Why Proper Training & Cross-Training Are No Longer Optional in Printing & Packaging Plants

Written by: Shannon Polaski-Buchholz

The printing and packaging industry is evolving quickly. Presses are more advanced, customer expectations are higher, and experienced operators and supervisors are becoming harder to replace. Yet one critical issue continues to hold many plants back:

A lack of structured training and cross-training.

For years, many plants have relied on tribal knowledge, informal shadowing, or “learning as you go.” While that may have worked in the past, today it creates real risks to productivity, quality, safety, and long-term growth.

The Real Cost of Poor Training

When training is inconsistent or undocumented, plants often experience:

• Increased downtime and longer make-ready times

• Higher scrap, waste, and rework

• Inconsistent print quality

• More safety incidents and near misses

• Burnout among key employees who “know everything”

• Production disruptions when a critical team member is out

Often, companies don’t realize how vulnerable they are until one experienced operator leaves or retires — and suddenly no one else knows how to run the press, troubleshoot issues, or keep production moving.

Why Cross-Training Is Critical in Today’s Plants

Cross-training doesn’t mean everyone needs to be an expert at everything. It means building flexibility and coverage into your operation.

In a well cross-trained facility:

• Operators can run more than one press or line

• Helpers understand setup basics and quality checks

• Prepress understands pressroom challenges

• Supervisors can step in when needed

• Maintenance and production teams communicate better

This flexibility reduces downtime, limits overtime pressure, and keeps production stable when the unexpected happens.

Cross-Training Improves Retention — Not Just Output

A common concern is that training employees will make them more likely to leave.

In reality, the opposite is true.

Employees stay longer when they:

• Feel invested in

• See opportunities to grow

• Gain new skills and responsibilities

• Aren’t stuck doing the same narrow task every day

Cross-training builds engagement and loyalty. It sends a clear message that the company values its people and their future.

Training Is Also a Safety Issue

Printing and packaging environments involve heavy equipment, chemicals, tooling, and fast-moving machinery. Inadequate training increases the risk of:

• Improper machine adjustments

• Bypassing safety procedures

• Missed warning signs

• Equipment damage or injury

Structured training programs and regular refreshers protect employees, reduce incidents, and help maintain a safer workplace.

What Effective Training Actually Looks Like

Strong training programs don’t have to be complicated or expensive. The most effective ones often include:

• Documented SOPs for presses, equipment, and processes

• Clear onboarding plans for new hires (not just shadowing)

• Skill matrices showing who can run what

• Cross-training built into production schedules

• Mentorship from experienced operators

• Ongoing refreshers and skill updates

Even small improvements in training structure can create noticeable gains in efficiency and morale.

Training Gives You a Hiring Advantage

Plants with solid training and cross-training programs are significantly easier to recruit for.

Experienced candidates want to know:

• How they’ll be trained

• What support systems are in place

• Opportunities for advancement

• How teams are structured

Companies that can confidently explain how they develop their people stand out immediately in a tight labor market.

Final Thoughts

The printing and packaging industry can no longer afford single points of failure. Proper training and cross-training aren’t “nice to have” — they are essential for stability, safety, retention, and long-term success.

Plants that invest in their people today will be the ones still running strong tomorrow.