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Forest Products, Pulp, Paper & Packaging > Flexible & Specialty Packaging Practice

Flexible & Specialty Packaging Practice

Umbrex connects companies in flexible & specialty packaging to independent consultants with deep experience in the industry.

Over 90% of our Flexible & Specialty Packaging Practice consultants are alums of McKinsey, Bain, or BCG.

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Find a consultant in our Flexible & Specialty Packaging Practice

Prefer email? Write to [email protected]

Client Segments Umbrex Serves

  • Film extrusion and oriented base film producers: Manufacturers of PE blown/cast films and oriented BOPP/BOPET/CPP; optimize resin strategy, line speeds, gauge innovation, PCR integration, and global capacity deployment.
  • Integrated flexible packaging converters: Multi-plant converters printing, laminating, and pouching plastic rollstock for food, beverage, and personal care; improve OEE, scrap, pricing, sustainability claims, and design-to-value.
  • Labels and shrink-sleeve converters: Converters of filmic pressure-sensitive labels and shrink sleeves for consumer goods; scale digital print, workflow automation, SKU complexity management, and brand-service differentiation.
  • Healthcare and pharma flexible packaging specialists: Producers of sterile barrier pouches, pharma lidding, and high-barrier laminates; elevate GMP, quality systems, validation, serialization, and customer audit readiness for regulated growth.
  • Industrial and bulk flexible packaging manufacturers: Producers of woven PP FIBCs, valve sacks, and protective films; optimize performance, conversion cost, channel strategy, and circularity to win in construction, agriculture, and chemicals.

Selected Capabilities of our Flexible & Specialty Packaging Practice

Strategy & Corporate Development

  • Corporate Strategy And Portfolio Shaping: Define where to play across films, laminations, labels, medical and industrial; segment end-markets; allocate capital to high-barrier and healthcare; lift growth, mix, and ROIC.
  • M&A Strategy, Diligence And Integration: Source targets across extrusion, printing, lamination, adhesives, and recycling; execute market and operational diligence; define synergies and post‑merger integration; accelerate EBITDA capture and strategic fit.
  • Vertical Integration And Resin/Circularity Strategy: Set make‑versus‑buy for resin compounding, film extrusion, metallization, and post‑consumer recycled (PCR) reprocessing; secure supply and cost advantage; enable recyclable mono‑material portfolio and margin uplift.
  • Footprint Restructuring And Capacity Roadmap: Design multi‑year footprint and capacity plan across plants, presses, and lines; prioritize consolidations, debottlenecks, nearshoring; improve service levels, cost position, and capital efficiency.
  • Carve‑Outs And Separation Planning: Execute carve‑outs of non‑core film and printing assets; build standalone models, Transition Services Agreements (TSAs), and disentanglement plans; maximize valuation and speed to close.

Operations

  • Extrusion Centerlining And Gauge Control: Stabilize blown/cast film with die, air ring, temperatures, IBC, haul-off, and thickness control; cut gauge variation and gels; lift OEE, yield, and film quality.
  • Printing Make-Ready And Registration Optimization: Optimize flexo/gravure web handling, anilox/plates, viscosity control, dryers, and auto-register; reduce makeready time and waste; increase speed, print quality, and uptime.
  • Lamination Dryer And Cure Optimization: Set coat weight, nip, tension, and dryer profiles; optimize adhesive mix and solvent balance; compress cure time; increase line speed, bond strength, and first‑pass yield.
  • SMED And Scheduling For Short Runs: Implement SMED on presses, laminators, slitters; standardize change parts, ink kitchens, and pre-sets; sequence by colors and webs; increase throughput, uptime, and schedule adherence.
  • Slitting, Pouching And Conversion OEE Uplift: Improve web tension control, knife setup, zipper and fitment changeovers, and pack-out; reduce edge trim and defects; raise cases per hour, uptime, and schedule adherence.

Supply Chain

  • Integrated S&OP And Demand Planning: Build end-to-end S&OP linking customer demand to constrained capacity across extrusion, printing, lamination, and conversion; improve forecast accuracy, OTIF, and inventory turns.
  • Network Footprint And Flow Optimization: Optimize plant footprint, make-versus-transfer flows, cross-docks, and mode mix; rebalance lanes and service regions; reduce lead time, freight miles, and cost-to-serve.
  • Inventory Strategy, Decoupling And Replenishment: Set multi-echelon safety stocks for substrates, films, inks, adhesives, and WIP buffers; design reorder policies and kanban; cut stockouts, obsolescence, and working capital.
  • Transportation Planning And Load Optimization: Design routing guides, load building, cube utilization, and appointment scheduling; reduce freight cost, damage, and dwell; improve OTIF and carrier performance.
  • Order Promising, Allocation And Capable-To-Promise: Implement available-to-promise and capable-to-promise using press constraints, artwork readiness, and transit times; allocate during shortages; raise promise accuracy and customer service.

