmentally friendly products and practices.
• Cutting and shaping: Die-cutting cuts material into specific shapes and sizes. Alternatively, slitting cuts large rolls of material into smaller, more manageable sizes for further processing or direct use.
• Lamination and coating: In lamination, layers of materials are bonded together to enhance strength and functionality. Materials may also be coated with a finish like wax to enhance aesthetic appeal and protection. It is often used for food and luxury packaging.
• Printing and branding: Printing processes are used to add branding, product information and appealing designs to packaging. These can include other custom features like quick response (QR) codes or tamper-evident markings.
• Folding and assembly: Automated machines fold the cut materials into their final shape for products like boxes. Assembly may also involve adding components like windows.

Common Packaging Converting Methods in Printing

Packaging conversion applies to a range of industries, including consumer goods, retail and e-commerce. While printing has its own category, as it modifies original materials, it is seen as a type of converting method. 

Several printing methods are available, including screen printing, pad printing and die-cutting, each catering to different end product needs. Here are some of the more popular printing methods. 

Flexographic Printing

Flexographic printing, flexography or flexo, is a versatile method that uses flexible relief plates to transfer ink onto materials like paper or cardboard. It is cost-effective for large-scale production and capable of producing continuous patterns. Benefits include:

• High-speed printing, ideal for long runs.
• Quick-drying UV-curable or water-based inks.
• Prints on porous and non-porous surfaces.

Digital Printing

Digital printing uses computer-driven processes to print directly onto materials, eliminating the need for printing plates. It takes computer designs straight to the printer, speeding up turnaround times. It is often used to print personalized labels, small-run packaging and prototypes. 

Digital printing is ideal for custom products. It can print complex colors and delivers brand-protection features like micro text, tactile images and guilloches. You can get high-quality, precise printing with vibrant colors. 

Lithographic Printing

Lithographic, litho or offset lithography printing involves transferring an image from a plate to a rubber blanket and then onto the material. It is often used for premium packaging, like high-end retail boxes, beverage cartons and gift boxes. It is ideal for flat, smooth surfaces like cardboard and paper. It also produces sharp, high-resolution images.

Gravure Printing

Gravure printing uses engraved cylinders to transfer ink directly to the material, making it ideal for long runs and high-volume production. It is most often used to print onto labels and wrapping materials. It works well on flexible materials and offers consistent, rich color production.

Pros and Cons of Converting Printing Methods

Each of these packaging solutions offers unique advantages and drawbacks, depending on their intended application. Here is an outline of these pros and cons to help you narrow down which printing method may best suit your product needs:

What to Expect During the Conversion Process

Printing plays a central role in packaging conversion, ensuring the package communicates and meets regulatory requirements effectively. The printing phase — which demands close collaboration between designers, converters and printers — follows these steps:

1. Design preparation: First, the graphics, text and branding elements are finalized, and files are converted into a format suitable for the chosen printing method.
2. Plate creation: Printing plates or cylinders are created using methods like flexography or gravure. Digital printing skips this step, saving time for shorter runs.
3. Printing execution: Designs are transferred onto the packaging material, and quality control efforts are used to ensure color fidelity, proper alignment and resolution.

Innovations in Packaging Conversion

In recent years, printing technology has revolutionized packaging conversion by enhancing customization, speed and sustainability. In digital printing, we have gained on-demand printing, which reduces waste and inventory costs in the short run. 

Variable data printing (VDP) is another innovation that enables unique designs or personalized content for individual packages, which is perfect for targeted marketing.

Sustainable printing solutions are also more readily available. Printers use water-based or UV-cured inks that minimize environmental impact. The right printing partner will also use recyclable or compostable materials to meet consumer demands for more sustainable packaging.

It is also becoming more common to use near field communication (NCF)-enabled designs or QR codes to allow brands to connect with customers digitally, enhancing the impact packaging makes and its longevity during reuse.

Create Custom-Printed Boxes With DIYpack Today

Packaging conversion is essential in product protection, ensuring goods are safe during transport and storage. It also provides a platform for showcasing brand identity and product information while supporting your organization's sustainability efforts.

With over 60 years of direct manufacturing experience, DIYpack invests in leading industry technology to ensure printing efficiency and high-end product quality. We give you direct access to our materials and technology while you design your own box. All of our printing is done digitally, allowing us to print to your specifications, volumes and other needs.

Contact us today for more information or for assistance placing your order.