Matt Answers

What Are Overrun and Underrun in Flexible Packaging?

Why the shipped quantity can differ from the purchase-order quantity.

Short answer

Overrun means the finished quantity is above the ordered amount; underrun means it is below. Web printing and converting involve setup waste, roll lengths, quality removals, and production counting that can make an exact finished quantity impractical. The acceptable tolerance must be stated in the quote and purchase terms.
Printed rollstock web leaving a wound roll
Buyer diagramVisual context for what are overrun and underrun in flexible packaging?.

Do not assume a universal percentage

Tolerance can vary with supplier, process, product, and order size. Read the actual quote terms and ask how invoices are handled before the purchase order is released.

Plan inventory around the range

If a launch or promotion needs a hard minimum, say so early. Procurement and operations should understand both the possible low and high receipt quantities, especially on small runs where setup has a larger proportional effect.

Source basis: PC-005, PC-113. Customer details, prices, volumes, and identifying artwork are intentionally excluded.
Written byMatt Louie
PublishedAugust 11, 2026
Last reviewedAugust 11, 2026
Review statusGeneral packaging education
SourcesPC-005PC-113

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