Procurement & Strategic Sourcing

  • Resin And Film Strategic Sourcing: Build category strategies for PE, PP, PET, nylon, PCR resins and specialty films; implement indexation to monomers/crackers; secure allocation; reduce cost, volatility, lead times.
  • Inks, Adhesives And Solvents Sourcing: Consolidate suppliers; standardize specs and color bases; negotiate tolling and solvent returns; ensure food-contact compliance; lower unit cost, waste, VOCs, and supply risk.
  • Components, Fitments And Specialty Materials Sourcing: Source zippers, spouts, valves, release liners, aluminum foil, metallization; dual-source critical parts; qualify alternates; improve availability, lead time, and total cost of ownership.
  • Should-Cost Modeling And Clean-Sheet Costing: Build should-cost models for films, laminations, and conversion; decompose resin, energy, labor, overhead; inform negotiations; capture price downs and savings transparency.
  • Procurement Operating Model And eSourcing Enablement: Design category charters, center-led governance, and SRM; deploy spend analytics, eRFx, and e-auctions; upskill buyers; accelerate savings, compliance, and supplier performance.

Product

  • Design-To-Value And Specification Optimization: Redesign film and laminate structures—downgauging, resin substitution, barrier tuning—to meet requirements at lowest total cost; reduce material usage, scrap, and unit cost.
  • Recyclable And Mono-Material Platform Development: Develop recyclable mono-material PE or PP platforms; remove incompatible layers; align to How2Recycle and CEFLEX guidelines; protect performance while enabling retailer acceptance and claims.
  • Barrier And Shelf-Life Roadmapping: Map oxygen and moisture barrier needs by application; evaluate EVOH, AlOx, SiOx, coatings; design cost-effective structures meeting shelf-life targets and machinability; expand addressable markets.
  • Platform Standardization And Modular Formats: Standardize pouch, lidding, and flow-wrap platforms; modularize zippers and fitments; rationalize webs and widths; reduce changeovers, stock-keeping units (SKUs), and lead time; protect customer requirements.
  • Customer Co-Development And Rapid Prototyping: Establish customer co-development sprints with design-of-experiments, lab testing, and pilot trials; accelerate qualifications and line trials; win specifications and grow share in targeted categories.

Organization

  • Operating Model And Organization Design: Redesign enterprise, business unit, and plant structures; set spans and layers, decision rights, center-led functions; clarify product, engineering, supply chain roles; speed decisions and accountability.
  • Commercial Organization And Coverage Model: Design commercial organization, account segmentation, hunter-farmer roles, technical service deployment, estimating and customer service; streamline interfaces with product management; improve responsiveness, win rate, and growth.
  • Performance Management And Incentive Alignment: Build KPI cascades, tiered reviews, and visual management; link incentives to throughput, scrap, schedule adherence, service, and cash; reinforce accountability and sustained results.
  • Workforce Strategy And Skilled Trades Pipeline: Develop workforce plan, skills matrices, apprenticeships, and training for extrusion, printing, lamination, maintenance; strengthen recruiting partnerships; reduce turnover, time-to-competency, and overtime reliance.
  • Shared Services And Centers Of Excellence Design: Establish shared services and Centers of Excellence for planning, quoting, prepress, and master data; define service levels and governance; reduce cost, errors, and cycle time.

Pricing

  • Price Architecture And Segmentation: Define list, discount, rebate, and surcharge structures by substrate, laminate, print colors, volume tier, and channel; embed cost-to-serve and run length; improve price realization.
  • Resin And Input Indexation Strategy: Design index-linked pricing to polyethylene, polypropylene, PET, solvents, and London Metal Exchange aluminum; implement surcharges and floors; reduce price-cost lag, volatility, and margin erosion.
  • Quoting And Configure-Price-Quote Enablement: Stand up configure-price-quote (CPQ) using specs, colors, web width, run length, tooling amortization, and changeovers; cut quote cycle time, errors; raise win rate and margin.
  • Contract Pricing And Deal Desk Governance: Set price floors, guardrails, indexation pass-through, and payment terms; standardize approvals; curb unauthorized exceptions; protect margin and discipline in strategic accounts.
  • Pocket Margin Analytics And Leakage Control: Build price waterfall across freight, accessorials, scrap credits, tooling, rush fees, rebates, and chargebacks; target fixes by SKU and account; lift EBITDA.

