When precision, consistency, and scalability matter, Sun Process Converting Inc. delivers. For more than 45 years, we’ve partnered with OEMs, manufacturers, and industrial suppliers as a trusted contract converting provider, offering the flexibility, expertise, and technical control needed to turn raw materials into production ready components.
From precision slitting and rewinding to sheeting, die cutting, and laminating, our vertically integrated operation ensures each job meets exact specifications while maintaining ISO 9001:2015 quality standards.
What Is Contract Converting?
Contract converting is the process of transforming raw, rolled, or sheet materials into finished, application ready products using specialized equipment and precision processes. At Sun Process Converting, we work with a wide variety of pressure sensitive films, foils, vinyls, and laminates, applying coatings, adhesives, and surface finishes before converting them into precise shapes, rolls, or sheets.
Whether you supply your own material or select from our hundreds of in stock substrates, our converting team applies the same disciplined approach: consistent control, tight tolerances, and flawless finish.
Common goals of contract converting include:
- Achieving specific roll widths, lengths, or diameters for OEM integration.
- Laminating multiple substrates for functional or decorative purposes.
- Creating pressure sensitive or adhesive backed products ready for downstream use.
- Preparing materials for automated production or packaging environments.
In short, we take your material (or ours) and convert it into something that saves you time, reduces waste, and enhances production efficiency.
Precision Slitting & Rewinding Capabilities
At the core of our converting operation are precision slitting and rewinding services designed to deliver clean edges, uniform tension, and repeatable roll consistency across a wide range of flexible materials.
Precision Slitting
Sun Process uses high performance slitter rewinders capable of handling diverse materials such as polyester, polycarbonate, PVC, aluminum foil, and multi-layer laminates. Our precision slitting systems maintain tight edge control, allowing us to produce slit rolls with widths down to fractions of an inch and tolerance levels that meet the most demanding customer specifications.
Whether you require narrow rolls for label stock, tapes, or adhesive liners, or wide master rolls for further downstream processing, we maintain exacting uniformity throughout the run.
Key Advantages of Our Slitting Services:
- Razor, shear, or score slitting for different material types and thicknesses.
- Edge quality optimization to minimize fray or deformation.
- Advanced tension and alignment controls for dimensional stability.
- In-line inspection to ensure edge accuracy and roll integrity.
Our technicians understand how small deviations in slit width can affect lamination, coating, or printing performance. Every job is engineered to deliver consistent quality from start to finish.
Slitting and Rewinding
Our slitting and rewinding process goes beyond simple roll division. We integrate precision tension control, optical edge guiding, and static elimination systems to produce rolls that unwind cleanly and perform flawlessly in your downstream equipment.
Whether you’re managing high-speed printing, laminating, or packaging lines, Sun Process provides tight, even rolls that run true, reducing material waste, downtime, and alignment issues.
Rewinding Benefits:
- Improved roll consistency for automated handling and die cutting.
- Optimized tension profiles to prevent telescoping or blocking.
- Clean, contamination-free winding for sensitive films and foils.
- Multiple core sizes and orientations for custom packaging or machine loading.
End-to-End Contract Converting Expertise
As a fully equipped custom coater and converter, Sun Process Converting integrates multiple in-house processes under one roof. This means we can handle every stage of production (from coating and laminating to slitting, sheeting, die cutting, and hot stamping) with full traceability and ISO-level process control.
Integrated Capabilities Include:
- Adhesive Coating & Laminating: Apply functional or decorative layers to improve durability, adhesion, or optical clarity.
- Die Cutting: Convert rolls or sheets into precise shapes for labels, gaskets, or decorative films.
- Sheeting & Flat Cutting: Transform roll stock into exact sheet dimensions for printing, packaging, or assembly.
- Hot Stamping: Add branding, safety markings, or decorative accents with precision.
By combining these capabilities, we offer customers complete, start-to-finish contract converting solutions that reduce logistics complexity and ensure consistent results.
Materials We Convert
Our technical team has decades of experience converting diverse materials, including films, foils, papers, and specialty substrates, into high-performance, application ready formats.
Common Material Types Include:
- Polyester (PET), Polypropylene (PP), and Polyvinyl Chloride (PVC)
- Polycarbonate films
- Pressure sensitive vinyl media
- Embossed and decorative films
- Industrial aluminum foil and metallized polyesters
- Protective overlaminating films
- Specialty coated or adhesive backed composites
Because we also offer custom coating and laminating, we can combine multiple layers of functional and decorative materials (such as adhesives, foils, and films) to meet specific customer or OEM requirements.
Industries Served
Sun Process Converting supports a wide spectrum of markets where precision and reliability are critical:
- Industrial Manufacturing: Release liners, spacers, gaskets, and insulation films.
- Graphics & Signage: Pressure sensitive vinyls, overlaminates, and printable films.
- Electronics: EMI/RFI shielding foils and protective insulators.
- Aerospace & Automotive: Decorative and protective laminates resistant to abrasion and chemicals.
- Packaging & Labeling: Printable films and die-cut components for labels, tags, and safety graphics.
Each market has distinct material, adhesive, and dimensional requirements, and our converting team works closely with your engineers to ensure performance and compliance.
Commitment to Quality & Precision
Sun Process operates under the ISO 9001:2015 quality management system, ensuring every phase of production is measured, documented, and verified. Our vertically integrated model allows us to maintain complete control over all aspects of the converting process, from incoming material inspection through final slitting and packaging.
We also offer materials recognized under the Underwriters Laboratories (UL) component program, ensuring compliance with critical safety and performance standards. Every converted product is subject to rigorous in-process inspection and final QA testing.
Quality Highlights:
- ISO 9001:2015 certified quality management
- In-process roll monitoring and inspection
- Traceable lot control and documentation
- Material certifications available upon request
When you partner with Sun Process, you gain not just a converting vendor, but a manufacturing extension of your own quality system.
Why Partner With Sun Process Converting?
Technical Expertise
Our engineering team combines decades of practical experience with innovative problem solving to optimize every project for performance and cost. Whether you need tight tolerances, controlled adhesive thickness, or advanced tension management, we deliver with precision.
Cost Efficiency
Because we manage coating, laminating, and converting in-house, we eliminate the need for multiple vendors, reducing freight, lead time, and handling costs. The result: shorter turnaround, consistent product quality, and reduced waste.
Scalable Production
From prototype to large scale production, our equipment and processes are designed for scalability. We can quickly adapt to volume changes while maintaining the same level of quality and consistency.
Customer Focus
Every project receives individualized attention from our technical representatives, who work directly with your engineering and procurement teams to ensure requirements are met and expectations exceeded.
The Sun Process Advantage
With over 200,000 square feet of manufacturing, inventory, and office space in Mount Prospect, Illinois, our facility is equipped to handle even the most complex converting projects. Located just minutes from Chicago’s O’Hare International Airport, we maintain a national distribution system to serve customers across North America efficiently.
When you choose Sun Process for contract converting, you gain a partner with:
- 45+ years of technical and production experience.
- Full in-house control from coating to converting.
- ISO 9001:2015 certified quality systems.
- Competitive lead times and nationwide delivery.
- Personalized customer service and technical support.
Request a Quote
Ready to streamline your production and enhance product quality through contract converting?
Contact Sun Process Converting Inc. today to discuss your application, materials, and performance targets.
Our technical team will help you identify the ideal precision slitting, slitting and rewinding, or coating solution for your needs, and deliver results that meet your specifications, on time and on budget.