Rotary Dies Technology Showcase
Use this guide to find the right rotary die equipment for your needs.
October 2008 by Missy Smith
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Company: Schober USA, www.schoberusa.com
Product: Tungsten Carbide dies
What are they?: Tungsten Carbide dies from Schober USA are used to manufacture various products such as flexible packaging, folding cartons, high-volume household and personal care products, technical parts, and more.
Features/Capabilities:
• Available in solid or segmented designs or with shells
• Maximum length of 13.8˝ and a maximum diameter of 7.8˝
• Can absorb vibrations and keep all relevant parameters to minimum variation for predictable die/anvil life cycles
• Can be re-sharpened as often as regular dies
Company: Gerhardt, www.gerhardt-usa.com
Product: Five Star & Seven Star Rotary Dies
What are they?: Gerhardt manufactures a complete line of rotary cutting tools, which are made from premium grade tool steel for all diecutting applications.
Features/Capabilities:
• High-quality tool steel
• The Five Star Rotary Die is CNC engraved and fully hardened, designed for paper and films, and custom designed to high industry standards
• The Seven Star Rotary Die is EDM Spark Eroded and is fully hardened, is designed for tight tolerances and complex geometries, and is designed to be extremely durable in metal-to-metal applications.
Company: Bunting Magnetics, www.buntingmagnetics.com
Product: Magnetic CerfaceTM Die-Cutting Cylinders
What are they?: Diecutting cylinders
Features/Capabilities:
• RP shearing action, resulting in the highest level of cut quality
• Various steel alloys, several hardening techniques, and designs with and without journals.
• Surface-mounted ceramic magnets that create a super-hard, abrasion-resistant surface over a strong, solid-metal core designed to eliminate deflection.
Company: RotoMetrics, www.rotometrics.com
Product: Multi-Score Flexible Dies
What are they?: These dies combine scoring technology with a flexible die that runs on a magnetic cylinder cutting against an anvil roll, allowing converters, whose presses have die stations without removable anvil rolls, to run folding-carton jobs.
Features/Capabilities:
• Standard plate height of 0.035˝
• Die must be run as an “undercutter” unless the converter is able to use a turn bar to flip the web
• The carton dieline should be rotated slightly, so there is no true cross blade on the die, configured at approximately a 5-degree angle on the layout
• A specific magnetic cylinder is required, which uses a combination of high-strength and standard magnets, and which has a minimum repeat of 16˝
Company: Electro-Optic US, www.electro-optic.com
Product: Dura Line Special-C Flexible dies
What are they?: Flexible dies that combine the sharpness and precision of the company’s GOLD LINE TOOL with long life performance.
Features/Capabilities:
• Resistent black ion coating protects the dies against wear-out from abrasive inks, luminescence ink, metallic ink, and writeable color and writeable lacquer.
• Designed for materials like Tyvek, Primax, Polyester, Polyexact, foils, laminations, and integrated labels and cards
Company: Sohn Manufacturing, www.sohnmanufacturing.com
Product: Model RLDC 525 Heavy Duty Die Cutter
What is it?: The Model RLDC 525 is a narrow-web rotary laminating and rotary diecutting machine, which is designed to convert a wide range of materials. It has five top die stations and two back die stations.
Specifications:
• Dimensions: 96˝ x 38˝ x 75˝
• Weight: 1,000 pounds. depending on options
• Electrical: 220V/60 Hz. (others optional)
• Variable-speed electric drive
• Gearing: 125 C.P. or 32 D.P. (which is optional)
• Roll Size: 15˝
• Core Size: 3˝ I.D. (others optional)
• Overhead spindles optional
Company: Wilson Manufacturing, www.wilsonmfg.com
Product: Fully hardened machine sharpened dies
What are they?: Cutting dies sharpened with a high level of accuracy, including multi-levels such as slit-over-perf blades.
Features/Capabilities:
• Machine-sharpened to offer a consistent angle along every inch of blade, with no variances
• Part sizes are maintained to much tighter tolerances
• Machine sharpened to produce the same high yeilds after retooling; no changes between a new die and one with four resharpenings
Company: Atlas Die, www.atlasdie.com
Product: Flexible Cutting Dies
What are they?: Atlas Die flexible dies are custom designed for rotary diecutting converters of pressure-sensitive materials, tags, envelopes, business forms, and specialty items.