Finance

  • Integrated FP&A And Rolling Forecasts: Build driver-based FP&A linking volume, mix, resin index, scrap, OEE, and labor to S&OP; improve forecast accuracy, earnings visibility, and cash management.
  • Standard Costing And Variance Management: Implement standard costs by substrate and process; analyze material usage, scrap, downtime, throughput, and absorption variances; increase transparency and accountability by plant and line.
  • Working Capital And Deductions Optimization: Redesign credit policy, terms, collections, and dispute resolution for claims and chargebacks; deploy analytics; reduce DSO, invalid deductions, and inventory days.
  • Capital Investment Governance And ROIC: Establish portfolio governance, stage gates, and post‑audits for presses, laminators, slitters, and recycling lines; standardize IRR thresholds; lift ROIC and benefits realization.
  • Commodity Risk, FX, And Hedge Accounting: Define policy for resin, energy, solvents, aluminum, and foreign exchange; implement hedging under ASC 815 and IFRS 9; reduce earnings volatility and cash shocks.

AI, Data & Analytics

  • Predictive Maintenance And Asset Health Analytics: Build machine learning models on historian, vibration, thermography for extruders, presses, laminators, slitters; predict failures; reduce downtime and maintenance cost; improve Overall Equipment Effectiveness (OEE).
  • Process Control And Quality Optimization Analytics: Use multivariate models to optimize extruder temperatures, die, air ring, tension, dryers, ink viscosity, coat weight; cut gauge variation, solvent retention, registration errors; lift yield.
  • Computer Vision Print And Defect Inspection: Deploy computer vision for print defects, color drift, registration, pinholes, gels, wrinkles, delamination, and seal integrity; automate grading and alerts; reduce claims, rework, and scrap.
  • Demand Sensing And Forecasting For Packaging: Build machine-learning forecasts using orders, point-of-sale (POS), promotions, seasonality, macro and weather signals; improve accuracy, plan stability, service, and inventory turns across extrusion-to-conversion.
  • Production Sequencing And Changeover Optimization Engine: Apply mixed-integer optimization to sequence presses, laminators, slitters by colors, solvent families, and due dates; minimize cleanouts and makeready; increase throughput and on-time in-full (OTIF).

Transformation

  • Transformation Office And Value Tracking: Establish Transformation Office, governance, stage gates, and value tracking across extrusion to conversion; prioritize waves; enforce cadence; deliver EBITDA, cash, OTIF, and CO2e improvements.
  • Zero-Based Cost And SG&A Reset: Run zero-based cost across plants and corporate; redesign service levels, spans, outsourcing; eliminate non‑value work; deliver structural cost takeout and resilience.
  • Complexity Reduction And SKU Simplification: Rationalize structures, webs, widths, inks, plates, colors, and pack formats; reduce changeovers, scrap, and inventory; improve throughput, schedule adherence, and cost-to-serve.
  • Rapid Performance Uplift And Cash Acceleration: Run 90‑day sprints on OEE, scrap, makeready, solvent usage, and purchasing compliance; monetize inventory and receivables; deliver immediate EBITDA and cash benefits.
  • Digital Operations And Lean Adoption At Scale: Scale tiered daily management, leader standard work, OEE dashboards, and advanced analytics use cases; institutionalize problem solving; sustain gains across presses, laminators, and slitters.

Sustainability

  • Net Zero And Decarbonization Roadmap For Packaging: Baseline Scope 1, 2, 3; build abatement curve; optimize dryers/ovens, Regenerative Thermal Oxidizer heat recovery, electrify, add renewable PPAs; reduce CO2e intensity and energy cost.
  • Solvent Management And Air Emissions Reduction: Map solvent balance; implement recovery, low-VOC inks/adhesives, Regenerative Thermal Oxidizer optimization, leak detection; cut volatile organic compounds, hazardous air pollutants, losses, and permitting risk.
  • Circularity And Recycled Content Integration: Build closed-loop scrap reprocessing, post-consumer recycled resin roadmap, supplier qualification and claims verification; increase recycled content, reduce virgin resin, and Scope 3 emissions.
  • Life Cycle Assessment And EPD Enablement: Conduct life cycle assessments (LCAs) for films and laminations; publish Environmental Product Declarations; support retailer scorecards; win specifications with credible footprint and recyclability data.
  • Net Zero Target Setting And ESG Operating Model: Set Science Based Targets initiative pathway; design governance, metrics, and greenhouse gas (GHG) Protocol data model; integrate with capital planning; accelerate decarbonization and compliance.

