Cutting it right
Selecting the right sort of cutting equipment for a print finishing
department is absolutely critical; choose wrong and you risk running
into all sorts of issues when it comes to cutting and finishing off
printed work.
Die cutting remains one of the most trusted forms of cutting in the
print industry, having been around in some form since the mid-1800s.
Modern die cutting machines offer all sorts of helpful features and
options to make the cutting process even easier for
print-service-providers (PSPs).
O Factoid: Die cutting was first introduced in the mid-1800s O
Here, we find out more about some of the latest die cutting
machines available to the print market and take a closer look at how
these solutions can help users improve the quality of their printed
work.
Flexibility and reliability
Morgana Systems counts die cutting machines among its wide-ranging
portfolio of print finishing solutions. Ray Hillhouse, vice president of
sales and marketing for the Plockmatic Group Offline Business Unit,
which includes Morgana, says that PSPs looking to invest in a die
cutting machine should consider flexibility, reliability, and
performance.
“These print companies should be keen to handle as many finishing
tasks in-house as they can – the immediacy of digital printing can
easily get lost when sending finishing tasks out to third parties,”
Hillhouse says, adding: “They should be looking for a product that can
bring as wide a range of functionality as possible – die cutting,
including complex cutting, creasing, kiss-cutting, perforating,
embossing and debossing are all available from Morgana kit.
“Issues can certainly arise from poorly maintained or aged
equipment. We all know the printer which is still banging this type of
work through a tired, dirty, old platen style of machine that was last
serviced before the year 2000. When printers fail to invest in die
cutting equipment they can miss out on a lucrative amount of business.”
As to why PSPs should consider die cutting over other technologies,
Hillhouse explains die cutting is a service that is being demanded more
and more as customers seek ways to differentiate their print and ensure
it stands out from the crowd.
“It is an excellent option for a printer to use to go and win new
business,” Hillhouse says, adding: “By increasing the services on offer,
a printer has a greater chance of winning business because they have
control of delivery times, rather than having to rely on third-party
suppliers.”
With this, Hillhouse draws attention to the latest products
available from Morgana. The first comes in the form of AeroDieCut,
which, developed by Uchida, uses regular cutting and creasing forms,
combined with a patented system of moving press rollers that provide the
necessary pressure to cut through and score substrates.
Hillhouse says the product is ideal for short-to-medium-run work
and can process complex cuts, creases, embossing, and perforations on
printed materials in a single pass. It also has the ability to produce
step-and-repeat work where just one cutting forme can be employed to
step across a printed sheet up to five times.
The AeroDieCut can accommodate cutting formes of up to 350 x 550mm,
with a die board thickness of up to 18mm, and a cutting rule height of
23.3mm to 23.8mm, as well as paper sizes of up to 365 x 515mm, with a
maximum finished size of 310 x 485mm.
The new AeroDieCut from Morgana and Uchida can accommodate cutting formes of up to 350 x 550mm
For longer run work, Hillhouse points to the Rotary Die Cutter (RDC).
The cutting system on the device is composed of an upper magnetic
cylinder, holding the cutting matrix in place, and a lower counter
cylinder. A pin register system on the magnetic cylinder helps the
operator to install the cutting matrix accurately, while the
side-alignment of sheets is managed by adjustable straps allowing the
machine to maintain accurate sheet position.
Features include a top-sheet, air-suction deep pile feeder to help
ensure reliable sheet feeding, with the ability to accommodate up to
400mm of printed sheets. In addition, an 8” touch screen user interface
provides for fast and efficient job change overs.
Maximum sheet size for the RDC is 368mm x 508mm, while it offers a
maximum die cutting area of 361mm x 472mm, can handle materials up to
400gsm thick and run at speeds of up to 6,000 sheets per hour.
Fresh approach
Next and Graham Moorby, joint managing director at Printers
Superstore, explains that when it comes to investing in a new die
cutting machine, print companies should make a fresh approach.
“Die cutting can add value to a sheet and is often worth more than
the actual print these days,” Moorby says, adding: “While it’s easy to
keep using the same old methods, smart printers will always check out
the latest technologies, which can give them the edge over their
competitors.
While it’s easy to keep using the same old methods, smart printers
will always check out the latest technologies to give them the edge”
“Laser die cutting can truly open up a world of unique new products
and potential new markets. Machines such as our LC Series are amazing
and enable a range of design options that would be impossible to achieve
using traditional metal dies.
“As well as the ability to tackle jobs that would be impossible to
finish conventionally, being all-digital means no forms or die are
required, and make ready speed can be cut to minutes. Also repeat jobs
can be stored and recalled in seconds. With our machine you can cut,
crease, perf and etch in one pass.”
Expanding on the LC Series, Moorby highlights the LC 340S in
particular. Available in the UK exclusively from Printers Superstore,
the machine can kiss-cut to create products such as adhesive labels, as
well as crease, perforate and etch into a variety of substrates.
