Improved tools for cutting down time

12 February 2018



For years, converting has been seen as a cost centre of manufacturing, something that causes delays to production or quality control that is a headache for production and operations staff. But modern technological developments make this a thing of the past, as experts and machine builders are keen to tell Converting Today.


Machine producers have been busy, and the experts in Berhalter are global leaders in die-cutting innovation, with the latest round of product launches being no exception. In September 2017, Berhalter introduced its patented technology for cut in-mould and polyester labels.

The Berhalter Label-light punching tool is a patented concept that combines the improvements of flat-bed die cutting, such as unique print-to-die registration and perfect handling properties. The cost of a Label-light punching tool is as much as 70% lower than a traditional punching tool, even allowing a label contour correction of ±0.5mm. Moreover, there is no need to regrind a Label-light tool – the cutting components can be easily exchanged by the operators in order to continue production immediately.

In addition, Berhalter presented the B 500 high-performance die-cutting machine, equipped with IML production. With eight synchronised but separately and individually controlled servo drives, the B 500 sets a new standard in high-precision, print-to-die registration. The foil tension is automatically monitored and regulated. This means that the die-cutting conditions are maintained throughout the process, irrespective of how well the reel is wound. The result is precise, dimensional accuracy of the in-mould label.

As materials become more complex and sensitive, and quality demands grow stricter, seamless integration between die-cutting machines and die-cutting tools is more important than ever. Reducing cost also means using thinner in-mould labelling films. Berhalter aims to be the leading company in the packaging materials industry by die cutting and processing IML labels as thin as 40μ, and even thinner films. Other important aspects include the stack accuracy of labels, as well as the static charge on plastic films. These latest systems are non-contact die-cutting process, which is ideal for the avoidance of static charges.

The Berhalter offerings can also carry out additional operations, such as the finishing of a surface texture, the insertion of a micro-perforation (for applications in the deep-drawn or blow-moulding area), pre-cut holes (for injection nozzles) or die-cut holes for technical functions (centring aids and windows). They are all simple to manage and run on these machines without expert operators, making it easier to plug them into existing lines to upgrade them.

Reverse cutting

Another recent development comes from Marbach Group, which has introduced its reverse-cutting technology for use in various paperboard and corrugated board packaging applications. The new height-adjustable anvil included in the technology will allow customers to adjust the anvil height of their die-cutting machines by themselves and is considered to be optimal wherever attractive appearance, complete dust resistance and easy-to-open features are essential.

Marbach Group marketing manager Tina Dost says, “When using the reverse-cutting technology, the highest precision is vital for optimal function because, in reverse cutting, the board is scribed on both sides – from the inside and outside of the package.

“This task becomes more difficult the thinner the paperboard is. With the new, height-adjustable anvil, our customers can now save make-ready time and achieve more consistent results,” she adds.

Marbach’s new reverse-cutting technology uses an aluminium block, the exact height of which depends on the thickness of the die-cut material. Unlike traditional solutions, the aluminium block is not inserted into a laser-cut contour in its complete height. It is inserted in a height minus the die-board thickness and screwed onto the cutting die from above. Foils are placed beneath the anvil, which can be adjusted in its height very quickly and easily through the removal or addition of these foils. Dost adds, “In this way, our customers can set up their tool in the die-cutting machine much more quickly and precisely than with the conventional reverse-cutting technology.”

Customer perspective

From the user’s perspective, these changes are well timed and eagerly anticipated. Reg Cunningham, process improvement manger at Specialty Finishing, is one such customer who is clear on what he is looking for when acquiring die-cutting technology.

“It all depends on the substrate and what that cutter is designed for,” he says. “The cost of these different dies ranges from hundreds of dollars to many thousands of dollars, depending on what type of die cutter you have. Some dies will last for thousands of impressions and others will last for millions.

“Here’s what I can see from the standpoint of the folding carton packaging part of the industry. On the flat-bed die cutters, you see more companies going to steel 1mm plates with a wooden steel rule die. In the past, you needed a steel die to use a steel counter plate. Today, the wood is made differently and doesn’t expand or contract, so the scores or creases don’t move. This makes for a better crease: it never changes. With smaller nicks holding the sheets or web together, there is no counter to go over or catch, and no marks on the carton from the counter,” he continues.

I am really keen on the productivity benefits of in-line foiling, die cutting and blanking for high-volume, high-end packaging.

– Richard Pacey, Qualvis

“With the steel counter plate, you get a better score, as the cutting rule gets flatter after many impressions. With the fibreglass counter material, as you get more impressions on the counter, the square edge on the fibreglass wears and goes round, thus making the score not fold as well. For the rotary side of die cutting, you can buy a magnetic die-make cheaper than the full, hard rotary die; this makes it easier for label converters to change out dies and patterns faster.”

Cunningham is excited about the future of the industry. He says, “The next stage will be die cutting with no dies. It’s out there already in the early stages, using lasers to cut. In the label industry, they have no creases or scores now. There will be no die change: just send a new programme to the laser with the new label. There is no die to go flat, a faster changeover and no die to store or buy. This will reduce cost and increase competition in the market.”

While the future is full of change and innovation, Cunningham does not believe that it will all come at once, or even that it will replace many techniques and technology in the industry. “For the converting industry, it will take a little longer because of the crease, but it’s being worked on right now,” he says. “For flatbed die cutting, the platen has to go up and down, and a gripper must go through. With a laser, there is no up and down, and the creases will be made before the laser cuts the packaging. They are using it in the greeting card business because they can make cuts that can’t be done with a cutting die. It’s coming. It will change the way we do things in die cutting, just like it changed the way we make cutting dies.”

New possibilities

For converters, competing in a market that demands innovation, economies of scale, accuracy, and high levels of packaging strength and flexibility, die cutting is embracing technology that makes such competition possible.

“Digital die cutting, such as plotter and laser methods, has enabled easy and effective dummy production, as well as the use of IT technology and digitalisation in tool making,” says Timo Kallio, technical service director at Metsä Board. “In addition, using a steel counter plate instead of matrix plates has enhanced how converters approach die cutting.

“Special varnishes and lacquers can make embossing and braille instead of mechanical embossing. Tool material development and easy-to-make tooling have enabled fast make-readies, and the folder gluer is often a more economical option for braille made using die cutting,” he adds.

Richard Pacey, technical director at Qualvis, says, “I am really keen on the productivity benefits of in-line foiling, die cutting and blanking for high-volume, high-end packaging. I think development in this area is particularly interesting, given our core business. The recent investment for our die shop is a new state-of-the-art Servi form rule processor with broaching capability. It has greatly improved the output of our in-house die shop and reduced the make-ready times in our cut crease department, specifically reducing patch-up time.”



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