Compliance

  • Compliance Operating Model And Controls Design: Design compliance governance, policies, controls, training, and issue management across plants and functions; embed three lines of defense; improve audit readiness and reduce violations.
  • Compliance Risk Assessment And Monitoring: Run compliance risk assessment; map controls and testing for antitrust, anti‑bribery, data privacy, human rights; deploy monitoring and hotlines; reduce incidents, fines, and reputational risk.
  • Trade Compliance And Customs Optimization: Build trade compliance for tariff classification, United States–Mexico–Canada Agreement qualification, Section 301, aluminum antidumping and countervailing duties; tighten broker governance; reduce duties, penalties, and delays.
  • Extended Producer Responsibility Reporting Compliance: Design processes for Extended Producer Responsibility reporting and UK Plastic Packaging Tax; calculate fees, validate recycled content, file reports; minimize noncompliance risk and cost.
  • Claims And Labeling Compliance Governance: Establish governance for recyclability, compostability, and recycled content claims; align to Federal Trade Commission Green Guides and retailer standards; reduce exposure, chargebacks, and delisting risk.

Program & Portfolio Management

  • Enterprise Portfolio Governance And PMO: Establish Program Management Office (PMO), governance, and stage gates across extrusion-to-conversion; prioritize by value, risk, and capacity; improve on-time, on-budget delivery and benefits realization.
  • Strategic Prioritization And Resource Capacity Planning: Build portfolio selection models and resource capacity; balance outages, capital, information technology (IT), and product changes; maximize throughput, minimize bottlenecks, and speed lead times.
  • Commercialization And Artwork Change Portfolio Governance: Standardize charters, stage gates, and approvals for specs, artwork, plates, and regulatory claims; reduce revisions, delays, and write-offs; improve launch speed, compliance, and customer service.
  • Benefits Realization And Value Tracking Office: Standardize business cases, owners, baselines, and KPIs; track EBITDA, Overall Equipment Effectiveness (OEE), scrap, solvent usage, and CO2e; prevent leakage and double counting; assure benefits.
  • Portfolio Risk Management And Executive Reporting: Implement risk taxonomy, heatmaps, leading indicators, and health checks; run portfolio reviews; enable fast course corrections; reduce slippage, overruns, and value erosion.

Information Technology

  • ERP And Configure-To-Order Enablement: Design and deploy ERP for make‑to‑order packaging; integrate configure‑price‑quote, specs, BOMs, routings, and costing; reduce quote-to-cash cycle time, rework, and accelerate financial close.
  • Manufacturing Execution System And Shop-Floor Integration: Implement MES integrated with presses, laminators, slitters, ink kitchens, vision systems, and historians; capture downtime, waste, recipes, genealogy; raise OEE, traceability, and right‑first‑time.
  • Data Platform And Master Data Governance: Build cloud data platform integrating ERP, MES, quality, and logistics; standardize master data and KPIs; enable self‑service analytics; improve decision speed, accuracy, and data reliability.
  • Artwork, Specification And Product Lifecycle Management Systems: Implement artwork management, specification management, and Product Lifecycle Management; digitize approvals, version control, and attributes; accelerate commercialization, cut errors, and reduce audit and recall risk.
  • B2B Integration And EDI Modernization: Modernize Electronic Data Interchange with retailers and brand owners; automate orders, forecasts, ship notices, invoices, and chargebacks; improve OTIF, accuracy, cash flow, and service.

