Die cutting machine application die cutting technology analysis: Flexo printing linkage processing production line has been increasingly used in folding carton processing, has become the most rapid development of a printing process, the development of the carton processing industry Huge power. Even in some regions where the carton processing market has grown the slowest, there have been significant developments.
There are still some processors who do not believe that post-press processing such as die-cutting, waste disposal, and molding processing is a crucial part of flexographic printing production. However, only the carton that has been die-cut, discarded and formed has the actual packaging and transport properties, and it can be regarded as a truly practical package. Incomplete post-printing actually makes perfect printing meaningless.
There are still many factors that limit the processing efficiency of the carton processing plant. For example, whether a paper feed is used for sheet feeding or web feeding, round die cutting or flat die cutting, and on-line die-cutting or off-line die-cutting all have a direct impact on the entire plant's production capacity. Business interests and ability to serve customers.
Compared with the processing of sheetfed and web, in the carton processing industry, the process that still occupies a relatively large market share is still the single-sheet paper feeding, multi-machine offset printing, and flat pressing and cutting. The process flow is:
Paper Roll - Sheetfed - Pause - Printing - Pause - Flush - Pause - Die-cut - Pause - Waste - Finishing the carton
Assessing capital investment and labor costs, if you also operate a carton processing plant in this mode, you will certainly face tremendous pressure.
Therefore, the existing sheet-fed paper carton processors need to take two approaches if they want to lead the competition: First, in the case of existing equipment, to achieve the highest possible production speed; Second, to achieve high-volume processing Under the low-cost production, such as a variety of different specifications of the carton together for processing.
The high cost of equipment investment, the time-consuming conversion of India and the United States, and the difficulty of managing multiple sets of processing equipment at the same time, especially the difference in speed matching between printing and finishing, are continuously reducing sheetfed offset + flattening die cutting The proportion of carton processing.
A typical flexographic printing process is a process in which the web material directly enters the printing section and the processed finished product is output from the other end. The process flow is:
Paper Roll - Printing + Die Cutting - Finishing the Carton
Obviously, this mode of production has reduced capital investment, die-cutting consumption and labor input, and shortened the delivery time of finished products to customers. This is very different from the multiple processing steps that are repeated in the single-sheet paper carton processing.
After realizing this difference, considering the processing time limit, the following results can be compared: Offset printing requires five sets of printing equipment, while flexographic printing requires only one set of printing equipment; Offset printing requires six processes, The flexographic printing process requires only two processes; the offset process eventually requires 10 to 12 workers, while the flexographic printing process requires only 2 to 3 workers. The pros and cons of craftsmanship are obvious.
Comparison between circular die cutting and flat die cutting
Whether it is a sheet-fed or web printing method, if flat die-cutting is provided, there will be some defects in the subsequent processing. Therefore, the choice of die-cutting process becomes the second most important determinant in carton processing.
Although the price of round die-cutting die is still higher than that of die-cut die-cutting die, the gradual reduction in the price of round die-cut die-cutting die and the gradual improvement in its reliability have led to an expansion of its popularity. So far, more and more carton processors have realized the superiority of circular press die cutting methods, mainly reflected in the higher average processing speed and similar consistency of the processing technology (rotary printing + round pressure Round die cutting), lower investment and recognition of simple and quick preparation.
In terms of equipment investment, the price of a flat die-cutting die cutting machine is sufficient to purchase more than one round press die cutting machine. Although the price of circular die cuts is slightly higher, its investment can be postponed. It is only necessary to purchase molds when they actually receive orders for special carton processing. Further, the modern round die-cutting die plate has been made so precise that most of the prepress preparation work is done in the die-processing factory. Die-cut plates are used to make padding, hollowing out, and indentation pads. Preparation work is no longer required in printing companies. Printing companies only need to use a thin double-sided adhesive for sticking, which actually reduces costs.
Of course, the most important of all the factors is still the production efficiency. Compared with the flat-platen die-cutting process, the round-ring die-cutting process has a much higher production efficiency. After successfully adopting new methods such as reducing the cutting blank, the success factor of carton processing production is the number of processing per unit time, ie, how to increase production efficiency. Although the combination of flat die-cutting die cutting and web printing process also has a high processing speed, the high equipment maintenance costs, difficulty in die-cutting and waste-discharging, and difficulty in registration make the actual processing and production capacity inferior. Round pressure die cutting process.
Of course, round die cutting is not a panacea. Large-format printing small carton processing production using flat-press die-cutting process still has advantages, and in some respects even exceeds the processing capacity of the narrow-width turn + round-pressure die-cutting process.
It should be noted that there are numerous types of round press die cutting machines that require considerable knowledge to make successful choices.
Solid Die Cut and Magnetic Die Cut
The solid die-cut version of steel alloys has been the dominant die-cut version for round-press die cutting for nearly 20 years. In the past, the die-cut version was expensive. Considering that the carton processors should continue to maintain their competitive advantages, the mold price has been significantly reduced in recent years, almost to the point where carton processors do not need to think too much. The mold manufacturing process has also advanced to the point where it can be delivered within a few days (while previously it may take several weeks, large molds may even require several months), the machining accuracy of the mold is also getting higher and higher, and the mold is handed over All die-cutting preparations have been completed before shipment.
