FAQs

Some can perform limited converting, but most are not structured for complex multilayer, adhesive-based, or contamination-sensitive applications that require specialized process control.

Yes. Some suppliers maintain cleanrooms but only apply them to specific operations or products. Confirm that cleanroom conditions are integrated directly into the converting processes for your project—laminating, die cutting, slitting—and ask for documentation showing how those processes are controlled and monitored under cleanroom conditions.

Advantage Converting understands the importance of maintaining the surface quality and integrity of materials used in the manufacturing of green energy solutions. We can maintain the surface and edge quality of materials while meeting tolerances of ±.004″ for slitting and die cutting, often times even tighter. Or proprietary methods ensure a flat edge, thereby avoiding rippling that is especially common in foils. We also provide clean room manufacturing for materials that require environmental controls.

Die cutting is a great option for scaling production and increasing production efficiency. Die cutting can hold very tight tolerances at high output volumes. Tooling can be built to cut multiple parts simultaneously to best yield material, not only increasing efficiency but reducing scrap rate.

The distinction requires lot traceability and process documentation. If a supplier can correlate yield data with specific material lots and specific process parameters, they can usually isolate the cause. If they cannot, both variables are suspect. A supplier without lot traceability cannot reliably distinguish material-driven from process-driven yield loss.

Process changes during scale-up — new tooling, higher volumes, different material lots — must go through change control under ISO 13485:2016. Components developed at an R&D or developmental level are not yet operating under a validated production process. Scaling up requires demonstrating that the production process consistently meets specification under real production conditions, which means validation steps are required before full production release — not just operational adjustments. This makes the transition to production-level manufacturing a defined quality event, not just an operational one.

Adhesive chemistry, coating weight, substrate thickness, and liner release force all vary naturally between lots. A process optimized for one lot may underperform with another. Production processes need to be qualified across the range of incoming material variation, not just against a single prototype lot.

Yield expectations vary significantly by application complexity, material type, and tolerance requirements. More relevant than a benchmark rate is whether the supplier can demonstrate consistent yield within a defined range, identify causes when yield deviates, and show a track record of corrective action. Ask for yield data across multiple production runs, not just a single reference number.

Custom die cutting is the process of shearing materials using specialized tooling (a die) to mass produce a shape. The die has sharp edges that pierce the material, similar to how a cookie cutter is used to make shapes out of dough. Custom die cutting involves creating custom dies to obtain a unique, flat shape.

Advantage Converting uses a variety of advanced die cutting equipment and techniques that allows us to meet various specifications for size, shape, application, and volume needs. We have the capability to die cut up to 78 inches wide, die cut parts in a roll-to-roll process, and can process a wide variety of materials on our existing tooling and equipment.

Medical converting is the modification and assembly of various materials during the manufacturing of a medical product. Often, individual components are the output of a converting process, and those components are assembled to produce the finished product. There are a variety of medical converting processes, including laminating, die cutting, and slitting and rewinding. A wide range of materials are used in medical converting depending on the product’s specifications. Often, these materials are medical-grade, and the converting processes take place in a clean room.

Advantage Converting has provided medical converting services for more than 25 years. Medical converting applications include advanced wound care, medical devices and disposables, microfluidics, wearables, and flexible packaging.

Process validation is the documented demonstration that a converting process consistently produces conforming output under defined conditions. Without it, production performance depends on the same conditions that existed during prototyping—which are rarely replicated exactly at scale.

Tolerance assignment without process capability data. Assigning tolerances based on functional requirements without evaluating whether the accumulated tolerances across all converting steps are achievable at production yield. The design is correct; the manufacturing system required to produce it consistently does not exist at that tolerance level.