Folding-Gluing working with Short-Runs Plus Rotary Die-Cutting a Popular Option for Short-Run Cartons
Rollem has been mentioned in Post Press Magazine:
Rotary Diecutting a Popular Option for Short-Run Cartons
In addition to many changes being made with folding/gluing to accommodate short-run folding cartons, there also is a trend toward using rotary diecutting equipment for short-run work. Rotary diecutting utilizes two magnetic cylinders spinning inward toward one another using a thin flexible die(s) with a metal back to adhere to the cylinder(s) (certain machines use two dies, others just one). When the sheet of cartons travels between the two cylinders, downward pressure is applied via the machine and the cutting blades on the flexible die cuts the sheet on the other side after the rotation is complete.
One of the biggest advantages of rotary diecutting is changeover time from one job to another. As with folding/gluing, this is extremely important for short-run work to create a suitable profit level on the job. A rotary machine can be changed from one job to the next in as little as 10 minutes, where a more conventional diecutting press can take as long as one hour. Another advantage of rotary diecutting is it provides the operator the ability to create more complex diecutting patterns because the die is CNC engraved vs. the bent steel used on a conventional steel rule die. In addition, flexible dies are much easier to store and can be housed in small filing cabinets, which can help finishers and folding carton manufacturers decrease overall storage space for cutting dies.
There are limitations that must be considered with rotary diecutting as well. The major limitation of the process is with the thickness of the stock/material being diecut. The flexible dies have overall limitations on how far they can cut into the material, where steel rule dies are conventionally two to three inches thick, allowing taller cutting blades to reach through thicker stocks and materials. So, it is important to check the thickness of the carton before considering rotary diecutting as an option.
Folding carton production on rotary systems is ideal for short-runs given the ability to change from one carton skew to another in as little as 10 minutes, which enables companies to justify carton runs as small as 500 sheets. Those sort of runs are difficult to justify on a larger platen press where set-up can be 30 minutes to an hour to run the machine for five to 10 minutes for a 500 to 1,000 sheet job.
This information was provided by Kevin Corwin, product manager for Rollem’s Insignia diecutting line.
