In the last issue of NarrowWebTech, we presented the important basics of rotary die-cutting. In this follow-up article, we now deal with diecutting issues that frequently occur in daily production. The article focuses on typical problems, which arise when die-cutting labels with flexible dies. Most of these problems are related to the cutting depth. In the final part of our series we will provide solutions for other special challenges, like die-cutting on thin PET liners.
Typical die-cutting issues
Die-cutting can be described as a process, in which the label face material is compressed by the tool’s cutting edge until it bursts. However, the silicone layer and the liner material should remain undamaged. While compressible materials like paper only need comparatively low pressure to be completely cut, tough filmic materials like PE need more pressure and usually a steeper cutting angle to be separated.
The material to be cut is only one of the crucial components of the die-cutting process. The other two are the cutting unit (especially the cylinder gap), and the cutting tool. All three components must be optimally coordinated to achieve perfect die-cutting results. Most die-cutting problems are caused by one of the three components, or respectively by their interaction. The following trouble-shooting guide presents typical die-cutting issues and how they can be analysed by the operator. After a short description of the problem and its characteristics, we show possible causes and the measures which can be taken, so that in many cases the problem can be solved (or avoided) directly on-site. Read the full article in our eDossier “Die-cutting problems.“
This short list of die-cutting issues should make it clear that many problems can be avoided in advance. The perfect condition of the machine, the cylinders and the cutting tool are fundamental prerequisites for flawless die-cutting results. Moreover, a detailed indication of the material to be cut and the size of the gap must be given with an order, so that the flexible die can be perfectly adjusted to the individual requirements.
In the next and final part of the article series we will deal with more specific die-cutting topics, such as cutting on thin liners or with extreme adhesives. More tips and tricks for die-cutting also can be found in the Wink “ABC of the Cutting Tools”. This compact format manual describes causes of unsatisfactory cutting results and how these problems are to avoid or to remove. The manual also describes the basics of die-cutting and care instructions for cutting tools. Learn more about the “Die-cutting problems” – you can easily download it for EUR 1,99 in our shop.
This article was first published in NarrowWebTech 4-2014.