Description
Converting · Operations
Converting Operations
Understand converting operations, investigate defects through a structured diagnostic process, and support production decisions with technical evidence.
StartsNovember 12, 2026
FormatOnline
Duration3 months
Commitment50 hours · 4–5 hours/week
Who it is for
Converting operators and supervisors, production managers, process specialists, and maintenance professionals.
Capability developed
Develop a structured operations capability
Connect the systemRelate materials, equipment, variables, and conditions.
Interpret evidenceUse observations and data to understand what is happening.
Build technical judgmentMove from isolated facts to supported conclusions.
Communicate decisionsExplain findings and next actions clearly.
Built with The INSCO Method
Technical knowledge applied to production cases
Participants investigate symptoms, contrast hypotheses, and defend decisions using evidence.
Initial Diagnostic ProfileEstablishes the starting point.
Interactive CasesTurn production situations into practice.
Coach AIChallenges technical reasoning.
Diagnostic Development ReportMakes progress visible.
Course support
Interactive cases
Live webinars
Individual technical challenge and live industry exchange
Coach AI
Challenges each hypothesis with corrugated-process knowledge and technically argues whether the participant’s answer is well founded—without providing the solution.
Industry Trainers
Industry Trainers analyze complex cases, explore selected subjects in depth, answer technical questions, and share experience in live webinars.
Course syllabus
13 modules
Open each module to review its technical scope.
01. Corrugated box manufacturing
- Definition and general characteristics
- Structural characteristics of corrugated boxes
02. Flexographic printing and ink systems
- Types of printing
- Flexographic printing
- Ink components: pigments, resins, alkalizing agents and antifoam agents
- Ink kitchen and machine-side ink control
- Machine-side elements required during production
- Wetting agents used on press
- Rheology, thixotropy and viscosity
- pH control
- Viscosity control
- Dot gain and color control
- Three-color and four-color printing
03. Anilox rolls
- Metal anilox rolls
- Ceramic anilox rolls
- Cell shapes
- Line count, volume, cell dimensions and engraving angle
- Area between cells
- Printing problems and image quality
- Cleaning and maintenance
04. Printing plates
- Photopolymer plates
- Liquid photopolymer
- Solid photopolymer
- Digital plates
- Plate caliper and hardness
- Other specifications
- Machine problems, cleaning and storage
05. Ink regulation systems
- Ink regulation systems
- Rubber roll to anilox systems
- Reverse doctor blade systems
- Chambered doctor blade systems
- Advantages and disadvantages of chambered doctor blade systems
06. Common printing problems
- Printing problems caused by machine adjustments and parameters
- Overprinting, trapping, bleed and filling-in
- Most common problems and solutions
- Steps to improve printing performance in the plant
07. Prepress and repro printing
- Process color printing
- Dot gain
- Types of printing
- Screens and gradients
- Machine test: objectives and execution
- Machine test and measurement of printing characteristics
- Machine test and conclusions
08. High-quality printing
- Substrate
- Types of flutes
- Anilox rolls
- Inks
- Ink control
- Printing plates
- Overprint varnishes
- High-quality printing machines
09. Rotary die cutting
- Rotary die cutting: concepts and parameters to control
- Influence of papers on die cutting
- Prefeeder and feeder
- Printing units
- Die cutting section
- Vibrator, scrap removal and delivery
- Order and cleanliness on the machine
- Checks before production
- Checks during production
- Palletizing and warehouses
- Die design
- Use of the die in the plant
- Cutting rules
- Creasing rules
- Rubbers in the die
- Polyurethanes
- Preventive maintenance of the die
- Most frequent problems in rotary die cutting
- Box dimensional variations: piggyback effect
10. Casemaker, regular slotted container and FEFCO 0201
- Flap box and casemaker concepts
- Prefeeder and feeder
- Flexographic printing units
- Slotter: creasing shafts
- Slotter: knife shafts
- Folder gluer
- Counter, bundle ejector and palletizing
- Order and cleanliness
- Checks before manufacturing
- Checks during production
- Palletizing and warehouse
- EMBA casemaker video
- High-speed Martin casemaker video
11. Flat die cutting
- Die cutting concepts, types and control parameters
- Influence of papers on flat die cutting
- Influence of corrugated board on die cutting
- Flat die cutter evolution
- Feeder, gripper bars and transport chains
- Die cutting section
- Scrap removal and bundle former
- Die design
- Proper use of the die in the plant
- Make-ready sheet
- Die wood
- Cutting rules
- Cutting knife specifications
- Creasing rules
- Creasing rule specifications
- Rubbers in the die
- Rubber specifications
- Nicks
- Scrap removal specifications
- Cutting plate and working pressure
- Preventive maintenance of the die
- Order, cleanliness and process control before production
- Process control during production
12. Paper, corrugated board and box tests
- The cardboard box
- Compression tests on paper
- Other paper tests
- Corrugated board tests
- Corrugated board ECT test
- Box compression test: BCT
- Differences between static and dynamic compression
- Compression losses during the production process
- Box functions
13. Converting waste
- Waste in converting
- Waste in feeding, printing and die cutting sections
- Waste in die cutting caused by process deficiencies
Next course · November 12, 2026
Converting Operations
Online · 3 months · 50 hours · 4–5 hours/week
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