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Low cost to create high efficiency die cutting method

Source:Dongguan Deli Intelligent Technology Co., Ltd.      Time:2021-04-25 17:49:51

In the production process of self-adhesive labels, the quality of die-cutting will directly affect the production efficiency of the next process-the labeling link, and it is easy to cause label breakage during the high-speed labeling process, which will cause label printing companies A lot of trouble and loss, but also intuitively affect the aesthetics of the terminal product and the customer's experience. There are many factors that affect the quality of die-cutting, and different label products have different requirements for die-cutting technology, methods, quality, efficiency, and cost control. In response to the above problems. This article starts with the commonly used die-cutting methods and sorts out the application status and advantages and disadvantages of various die-cutting methods in the current market for your reference.


At present, the die-cutting methods of self-adhesive labels are roughly divided into four types: CNC cutting machine, round die-cutting, flat die-cutting and laser die-cutting.


Die cutting one: CNC cutting and die cutting


From a cost-saving point of view, flat die-cutting and CNC cutting machines save the most material costs, especially CNC cutting machines. The cost of consumables is not only low, but also fast and convenient. There is no need to prepare a physical knife board or an electronic knife board. The cutting command can be executed through the computer or mobile phone APP, one or more special cutter heads start working at the same time, and the cutting work is performed automatically along the line set by the cutter map or the camera. The cutting depth of the cutter head is carried out according to the thickness of the material and the pre-set process requirements of the label. During the cutting process, the cutter head can be slightly adjusted according to the actual cutting marks.


In addition, the working area of the CNC cutting machine tool ranges from 300mm to 2000mm or more. The larger the cutting width, the lower the positioning accuracy and repeatability. The cutting speed range of the CNC cutting machine is 400mm/s~2000mm/s, and the number of cutter heads is larger. More, the faster the paper feed speed. Because the price of the CNC cutting machine is low, it is suitable for small label printing companies, printing houses or proofing. However, the die-cutting efficiency and die-cutting accuracy of the CNC cutting machine is lower than the other three die-cutting methods, and it is more suitable for manual labeling.


Die-cutting 2: Circular die-cutting


Circular die-cutting, also known as round-knife die-cutting, was first used in post-press processing, and later widely used in daily chemical, electronics, pharmaceutical and other industries. In recent years, with the rapid development of flexographic printing technology and the higher requirements of label printing companies for production efficiency, this die-cutting method has gradually become the main die-cutting method.


From the point of view of the in-line method, the circular die-cutting can be divided into in-line die-cutting and offline die-cutting. In-line die-cutting mainly occurs on the flexographic printing machine with its own round knife die-cutting unit, which can simultaneously complete the die-cutting requirements while completing the label printing. In the customer base of the market, in-line die-cutting accounts for about two-thirds, and the in-line die-cutting speed ranges from tens of m/min to 200m/min. In-line die-cutting can greatly improve production efficiency. Offline die-cutting is convenient for offline die-cutting requirements such as offset printing, gravure, and flexo printing.


At present, circular die-cutting is the most efficient and the best control of die-cutting accuracy (±0.0025mm, that is, the die-cutting knife must cut through the glue layer, but does not damage the silicone oil layer). It is a high-speed automatic labeling method. , Ultra-thin bottom paper (Glassine below 40g, PET below 0.030mm), non-marking requirements, special surface material knife angle control (40°~60°), special blade treatment such as adding wear-resistant coating (5~10μm) Dense chromium salt oxide), anti-stick coating, etc., round die cutting have obvious advantages.


The knives used in circular die-cutting are divided into engraving knives and flexible blades, and the circular die-cutting method of flexible blades is adopted, which more and more replaces the circular die-cutting methods of circular engraving knives and flat pressing. .


The circular engraving knife is a kind of blade that is directly milled out of the tool tip (cut line) on the 45# steel roller with computer-controlled three-axis or multi-axis (CNC), and then processed by other processing such as tool tip hardness. The circular engraving knife is integrated with the blade roller body. The flatness is controlled by the precision of CNC. The flatness is high and the operation is simple. The knife roller can be put into the chute to pressurize. The disadvantage is that the price is more expensive and it is inconvenient to replace. After the tool tip is worn, it needs to be sent back to the supplier for repairing the new tool tip. The repair time and logistics cost are relatively large. Generally, printing companies will spare multiple knife rollers to achieve grinding, transportation, The cycle used ensures continuous production.