Capital Projects

  • Front-End Loading And Investment Case Development: Develop front‑end loading stages 1–3 scope, layout, utilities, cost and schedule for extrusion, presses, laminators, slitters, recycling; model capex, opex, NPV, IRR; de‑risk approvals.
  • Contracting Strategy And OEM Sourcing: Define contracting and delivery strategy; source OEMs for extruders, presses, laminators, coaters, oxidizers; negotiate guarantees and liquidated damages; reduce claims, change orders, and schedule slippage.
  • Owner’s Project Controls And Risk Management: Establish cost and schedule baselines, earned value, change control, and risk registers; enable early warning and recovery; prevent budget overruns and schedule slippage.
  • Brownfield Expansion, Permitting And Construction Readiness: Run constructability reviews, utilities tie‑ins, solvent room classification, ventilation design, and permitting readiness; coordinate contractors and outages; compress timelines and protect operations.
  • Commissioning, Startup And Ramp-Up Management: Orchestrate pre‑commissioning, commissioning, solvent systems, performance tests, and operator training; stabilize quality and throughput; achieve acceptance criteria and nameplate capacity faster.

Quality Management Systems

  • Quality Management System Design And Certification Readiness: Design and implement quality management system aligned to BRCGS Packaging Materials, ISO 9001, FSSC 22000, or ISO 13485; conduct internal audits; achieve certification and approvals.
  • Statistical Process Control And Capability Program: Deploy SPC, control plans, and capability analysis on gauge, coefficient of friction (COF), seal strength, registration, solvent residuals; improve capability, yield, and right‑first‑time; reduce claims.
  • Supplier Quality And Incoming Material Control: Set supplier standards, audits, Certificates of Analysis, and incoming inspection for films, inks, adhesives, and fitments; implement first article approvals; reduce defects, downtime, and complaints.
  • Nonconformance, Complaint, And Corrective Action Management: Build nonconformance workflows, complaint handling, root cause analysis, and Corrective and Preventive Actions (CAPA); raise closure rates; cut credits, chargebacks, and warranty cost.
  • Color Management And Print Quality System: Standardize color targets, ICC profiles, spectrophotometry, and tolerances; implement on-press verification and approvals; reduce color drift, misprints, reprints, and customer deductions.

EHS & Process Safety

  • Process Safety Management System Design: Design and implement process safety management for flammable liquids; embed HAZOP, safeguards management, management of change, and pre-startup reviews; reduce explosion risk and downtime.
  • Solvent Handling, Ventilation And Electrical Classification: Assess solvent storage, mixing, and press rooms; engineer ventilation, area classification, intrinsic safety, bonding and grounding per NFPA and ATEX; cut ignition risk.
  • LEL Monitoring And Interlock Integrity Assurance: Specify and test lower explosive limit sensors, interlocks, purge cycles, and exhausts on dryers and ovens; implement proof testing; prevent fires, explosions, and production losses.
  • Regenerative Thermal Oxidizer Safety And Compliance: Audit RTOs and ductwork for overtemperature protection, bypass, relief, and deflagration isolation; optimize procedures and interlocks; reduce VOC exceedances, trips, and safety incidents.
  • Industrial Hygiene And Exposure Control Program: Build industrial hygiene for solvents and isocyanates; monitoring, controls, respiratory protection, and ergonomics; keep exposures below limits, reduce recordables, and strengthen compliance.

Regulatory Affairs & Product Stewardship

  • Food Contact Compliance And Documentation: Define strategy for Food and Drug Administration 21 CFR and European Union 10/2011; plan migration testing and Declarations of Compliance; secure approvals, reduce recall risk.
  • Chemical Risk Assessment And Safer Substitution Program: Establish non intentionally added substances screening and risk assessments; maintain restricted substances governance; prioritize substitutions; reduce Proposition 65 and perfluoroalkyl and polyfluoroalkyl substances risk, delistings.
  • Regulatory Watch And Change Management: Build regulatory watch and impact assessments for Europe, United States, and key markets; manage reformulations and change control; prevent noncompliance, supply disruptions, and customer penalties.
  • Healthcare Packaging Regulatory Pathway Enablement: Define regulatory pathways for healthcare packaging; develop ISO 11607 validation plans, drug master file submissions, and Letters of Authorization; accelerate customer approvals and market access.
  • Retailer Stewardship And Claims Substantiation: Translate retailer and brand owner stewardship policies into requirements; build claims substantiation dossiers for recycled content and recyclability; pass audits; reduce chargebacks and delisting risk.

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Umbrex rapidly connects you with independent professionals who combine top‑tier consulting experience at firms such as McKinsey, Bain, Boston Consulting Group with hands‑on roles.

Find a consultant in our Flexible & Specialty Packaging Practice

Prefer email? Write to [email protected]