Features/Capabilities:
• Precision ground on the b`ackside of the die to a parallel of ± 0.0001˝ to eliminate uneven cutting, decrease makeready time, and increase die life
• 801-B Surface Treatment to improve lubricity (acts as a release agent), without leaving residue on the stock being converted
• Reduces adhesive buildup on die knives to inhibit corrosion and improve die life by increased abrasion resistance
• 801-B Surface Treatment to provide adhesion qualities and will not crack, peel, lift, blister, or soften
Company: Bernal, Inc., www.bernalinc.com
Product: R/P Crush Cut Dies
What are they?: Bernal Inc. RP dies for the folding-carton industry provide long die life while maintaining like-new cutting quality, through the use of shearing blades, instead of crushing blades, on both the upper die and the lower die.
Features/Capabilities:
• 10 to 250 million revolutions before sharpening
• Cuts material thickness up to 0.125˝ (3.175 mm)
• Die diameter range: 3˝ to 24˝ (76.2 mm to 609.6 mm)
• Web width of 2˝ to 70˝ (50 mm to 1,780 mm)
Company: Kocher + Beck, www.kocher-beck.com
Product: UNIVERSAL flexible dies
What are they?: Dies that are manufactured from hardened spring steel—which is chemically etched, CNC-sharpened, and finished with smooth polished cutting edges.
Features/Capabilities:
• Various cutting angles, from 30 to 110 degrees can be applied to specifically match the requirements of the material
• Profile heights from 0.30 to 1.5 mm are available, allowing kiss cutting or cutting down to the anvil (steel to steel)
• Suitable for converting all types of single and multi-layered materials, thin card, self-adhesive paper, and synthetics
Company: Madern USA, www.madern.com
Product: Rotary diecutting tools
What are they?: Madern USA supplies rotary diecutting tools—widely used in the tobacco industry—based on two principles of cutting: Crush Cut (CC) and Madern Pressure (MP) Cut (Scissor Cut).
Features/Capabilities:
• Circumference: from 7.8˝ to 78˝
• Tool (face) width: from 3.9˝ to 67˝
• Special features, such as waste removal, punching, and perforations can be integrated in the cutting tool.
• Periphery equipment can be supplied according to machine specifications. pP
Product: Tungsten Carbide dies
What are they?: Tungsten Carbide dies from Schober USA are used to manufacture various products such as flexible packaging, folding cartons, high-volume household and personal care products, technical parts, and more.
Features/Capabilities:
• Available in solid or segmented designs or with shells
• Maximum length of 13.8˝ and a maximum diameter of 7.8˝
• Can absorb vibrations and keep all relevant parameters to minimum variation for predictable die/anvil life cycles
• Can be re-sharpened as often as regular dies
Company: Gerhardt, www.gerhardt-usa.com
Product: Five Star & Seven Star Rotary Dies
What are they?: Gerhardt manufactures a complete line of rotary cutting tools, which are made from premium grade tool steel for all diecutting applications.
Features/Capabilities:
• High-quality tool steel
• The Five Star Rotary Die is CNC engraved and fully hardened, designed for paper and films, and custom designed to high industry standards
• The Seven Star Rotary Die is EDM Spark Eroded and is fully hardened, is designed for tight tolerances and complex geometries, and is designed to be extremely durable in metal-to-metal applications.
Company: Bunting Magnetics, www.buntingmagnetics.com
Product: Magnetic CerfaceTM Die-Cutting Cylinders
What are they?: Diecutting cylinders
Features/Capabilities:
• RP shearing action, resulting in the highest level of cut quality
• Various steel alloys, several hardening techniques, and designs with and without journals.
• Surface-mounted ceramic magnets that create a super-hard, abrasion-resistant surface over a strong, solid-metal core designed to eliminate deflection.
Company: RotoMetrics, www.rotometrics.com
Product: Multi-Score Flexible Dies
What are they?: These dies combine scoring technology with a flexible die that runs on a magnetic cylinder cutting against an anvil roll, allowing converters, whose presses have die stations without removable anvil rolls, to run folding-carton jobs.