Since domestic label printing companies mostly use domestic engraving knives, the wear resistance of the blades is uneven, and the blades with poor wear resistance wear very quickly. The operators often use the method of pressure when the die-cutting effect is not good, but often One problem will be ignored, that is, the deformation rate and hardness of the bottom roll shoulder iron position under the die cutting unit, and how much pressure the bottom roll bearing or backup roll bearing can withstand will not be damaged. After the shoulder iron position is damaged or the bearing is damaged, It is difficult for the bottom roller to ensure concentric rotation, which brings certain difficulties to precision die-cutting. It is recommended that the pressure refer to the technical guide of the die-cutting seat to operate and use the pressure.


The round-pressed round flexible blade is generally selected from European high-quality, high-hardness spring steel, through a strictly controlled chemical etching process, and a kind of blade that is engraved by a computer program control device (CNC). The accuracy of the circular pressing circular flexible blade can be controlled within the range of ±2.5μm~±5μm from the design height to ensure the uniformity of die cutting. The higher the accuracy and life requirements of the blade, the higher the price. The price is determined by the combination Process, the length of the knife line, label printing companies need to customize different process requirements according to the needs of the actual product.


Compared with the circular engraving knife, the dimensional accuracy between the edge of the circular circular flexible blade is more accurate, and various process requirements can be customized, especially when the wear-resistant coating of the blade is only 5μm-10μm. The hardness can reach 73°~75°, which can not only meet the life requirements, but also protect the equipment well and reduce the occurrence of damage from heavy pressure. In addition, the delivery time of the round pressed round flexible blade is relatively short, which can be completed within 4 to 5 days, the cost is relatively low, and it is more convenient to replace and spare. However, round-pressed round flexible blades need to purchase a high-precision magnetic roller. When attaching the blade, you need to clean the surface of the magnetic roller and the blade bonding surface to prevent dust and other debris from adhering between the blade and the magnetic roller, which will damage the flatness of the blade. , The phenomenon of uneven cuts on the bottom paper appears.


Die-cutting three: flat die-cutting


Compared with the CNC cutting machine, the flat die-cutting method is the earliest and most used die-cutting method used by label printing companies. Flat-bed die cutting has low cost and high speed (depending on the complexity of graphics). The flat die-cutting knife plate generally adopts manual arranging or laser cutting, that is, CNC automatic scimitars, arranging knives, install the blades on the medium-density wood board, and finally install the arranged blades on the die-cutting machine knife. Seated.


Compared with the die-cutting efficiency of the CNC cutting machine, the die-cutting efficiency of the flat die-cutting machine is much improved. The paper speed is 20m/s~100m/s, and the price of the flat die-cutting machine ranges from tens of thousands to a few yuan. It ranges from 100,000 yuan, suitable for small orders, urgent orders, proofing, relatively narrow printing format, non-high-speed automatic labeling, and die-cutting of orders that are not strictly required for bottom paper cutting.


Die cutting 4: laser die cutting


Laser die-cutting is a die-cutting method that uses the beam emitted by a laser to focus on the printed material according to the designed cutting line shape, and the cut can be down to the micron level.


Laser die cutting does not need to make a solid knife plate, and can realize the rapid switching of different order graphics. The cutting graphics design can be completed on the computer, various graphics and material parameter settings, and the depth of the cutting traces are automatically generated. At the same time, the processing can be repeated. By retrieving the previously processed and programmed cutting program, production can be started immediately, saving the time of changing and adjusting the knife mold of traditional die cutting.


At present, the speed of laser die-cutting is slower than that of traditional die-cutting machines, the price is higher, the cutting edge is burnt, and there is the problem of the minimum line width of the cutting line. It is more suitable for invitations, greeting cards, candy boxes, cake boxes, and paper sculptures. For artworks, paper-cuts, gift boxes, etc., self-adhesive labels are rarely used.


In short, considering cost control, the order is small, you can choose CNC cutting machine and low-speed flat die cutting; the product structure tends to low-speed automatic labeling, manual labeling, and the order is large, you can choose high-speed flat flattening and low speed Circular die-cutting; large orders, product processes and materials are changeable, demanding on cut marks, and mostly high-speed automatic labeling order structure, it is recommended to use circular die-cutting, which is cost-effective; laser die-cutting is used for label printing The field is still a die-cutting method that everyone uses more cautiously. You can choose a suitable die-cutting method according to the product structure. The above only represent personal views, I hope it will be helpful to everyone.



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