The LC 340S is available in the UK exclusively from Printers Superstore
“The potential to open up new niche markets for the LC user is
huge,” Moorby comments, adding: “Any new piece of kit can give
businesses a lift and help refocus them but the laser die cutter is
certainly top of that tree.
“Not future proofing your business and not remaining competitive is
always a risk; the kit is your team and having a good team keeps you in
the game. It can be expensive, so you need to do your homework and get
the right kit for your business - but investing in the right products
makes life easier, reduces production stress and increases
profitability. The key is to make the right choices, but don’t keep
still.”
Premium products
Elsewhere and Rob Thurston, head of sales at Duplo UK, says the
whole point of die cutting is for consistent precision, and only high
quality and expensive die cutters have historically been able to produce
these results.
“Many of our customers who have purchased our die cutters had found
that they were sending large amounts of revenue out the door since most
commercial printers don’t have a die cutting service,” Thurston
comments.
“Our customers found that with the purchase of the Duplo DI CUT
range of rotary die cutters, they could keep the work in-house –
controlling costs and the time frame for the jobs – keeping the quality
of the products high.
“They have also been able to break through to different markets
than their usual customer base and to support their existing customer
base with more services. The end result is that more revenue is
generated with a cost-effective solution.”
Thurston also issues a warning against underinvesting in die
cutting, and explains that the whole point of the process of die cutting
is consistency, and the only way to achieve this is to invest in
quality equipment.
“Underinvesting in die-cutting can and will lead to lower quality
machines that do not adjust skew or won’t include X & Y sheet
registration,” Thurston says, adding: “This will mean that the print
will not consistently match the shapes being cut.
“Die cutting is reserved for premium printed products, and these
details noticeably stand out. Traditional die cutting is a very
labour-intensive process to make the dies up, but with rotary die
cutters job changes are a fraction of the time even if the dies are
slightly more expensive.”
Duplo’s latest die cutter comes in the form of the PFi Di-Cut 310,
which, launched in May 2020, replaced the existing 300 model. Running up
to 4,000 sheets per hour, the high-speed rotary die cutter utilises a
magnetic cylinder and flexible dies that process paper, laminates,
self-adhesive and synthetic stocks up to 400gsm.
Duplo’s PFi Di-Cut 310 can run at speeds of up to 4,000 sheets per hour
A faster and slightly larger magnetic cylinder adds up to 30% more
printed items per sheet, depending on the application, which Thurston
says means that the cost per sheet is lower and margins are higher. The
transport belt has also been improved to provide better grip, while the
air blowers have been increased to improve sheet separation and the main
motor and sensors have been improved to increase accuracy.
Unique features
Rounding up this overview is Vivid Laminating Technologies and its
VeloBlade portfolio of systems, which are available in a range of sizes
and can be fully operated remotely with minimum setup.
Veloblade models have the ability to process a whole host of
materials, from media as thin as tissue paper and tracing paper, up to
10mm substrates. The Veloblade systems also have four separate heads,
allowing them to perforate, crease, cut and kiss-cut all in one pass on
the same sheet.
Vivid Laminating Technologies Veloblade models can process media as thin as tissue paper
Lewis Evans, product manager at Vivid, says these wide-ranging
capabilities allow users to access all sorts of work across different
markets, helping them expand their business in the process.
“With companies getting back on their feet after the last few
years, they need to be able to create profitable products easily without
the need for specialist training; Vivid’s new Zip Core software will
help enormously with this process,” Evans says.
“Using the Veloblade effectively, you can create and produce any
sort of product that you can think of, without any wastage and with full
automation. Veloblade systems can produce unique packaging items and
also the ability to produce incredible fine detailed work.
“The 10mm cut depth allows you to tap into new markets and
substrates; we’ve been surprised by our own customers bringing examples
to us of how thin it can cut, but then it can still go right up to 10mm
foamex and foam core boards, the systems will even cut fabric and
v-groove grey board for packaging applications.”
A special feature for Veloblade is a ‘handwriting’ option, whereby,
when combined with the Zipcore Design Suite software – the new version
of which will be launched to the market soon – users can place a pen in
the system, and it will produce letters, invites and other pieces
automatically, mimicking actual handwriting.
In addition, Evans says the high level of automation associated
with the Veloblade means that once a customer has given permission,
Vivid’s team of experts can gain access to the System and offer
assistance and help with any particular jobs.
“If a customer is struggling with a particular project, we can
operate Veloblades remotely and solve issues quickly,” Evans says,
adding: “In fact, during lockdown, we were able to install a Veloblade
Volta 69+ in the Isle of Man and carry out all training completely
remotely – something available on all systems in the range.
“It’s that partnership with Vivid that really helps customers in what can be new markets for them.”
Vivid Laminating Technologies will be in attendance at Sign &
Digital UK this month to show off a brand new, “Game Changing” patented
application for the VeloBlade. This will initially be available on the
Volta models before being expanded to Nexus range.
This level of innovation highlighted by Evans is apparent across
the die cutting market, with new and exciting developments being
announced all the time. With this in mind, it could be time for you to
look at investing in new tech and taking advantage of these
advancements.
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