Although the mold manufacturing process has enabled molds to continue to reduce costs, physical diecuts still have some deficiencies for some carton processors and certain production conditions. In order to make up for this as quickly as possible, mold makers have accelerated the development of flexible die-cuts, ie magnetic die-cuts. It fixes the die plate by using a magnetic roller.
The development of magnetic die cutting is very rapid, mainly because of its low price. The price of a magnetic die cut is only about 25% to 30% of the price of a physical diecut. Through its application in recent years, the magnetic die-cut version has established its position in ultra-small carton processing. In particular, when a carton processor cannot determine whether a certain carton can be processed in large quantities, it can be applied to trial production of carton samples and test articles. Under normal circumstances, carton processors can fully use magnetic die-cutting if they can reasonably calculate the annual production volume of less than 8 million cartons, and use physical die-cutting when the output is greater than 8 million. The version is more suitable.
Here are two things to note. First, most magnetic die-cutting die-cutting processes require an auxiliary process or a waste bin, which is different from the physical die-cutting process. The physical die-cut version is equipped with an integrated pin-type waste discharge section, so it is advanced in terms of simplicity, reliability, and processing speed. Second, the magnetic die-cut version can no longer be re-ground after passivation of die-cutting blades. Cutting, and the solid die-cut version can be repeatedly ground 3 to 5 times after passivation of the normal die-cutting blade. This is why the above-mentioned 8 million carton processing quantity is used as a reason for selecting different die-cutting plates.
Future development trend
With the application of innovative technologies, carton processors who have become accustomed to the old processing model using sheetfed offset + flattened die-cutting are resisting the new changes by applying flexo printing + circular die-cutting The biggest obstacle. There is still a considerable amount of money invested in old processing equipment and traditional carton processing methods, and some major equipment suppliers are constantly reminding every carton maker what to do. However, they often do not understand the market pressure and business needs faced by carton processors. Only the new technologies that meet the future needs of carton processors will prompt them to carefully understand the new processing model.
Manufacturers of flexographic printing equipment suppliers and round press die cutting equipment have realized that based on the common long-term interests, both parties should cooperate with each other to complete the transition and transition of new and old equipment and processes as simply and smoothly as possible. Once carton converters learn about the advantages of new production processes, they will learn and learn from a variety of sources, from learning the theory of flexographic printing to learning to correctly install magnetic die cuts.
There are still some processors who do not believe that post-press processing such as die-cutting, waste disposal, and molding processing is a crucial part of flexographic printing production. However, only the carton that has been die-cut, discarded and formed has the actual packaging and transport properties, and it can be regarded as a truly practical package. Incomplete post-printing actually makes perfect printing meaningless.
There are still many factors that limit the processing efficiency of the carton processing plant. For example, whether a paper feed is used for sheet feeding or web feeding, round die cutting or flat die cutting, and on-line die-cutting or off-line die-cutting all have a direct impact on the entire plant's production capacity. Business interests and ability to serve customers.
Compared with the processing of sheetfed and web, in the carton processing industry, the process that still occupies a relatively large market share is still the single-sheet paper feeding, multi-machine offset printing, and flat pressing and cutting. The process flow is:
Paper Roll - Sheetfed - Pause - Printing - Pause - Flush - Pause - Die-cut - Pause - Waste - Finishing the carton
Assessing capital investment and labor costs, if you also operate a carton processing plant in this mode, you will certainly face tremendous pressure.
Therefore, the existing sheet-fed paper carton processors need to take two approaches if they want to lead the competition: First, in the case of existing equipment, to achieve the highest possible production speed; Second, to achieve high-volume processing Under the low-cost production, such as a variety of different specifications of the carton together for processing.
The high cost of equipment investment, the time-consuming conversion of India and the United States, and the difficulty of managing multiple sets of processing equipment at the same time, especially the difference in speed matching between printing and finishing, are continuously reducing sheetfed offset + flattening die cutting The proportion of carton processing.
A typical flexographic printing process is a process in which the web material directly enters the printing section and the processed finished product is output from the other end. The process flow is:
Paper Roll - Printing + Die Cutting - Finishing the Carton
Obviously, this mode of production has reduced capital investment, die-cutting consumption and labor input, and shortened the delivery time of finished products to customers. This is very different from the multiple processing steps that are repeated in the single-sheet paper carton processing.
After realizing this difference, considering the processing time limit, the following results can be compared: Offset printing requires five sets of printing equipment, while flexographic printing requires only one set of printing equipment; Offset printing requires six processes, The flexographic printing process requires only two processes; the offset process eventually requires 10 to 12 workers, while the flexographic printing process requires only 2 to 3 workers. The pros and cons of craftsmanship are obvious.
