What Types of Packaging Can Converters Do?

How would you feel if a bakery served you a cake in a burlap sack? 

Whoa, now there’s a mental image! Although product packaging often goes unnoticed, it’s a major part of application and usability. 

A good-looking, functional package goes a long way, and your product isn’t finished until it’s fully packaged as intended. Yet, it can be challenging to find suitable packaging when products have different requirements. 

Flexible material converters are especially adept at integrating packaging into your production process. For instance, Strouse offers a variety of in-line packaging options for the custom parts we convert.

If you hope to see your options for converting packaging and learn more about packaging in the industry, this article will provide you with all the information you need. Let’s begin. 

How Does Packaging in Converting Work?

When converted parts come off a press, they can be packaged through an in-line process or by hand. Each product has its own packaging requirements, and converters can accommodate this through a range of aesthetic and protective options. 

What Types of Packaging Are Converters Capable of?

Of course, each converter offers different options, but based on our experience and machine capabilities, these are the primary packaging in converting methods. 

1. PARTS ON A ROLL

Rolled parts are the cheapest type of packaging and are often ideal for automated applications. 

Many flexible materials come on a roll, with the parts left on a liner for users to peel off. The tension of the roll, part spacing, and other factors are adjustable, which can help with application. Before ordering parts on a roll, you should ensure you know how to properly store adhesive rolls. 

2. POUCHING

Pouching is often used to package individual parts; however, it can also be used to package multiple parts in one pouch. The pricing will depend on the configuration of the pouches, such as:

• How many parts-per-pouch?
• Does the pouch need to be labeled?
• Does the pouched product need to be in a carton?

• • Does the carton need to be in a shipper?
• What type of pouch do you need?
  • Heat-sealed, ziplock, cold-seal, etc.
    
    

2.1. HEAT SEALING

Heat sealing is another method used to close pouches as opposed to adhesive. The heat sealing process is typically an extra step that involves running the finished product into specific sealable pouches.

Pricing can fluctuate depending on:

• Is the heat seal pouching something we can do on press, or…
• Is the heat seal pouching required to be hand-packed then heat-sealed?

• • This adds cost due to time for finishers and may affect lead time

• Can the heat-sealed parts be bulk-packed and sent to a 3rd party packing company?

3. BLISTER PACKAGING

You’ve likely seen blister packaging used for pills, but it can also be used for other products. 

Blister packaging typically requires a specialized machine that allows an operator to place parts into a hopper that individually packs each part into a blister pack. The converter stocks both the blister material and the card (the back of the pack), which need to be sourced. 

Unfortunately, blister packaging can raise the cost of a production process, especially if it’s a custom-sized pack or the volumes aren’t large enough to fully automate the process.

4. SHEETED INTO BAG (BULK-PACKED)

Bulk-packing your products is one of the cheaper packaging methods converters use because it’s relatively easy to integrate into converting processes. 

Loose parts are loaded into bags as a simple, non-time-consuming process. This method does not require much labor, but because the result is bags of loose parts, it may not be ideal for storage and application. 

5. FAN FOLDED INTO A CASE

Fan folding is often used on perforated material that can be folded over onto itself and condensed into a case. This can allow you to produce large stacks of parts, often used for labels. Fan folding requires a specific machine to achieve which means more upfront costs to accomplish. 

6. BOXING

Boxes provide ample protection to the parts inside, which are often packaged in additional ways. However, getting your parts boxed can be a more expensive and complicated packaging method, depending on your goal.

When you start to incorporate a case vendor, it adds cost for:

• Type of case
  • Standard brown case
  • Heavy-duty brown case (for heavier materials)
  • White case
  • Glossy printed case (medical on-the-shelf type)

• Quantity of cases
  • Low quantity for custom-made cases can add up fast
• Printed cases 
  
  • Number of colors (affects cost)
• Every case manager will charge for print plates (these prices can range from $150 to upwards of $900)
  
  

What Are Some Potential Packaging Issues?

If your parts are hand-packed, they can have too many or too few parts due to human error. 

Another problem that can arise is when the artwork on printed cases or cartons is incorrect. A converter should always verify that your artwork is correct and send images of the proof to double-check.

Lastly, items being damaged during shipping is an example of a lapse in packaging. Understanding how many items are going into a case, the weight of those items, and how many cases are stacked upon one another can all be factors that determine damaged goods. 

How To Prepare For Your Packaging Process

The best way to prepare for product packaging is to have a plan. Reviewing these questions before the process can help you prepare to make packaging decisions.

• What is the intended use?
  - Who is the audience?
• Supply artwork to the converter (.ai files or PDF files work)
• How much packaging is needed?
  - Do you need parts in a pouch? How many?
  • • Do the pouches need specific artwork?
    • Any variable information needed (i.e. Lot #, expiration date, etc.)
    • How many pouches in a carton (+ do the cartons need labels)?
    • How many cartons in a shipper (+ do the shippers need labels)?
• Is this a medical device?
  - If so, does it need to be sterilized?

Each material has its own requirements, some far more complex than others. For example, Strouse has worked with materials that require particular light and humidity restrictions and must be shipped in foil bags that block all environmental components with desiccant packs for humidity control. 

Consider the requirements for your material and its adhesive shelf life before deciding upon a packaging method. 

Getting Started

Now that you know your packaging options, you might be ready to reach out to an adhesive converter to begin. 

A converter can help you figure out your packaging as a part of your whole production process. If any of the options we reviewed sounds ideal to you, or you have questions about additional packaging options, feel free to contact us today. 

Lastly, for more information on converting and other options you might have, check out our Learning Center.