Folding Carton Beginner Essentials

The Folding Carton Beginner Essentials series introduces key concepts of folding cartons, covering their definition, industry overview, processes (web and sheet), and tools like air hammer and stripping. It also explores automation in packaging and concludes with a recap, offering a comprehensive introduction to folding carton production.

Ben Markens

President

Paperboard Packaging Council

As a child, Ben grew up in a racially diverse neighborhood in Chicago. After moving to the east coast he watched, with curious eyes, as his father worked as the CFO of a camera business. During college, he worked on the camera company’s assembly line with people from very different economic realities. These experiences sparked Ben’s interest in supporting community and building business—two aims that would remain consistent throughout his career. 

The next leg of Ben’s career began in a paperboard and folding carton manufacturing company. Working his way up to Plant Manager in only five years, Ben mastered the skills he would soon use when he made the bold decision to break out and start a management consulting firm with his dear friend, Andy, and his wife, Jennie. Before long, Ben was traveling across the country, helping companies create tighter operating controls, superior performance, and increased profits. When PPC began to suffer from decreased engagement, shrinking membership numbers, and lost revenue, they asked Ben to take over. With a newly expanded team, Ben used his business and leadership skills to turn the association into a newly thriving organization.

Outside work, Ben loves to spend time with his family, serve on numerous nonprofit boards, and walk the many hills of his town, Ashfield, Massachusetts, where he has exceeded 10,000 steps per day, 365 days a year, for over six years without a miss. Obsessive and compulsive? Maybe! But he’s also compulsive about community, elevating our team, and making a difference.

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What is a Folding Carton?
1.2 What is a Folding Carton? - Learning Objectives
1.2 What is a Folding Carton? - Video Lesson
Open to view video.  |  3 minutes
Open to view video.  |  3 minutes The first lesson introduces the basic definition and purpose of folding cartons. You will explore the materials, structure, and typical uses of folding cartons in various industries. This section serves as a crucial starting point for anyone new to the field, establishing a clear understanding of the product and its importance in packaging.
1.2 What is a Folding Carton? - Assessment
4 Questions  |  Unlimited attempts  |  6/8 points to pass
4 Questions  |  Unlimited attempts  |  6/8 points to pass
1.3 Paperboard Packaging Industry Overview - Learning Objectives
In this lesson, students will explore current trends in the paperboard packaging industry, focusing on market size, growth projections, and category performance. The session provides insight into which end-use markets are growing, stable, or declining, and how this data can guide strategic decisions.
1.3 Paperboard Packaging Industry Overview - Video Lesson
Open to view video.  |  4 minutes
Open to view video.  |  4 minutes
1.3 Paperboard Packaging Industry Overview - Assessment
5 Questions  |  Unlimited attempts  |  7/9 points to pass
5 Questions  |  Unlimited attempts  |  7/9 points to pass
1.4 Sustainability Overview - Learning Objectives
This lesson introduces the inherent sustainability of paperboard packaging, covering managed forestry, recycling, and end-of-life pathways that support a circular economy. Students will also review regional forest-cover trends and how fiber can circulate multiple times before transitioning to other beneficial uses.
1.4 Sustainability Overview - Video Lesson
Open to view video.  |  4 minutes
Open to view video.  |  4 minutes
1.4 Sustainability Overview - Assessment
5 Questions  |  Unlimited attempts  |  7/9 points to pass
5 Questions  |  Unlimited attempts  |  7/9 points to pass
1.5 Web & Sheet Fed Operations - Learning Objectives
This lesson introduces foundational converting concepts for folding cartons, contrasting web-fed (roll-fed) and sheet-fed workflows, and clarifying common plant terminology around press “format.” It also covers press-size selection, material handling from rolls to sheets, and practical shop-floor terms like "butt rolls" and "poker chipping."
1.5 Web & Sheet Fed Operations - Video Lesson
Open to view video.  |  6 minutes
Open to view video.  |  6 minutes
Operations Overview
1.5 Web & Sheet Fed Operations
5 Questions  |  Unlimited attempts  |  8/10 points to pass
5 Questions  |  Unlimited attempts  |  8/10 points to pass
1.6 Paper Grain - Learning Objectives
This lesson provides an in-depth overview of grain direction in paperboard manufacturing and its implications in web-fed and sheet-fed printing operations.
1.6 Paper Grain - Video Lesson
Open to view video.  |  12 minutes
Open to view video.  |  12 minutes
1.6 Paper Grain - Assessment
5 Questions  |  Unlimited attempts  |  8/8 points to pass
5 Questions  |  Unlimited attempts  |  8/8 points to pass
1.7 Measuring a Carton - Learning Objectives
In this lesson, students will gain an understanding of how to properly measure folding cartons.
1.7 Measuring a Carton - Video Lesson
Open to view video.  |  6 minutes
Open to view video.  |  6 minutes
1.7 Measuring a Carton - Assessment
5 Questions  |  Unlimited attempts  |  8/10 points to pass
5 Questions  |  Unlimited attempts  |  8/10 points to pass
1.8 Operations Overview - Learning Objectives
In this lesson, students will gain an understanding of key definitions and sheetfed press fundamentals that affect estimating, setup, and production quality.
1.8 Operations Overview - Video Lesson
Open to view video.  |  10 minutes
Open to view video.  |  10 minutes
1.8 Operations Overview - Assessment
5 Questions  |  Unlimited attempts  |  8/11 points to pass
5 Questions  |  Unlimited attempts  |  8/11 points to pass
1.10 Automatic Packaging - Learning Objectives
In this lesson on automatic packaging, students will explore how folding cartons are used in automated fulfillment systems and why proper design and testing are essential.
1.10 Automatic Packaging - Video Lesson
Open to view video.  |  6 minutes
Open to view video.  |  6 minutes
1.10 Automatic Packaging - Assessment
5 Questions  |  Unlimited attempts  |  7/9 points to pass
5 Questions  |  Unlimited attempts  |  7/9 points to pass