Comparison between circular die cutting and flat die cutting
Whether it is a sheet-fed or web printing method, if flat die-cutting is provided, there will be some defects in the subsequent processing. Therefore, the choice of die-cutting process becomes the second most important determinant in carton processing.
Although the price of round die-cutting die is still higher than that of die-cut die-cutting die, the gradual reduction in the price of round die-cut die-cutting die and the gradual improvement in its reliability have led to an expansion of its popularity. So far, more and more carton processors have realized the superiority of circular press die cutting methods, mainly reflected in the higher average processing speed and similar consistency of the processing technology (rotary printing + round pressure Round die cutting), lower investment and recognition of simple and quick preparation.
In terms of equipment investment, the price of a flat die-cutting die cutting machine is sufficient to purchase more than one round press die cutting machine. Although the price of circular die cuts is slightly higher, its investment can be postponed. It is only necessary to purchase molds when they actually receive orders for special carton processing. Further, the modern round die-cutting die plate has been made so precise that most of the prepress preparation work is done in the die-processing factory. Die-cut plates are used to make padding, hollowing out, and indentation pads. Preparation work is no longer required in printing companies. Printing companies only need to use a thin double-sided adhesive for sticking, which actually reduces costs.
Of course, the most important of all the factors is still the production efficiency. Compared with the flat-platen die-cutting process, the round-ring die-cutting process has a much higher production efficiency. After successfully adopting new methods such as reducing the cutting blank, the success factor of carton processing production is the number of processing per unit time, ie, how to increase production efficiency. Although the combination of flat die-cutting die cutting and web printing process also has a high processing speed, the high equipment maintenance costs, difficulty in die-cutting and waste-discharging, and difficulty in registration make the actual processing and production capacity inferior. Round pressure die cutting process.
Of course, round die cutting is not a panacea. Large-format printing small carton processing production using flat-press die-cutting process still has advantages, and in some respects even exceeds the processing capacity of the narrow-width turn + round-pressure die-cutting process.
It should be noted that there are numerous types of round press die cutting machines that require considerable knowledge to make successful choices.
Solid Die Cut and Magnetic Die Cut
The solid die-cut version of steel alloys has been the dominant die-cut version for round-press die cutting for nearly 20 years. In the past, the die-cut version was expensive. Considering that the carton processors should continue to maintain their competitive advantages, the mold price has been significantly reduced in recent years, almost to the point where carton processors do not need to think too much. The mold manufacturing process has also advanced to the point where it can be delivered within a few days (while previously it may take several weeks, large molds may even require several months), the machining accuracy of the mold is also getting higher and higher, and the mold is handed over All die-cutting preparations have been completed before shipment.
Although the mold manufacturing process has enabled molds to continue to reduce costs, physical diecuts still have some deficiencies for some carton processors and certain production conditions. In order to make up for this as quickly as possible, mold makers have accelerated the development of flexible die-cuts, ie magnetic die-cuts. It fixes the die plate by using a magnetic roller.
The development of magnetic die cutting is very rapid, mainly because of its low price. The price of a magnetic die cut is only about 25% to 30% of the price of a physical diecut. Through its application in recent years, the magnetic die-cut version has established its position in ultra-small carton processing. In particular, when a carton processor cannot determine whether a certain carton can be processed in large quantities, it can be applied to trial production of carton samples and test articles. Under normal circumstances, carton processors can fully use magnetic die-cutting if they can reasonably calculate the annual production volume of less than 8 million cartons, and use physical die-cutting when the output is greater than 8 million. The version is more suitable.
Here are two things to note. First, most magnetic die-cutting die-cutting processes require an auxiliary process or a waste bin, which is different from the physical die-cutting process. The physical die-cut version is equipped with an integrated pin-type waste discharge section, so it is advanced in terms of simplicity, reliability, and processing speed. Second, the magnetic die-cut version can no longer be re-ground after passivation of die-cutting blades. Cutting, and the solid die-cut version can be repeatedly ground 3 to 5 times after passivation of the normal die-cutting blade. This is why the above-mentioned 8 million carton processing quantity is used as a reason for selecting different die-cutting plates.
Future development trend
With the application of innovative technologies, carton processors who have become accustomed to the old processing model using sheetfed offset + flattened die-cutting are resisting the new changes by applying flexo printing + circular die-cutting The biggest obstacle. There is still a considerable amount of money invested in old processing equipment and traditional carton processing methods, and some major equipment suppliers are constantly reminding every carton maker what to do. However, they often do not understand the market pressure and business needs faced by carton processors. Only the new technologies that meet the future needs of carton processors will prompt them to carefully understand the new processing model.
Manufacturers of flexographic printing equipment suppliers and round press die cutting equipment have realized that based on the common long-term interests, both parties should cooperate with each other to complete the transition and transition of new and old equipment and processes as simply and smoothly as possible. Once carton converters learn about the advantages of new production processes, they will learn and learn from a variety of sources, from learning the theory of flexographic printing to learning to correctly install magnetic die cuts.
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