Where bulk rollstock becomes press-ready performance
Many buyers focus on roll specs—basis weight, width, diameter. But in converting environments, roll-to-sheet performance is where real-world paper quality is tested. On a visit to a sheeting facility serving both offset printers and CPG packaging converters, we tracked how mill rolls are unrolled, squared, and counted—sheet by sheet.
The Sheeting Process
Large-diameter rolls (often 60–72″) enter high-speed sheeters that:
Cut to precise length and width (e.g., 23×35″)
Control for skew, dust, and curl
Stack in ream sizes or bulk pallet quantities
Wrap and label each batch with roll origin and sheet count
Real-Time Monitoring
The best sheeters use:
Laser edge alignment to control skew
Sheet counters tied to PLC systems
Moisture and curl sensors to prevent edge roll
Dust extraction to meet print-house cleanliness standards
We watched one batch of 100 lb C1S convert 6,000 feet of roll into 3,800 flat sheets at ±1/64″ tolerance. Slitter blade sharpness and humidity control were the difference between success and scrap.
Why This Matters for Buyers
Even if you don’t convert in-house, sheet conversion impacts:
Pressroom performance
Packing line uptime
Print registration and ink laydown
End-user satisfaction
Substandard sheeting leads to paper jams, skewed cuts, and double feeding.
What to Ask Your Mill or Converter
Do you control sheeting in-house or outsource?
What’s your sheet tolerance for size and skew?
Is sheeting tracked back to the original roll?
Do you test for curl and static?
From Roll to Reality
Your paper’s quality isn’t just formed on the machine—it’s confirmed at the cutter. And the mills that get sheeting right keep you (and your pressroom) on schedule.
