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Optimum Die-cutting Process Improves Die-cut Quality And Efficiency
May 29, 2018

Whether printing and packaging companies can survive in the fierce market competition, in addition to focusing on printing quality, the most important thing is price and service. Prices are directly involved in profits, and profits involve costs, reducing the cost of each production process that squeeze out the profit space, thereby winning the price advantage; fast delivery is the embodiment of corporate capabilities, but also an important factor weighing business service level. Therefore, it is very important to reduce costs and shorten delivery time scientifically and reasonably. This article will explain how to reduce the cost, improve the quality and efficiency, and shorten the delivery time by means of innovations in the die-cutting process, such as the improvement of die-cutting plates, connection points, and discarded version designs.

Change the standard configuration of die-cutting plate and reduce the cost of die-cutting plate

The base plate of the ordinary laser knife mold is a glued wood board, and the standard matching bottom mold is a resin bottom mold, which has certain limitations for the long-term product (large order). Among them, wood is an active material, its overall size and flatness will be affected by changes in the temperature and humidity of the environment; the service life of the resin bottom mold is about 450,000 times, its indentation effect is not as good as the previous period in the later period of use, so it may cause paste The inconsistent box effect or semi-finished products are unsmooth on automatic packaging machines, and in particular cannot meet the requirements of high-speed packaging machines. Long-term products must be frequently replaced when using resin bottom molds.

In order to meet the demand for consistent long-term product die-cutting quality, sandwich knife molds are usually used. By cooperating with flat steel bottom molds, it is possible to avoid the deformation of the paper at the moment of die-cutting and ensure the quality of product cuts, and the long life of the steel bottom mold ( 5 million times or so) to ensure the consistency of product indentation. However, the sandwich knife mold has two obvious defects: one is high cost, and the other is longer manufacturing cycle. Taking 15 ordinary cigarette packs as an example, the cost of ordinary laser cutters is about 3,000 yuan, and the cost of sandwich cutters is about 50,000 to 60,000 yuan, which is nearly 20 times that of ordinary laser cutters. The manufacturing period of ordinary laser cutters is 1 day. The production cycle of the sandwich cutter die is about 1 week and cannot meet the demand for rapid delivery. The steel bottom mold is a purely flat surface, the indentation groove is depressed, and the entire structure is integrated. The cut material is not stretched and deformed at the moment of die cutting, but is pressed and cut in a relatively free state, and the resin bottom is abandoned. The only limitation of die defects is that all the creasing slots are relatively fixed, so the cutter die is required to have a small deformation, and cannot be matched with the wood cutting die cutter of the general process, and a sandwich cutter die must be used.

Then, how to make high-quality die-cutting effect in the production of low-volume orders with fast delivery requirements? The solution is to use the advantages of ordinary laser cutters (low cost, fast manufacturing) to lift the limits of sandwich steel bottom molds. The point (the indentation groove is relatively fixed) is organically combined to meet the high requirements of the high-speed packaging machine for indentation of cigarette packages. The specific operation is as follows.

(1) In the pre-press plate-making process, try to design the layout according to the double-knife position as much as possible, even if the layout is based on the minimum 2mm double-bit design, the minimum is 2mm in one direction (horizontal or vertical). Knife position design typesetting.

(2) Ordinary laser die base plate Choose high-quality, 18mm-thick glulam wood, preferably Finnish plate, and require the moisture content of the wood to be 7% to 9% (bake when the moisture content exceeds).

(3) Change the design of the steel bottom mold: Change the integral structure of the whole plate to monolithic structure, ensure that the outer edge of the monolithic structure is larger than the incision outside the product (red line in Figure 1), and also ensure the two monolithic steel bottoms There is a clearance of 0.5 mm or more between the molds (see Fig. 2). When the overall size of the matching laser knife mold changes due to the influence of the ambient temperature and humidity, there is room for adjustment.

Because the improved single structure steel bottom mold has an adjustment gap, it can meet the micro size variation of the ordinary laser knife mold. When the size of the laser cutter die becomes larger or smaller, only the steel bottom die can be installed according to the positioning hole on the laser cutter die. Fig. 3 is a one-piece integrated structural steel bottom mold, and Fig. 4 is a single structural steel bottom mold assembling effect.

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