Reclaiming Core Focus
- Published: October 27, 2025
Why Outsourcing Secondary Slitting Adds Value to Primary Flexible Film Manufacturing
By Rob Tiller, Managing Director, PennPac Company
In the rapidly evolving world of flexible film manufacturing, throughput and sustainability are defining competitive advantages. Organizations are routinely examining how they allocate business and operational resources. For extrusion plants and converters focused on delivering high-performance films, one question keeps rising to the surface: Should we continue managing secondary slitting operations in-house? Or, is it time to outsource?
Outsourcing secondary slitting to a trusted toll slitting partner isn't just about reallocating resources. This activity is a strategic move that helps manufacturers double down on their core competencies while improving agility, efficiency and overall performance across their supply chain.
The Challenge of Managing Slitting Internally
In-house slitting may seem convenient at first glance. However, it often becomes a drain on overall capacity and financial resources. When a manufacturing operation diverts valuable floor space, labor and machine time to secondary slitting, it can dilute focus from core business drivers. For example: increasing extrusion output, upgrading production lines, innovating film recipes or investing in sustainability efforts.
Secondary slitting, is a post-production function that demands its own expertise, equipment and scheduling precision. It requires specialized setups, tight tolerances and the ability to manage varied roll sizes, film types. All the while, managing complex customer specifications. Add logistics management, inventory transaction activities and turnaround expectations into the equation, and it quickly becomes a logistical puzzle that can strain even the most efficient production environment.
This is where a qualified toll slitting partner can step in to alleviate the burden.
The Strategic Advantages of Outsourcing Slitting
Outsourcing to a dedicated slitting operation provides several key benefits. Such advantages are outlined next for your consideration.
- Allows Focus on Primary Operations
The foremost advantage of outsourcing is that it enables manufacturers to reinvest energy into their primary processes. Of which, include extrusion, coating, laminating and printing. These are the areas that require ongoing capital investment, R&D and production scale to remain competitive. Technology in these disciplines is evolving rapidly and requires the utmost attention to detail.
By redirecting internal resources toward refining through-put, reducing scrap, enhancing resin compatibility and innovating new film structures, companies can better meet the increasing demands for high-performance packaging solutions.
- Cost Efficiency Without Capital Investment
Setting up, or expanding an in-house slitting operation involves considerable capital expenditure: equipment acquisition, maintenance, training, labor and real estate. Conversely, outsourcing converts those fixed costs into variable ones. You only pay for the services you use. All without absorbing the overhead!
This cost efficiency becomes even more pronounced when addressing fluctuating volume demands, trial runs or temporary product substitutions. A slitting partner with scalable capacity allows you to flex operations as needed without overextending internal resources.
- Increased Speed to Market
Slitting specialists are structured to turn jobs quickly. With streamlined processes and a sole focus on material handling and slitting, these partners can often process orders faster than internal teams juggling multiple priorities.
Quicker lead times improve supply chain responsiveness, help meet urgent customer requests and reduce inventory bottlenecks. All of which are particularly important in today's fast-moving consumer goods markets, where packaging timelines are coupled with product launches and seasonal promotions.
- Inventory Agility and Freight Optimization
Many toll slitting partners offer strategically located facilities near major transportation hubs and customer clusters. This geographic advantage can reduce transit times, lower freight costs and create more flexible inventory staging strategies.
Partners with multiple slitting facilities and warehouse capabilities can act as regional distribution centers; ultimately helping to buffer inventory, serve customers faster and reduce the number of full-length rolls stored at your site.
- Specialized Equipment and Expertise
Outsourcing slitting gives manufacturers access to state-of-the-art slitting technology - without the capital burden. Reputable partners continually invest in new machines, laser-guided alignment systems and edge-trimming capabilities that enhance accuracy. Not to mention manage material loss which reduces scrap.
In addition to hardware, experienced slitting partners have technical teams well-versed in handling diverse film types: BOPP, PET, CPP, PE, High Barrier and Thermoforming films — to name a few. They understand the nuances of gauge variation, web tensions and winding quality. Furthermore, ensuring that finished rolls meet customer specifications.
- Reduced Scrap and Quality Issues
When slitting is done inefficiently or incorrectly, it may lead to high scrap rates, customer returns or loss of material value. Slitting experts optimize slit widths, core placement, roll alignment and cut quality. All of which, reduce waste and improve the usability of the earth's resources.
Some partners also provide secondary inspection and quality control services. Such inspections can identify potential defects before they reach the customer.
- Business Continuity and Risk Management
In today's supply-chain landscape, having a trusted slitting partner can add redundancy and resilience. Should one facility experience downtime or delays due to labor shortages, equipment failure or transportation issues, a multi-site slitting partner can redirect material to an alternate location.
This built-in continuity helps manufacturers protect on-time deliveries, preserve customer relationships and maintain production schedules with minimal disruption.
Considering a slitting partner that is not reliant on lease agreements, rental equipment, etc., can greatly reduce risk when it comes to reaction time and reliability. A partner who owns their property, facilities, equipment, etc., are in control and prove commitment.
What to Look for in a Slitting Partner
While the previously presented benefits speak for themselves, here are several qualities to prioritize when considering a partner to handle your secondary slitting:
Industry Experience: Look for partners with deep experience in flexible packaging and a strong understanding of your film types and application needs.
Facility Capacity: Ensure they have the space, equipment and staff to handle your volume with scalability.
Quality Control Protocols: Ask about their inspection systems, certifications and traceability.
Technology and Maintenance: Are they investing in their equipment and routinely calibrating machines for precision?
Communication and Transparency: Effective slitting is about timing and detail. Clear order confirmations, scheduling transparency and real-time status updates are essential.
Proximity to Operations or End Customers: Regional accessibility can cut freight costs and accelerate delivery timelines.
Final Thoughts: Success Begins at the Source
In flexible packaging, success is built on quality, speed and innovation. To achieve these goals, manufacturers must remain laser-focused on what they do best - producing high-performance films. Outsourcing secondary slitting to a trusted partner isn't a loss of control. It is simply a gain in strategic advantage.
With the right partner in place, you can streamline your operations, reduce costs, shorten lead times and redirect internal energy toward value-adding innovation. Ultimately, the question isn't whether you can continue doing slitting in-house. It's whether you should.
About the Author
Rob Tiller is the Managing Director at PennPac Company, a North American leader in flexible packaging film solutions. Rob works alongside a talented team of industry experts who continuously strive to provide the very best in service and reliability. After 30 years, PennPac has become a prominent partner to consider within the flexible films supply chain.