Features/Capabilities:
• Standard plate height of 0.035˝
• Die must be run as an “undercutter” unless the converter is able to use a turn bar to flip the web
• The carton dieline should be rotated slightly, so there is no true cross blade on the die, configured at approximately a 5-degree angle on the layout
• A specific magnetic cylinder is required, which uses a combination of high-strength and standard magnets, and which has a minimum repeat of 16˝
Company: Electro-Optic US, www.electro-optic.com
Product: Dura Line Special-C Flexible dies
What are they?: Flexible dies that combine the sharpness and precision of the company’s GOLD LINE TOOL with long life performance.
Features/Capabilities:
• Resistent black ion coating protects the dies against wear-out from abrasive inks, luminescence ink, metallic ink, and writeable color and writeable lacquer.
• Designed for materials like Tyvek, Primax, Polyester, Polyexact, foils, laminations, and integrated labels and cards
Company: Sohn Manufacturing, www.sohnmanufacturing.com
Product: Model RLDC 525 Heavy Duty Die Cutter
What is it?: The Model RLDC 525 is a narrow-web rotary laminating and rotary diecutting machine, which is designed to convert a wide range of materials. It has five top die stations and two back die stations.
Specifications:
• Dimensions: 96˝ x 38˝ x 75˝
• Weight: 1,000 pounds. depending on options
• Electrical: 220V/60 Hz. (others optional)
• Variable-speed electric drive
• Gearing: 125 C.P. or 32 D.P. (which is optional)
• Roll Size: 15˝
• Core Size: 3˝ I.D. (others optional)
• Overhead spindles optional
Company: Wilson Manufacturing, www.wilsonmfg.com
Product: Fully hardened machine sharpened dies
What are they?: Cutting dies sharpened with a high level of accuracy, including multi-levels such as slit-over-perf blades.
Features/Capabilities:
• Machine-sharpened to offer a consistent angle along every inch of blade, with no variances
• Part sizes are maintained to much tighter tolerances
• Machine sharpened to produce the same high yeilds after retooling; no changes between a new die and one with four resharpenings
Company: Atlas Die, www.atlasdie.com
Product: Flexible Cutting Dies
What are they?: Atlas Die flexible dies are custom designed for rotary diecutting converters of pressure-sensitive materials, tags, envelopes, business forms, and specialty items.
Features/Capabilities:
• Precision ground on the b`ackside of the die to a parallel of ± 0.0001˝ to eliminate uneven cutting, decrease makeready time, and increase die life
• 801-B Surface Treatment to improve lubricity (acts as a release agent), without leaving residue on the stock being converted
• Reduces adhesive buildup on die knives to inhibit corrosion and improve die life by increased abrasion resistance
• 801-B Surface Treatment to provide adhesion qualities and will not crack, peel, lift, blister, or soften
Company: Bernal, Inc., www.bernalinc.com
Product: R/P Crush Cut Dies
What are they?: Bernal Inc. RP dies for the folding-carton industry provide long die life while maintaining like-new cutting quality, through the use of shearing blades, instead of crushing blades, on both the upper die and the lower die.
Features/Capabilities:
• 10 to 250 million revolutions before sharpening
• Cuts material thickness up to 0.125˝ (3.175 mm)
• Die diameter range: 3˝ to 24˝ (76.2 mm to 609.6 mm)
• Web width of 2˝ to 70˝ (50 mm to 1,780 mm)
Company: Kocher + Beck, www.kocher-beck.com
Product: UNIVERSAL flexible dies
What are they?: Dies that are manufactured from hardened spring steel—which is chemically etched, CNC-sharpened, and finished with smooth polished cutting edges.
Features/Capabilities:
• Various cutting angles, from 30 to 110 degrees can be applied to specifically match the requirements of the material
• Profile heights from 0.30 to 1.5 mm are available, allowing kiss cutting or cutting down to the anvil (steel to steel)
• Suitable for converting all types of single and multi-layered materials, thin card, self-adhesive paper, and synthetics
Company: Madern USA, www.madern.com
Product: Rotary diecutting tools
What are they?: Madern USA supplies rotary diecutting tools—widely used in the tobacco industry—based on two principles of cutting: Crush Cut (CC) and Madern Pressure (MP) Cut (Scissor Cut).
Features/Capabilities:
• Circumference: from 7.8˝ to 78˝
• Tool (face) width: from 3.9˝ to 67˝
• Special features, such as waste removal, punching, and perforations can be integrated in the cutting tool.
• Periphery equipment can be supplied according to machine specifications. pP
Companies Mentioned:
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