Diecutting is getting ever more intricate as companies strive to produce the highest quality product in the shortest amount of time. Of course, there are numerous considerations that must be taken into account when investing in new technology.

Automation has gained significant footing in the diecutting arena, especially as companies look to grow their bottom line. Automation can help to increase productivity, eliminate human errors, and improve on-the-job training and skill development for the new generation of equipment operators. Automation enables converters to deliver labels while facing the ongoing workforce challenges so present in manufacturing. The implementation of automation allows converters to continue driving efficiency and profitability with a smaller headcount.

“In the context of Industry 4.1, the diecutting process will continue to become more automated, thus reducing labor costs as the need for manual operation and instances of human error decrease, leading to a more profitable operation,” says David Morris, president and CEO, Kocher+Beck USA.

“Over the past year, Wink has made remarkable strides in diecutting technology,” states Andre Gysbers, head of marketing and data analytics, Wink. “Enhanced automation within our production processes ensures unparalleled speed and precision. For example, our investment in fully automated die manufacturing allows most orders to ship on the same day. New laser hardening techniques have improved durability, while enhanced digitization aligns our tooling with modern, connected production environments. These innovations not only boost efficiency but also align with the evolving needs of digital printing.”

Automation has also helped to reduce setup and changeover times, thereby increasing efficiencies.  

“We are seeing a significant loss of institutional knowledge as Baby Boomers and Gen X leave the market to retire,” explains Keith Laakko, global VP of marketing, Maxcess. “Those capabilities need to be replaced by the younger generation. These workers are more tech savvy and more digitally knowledgeable. As a result, suppliers need to create solutions that are more automated and technologically astute to help this transition to be more about data and less about years of manual know-how.”

“Automation has been transformative for both suppliers and converters in the diecutting sector,” adds Gysbers. “Wink leverages automated production systems to deliver high-precision tools with unmatched efficiency. For converters, automation in diecutting solutions, like our SmartGap adjustable anvil roller, allows precise control over cutting depth, ensuring optimal results for intricate or demanding jobs. These advancements reduce downtime and enhance consistency, benefiting both productivity and quality.”

There are other trends, too. “We are also seeing customer demand for increased production speeds, along with wider presses, emphasizing the need for stability and accuracy within the die station,” says Morris. “Kocher+Beck is dedicated to new product development and continuous improvement across its product range. We consistently introduce new products and invest in the latest technology and equipment to support our customers with the highest quality products and services.

“The reduction in setup times is also noteworthy, allowing small batch sizes to become economically viable,” continues Morris. “As a result, businesses can now produce limited quantities without facing excessive costs, paving the way for more experimentation and innovation. Overall, these advancements in diecutting technology contribute to a manufacturing landscape that is not only more versatile but also better suited to meet diverse customer needs in a dynamic market.”

According to Laakko, converters are also expanding beyond traditional label production into new segments to increase their flexibility and versatility, including markets like battery, RFID, and medical applications. As a result, suppliers need to adapt and provide solutions that allow customers to be flexible. 

Digital printing is a consideration for diecutting, as well. Currently, there is a greater need for shorter runs and enhanced customization. “As a result, suppliers need to help converters speed up the changeover process, create solutions where customers can store data, recall jobs, and better organize materials and tooling for quicker recall,” says Laakko. “Better semi-rotary tooling solutions are also needed.”

“Diecutting technology has seen significant advancements leading to various solutions for creating short-run profitable jobs,” adds Morris. “These improvements are primarily due to the rise of digital equipment and advanced design software, which enable manufacturers to easily transition from producing one unique part to another with minimal effort. This increased agility makes diecutting, particularly with flexible dies, an appealing option for on-demand production.”

Kocher+Beck has undergone a process to efficiently manufacture digital dies by utilizing a fast-track system through the production process. In addition, Kocher+Beck has developed the GapMaster EM (Electronic Move). 

“The adjustable GapMaster EM counter cylinder system enables the gap between the magnetic and impression cylinders to be set electronically in precision increments of .0025 microns,” says Morris. “The possibility of a fast maximum opening of the EM to 200 µm means that new material can be fed through the unit quickly and easily without lifting the magnetic cylinder. This increases productivity and minimizes the potential for incorrect operation and downtime.”

As far as recommendations go, Wade Fouts, technical support manager, Wilson Manufacturing, says there are a number of best practices for converters to keep in mind.

“It’s beneficial for all converters to stock their toolbox with accessories that enhance die life and minimize downtime,” says Fouts. “Regular use of bearer wipers is crucial for every tool. Lubrication is essential to prevent heat buildup, which can irreparably damage both the bearers of the die and the anvil. Wipers also help keep bearers clear of debris that can pit them and cause permanent damage. Pressure gauges in the die station are essential, too. They simplify monitoring the tool’s performance to ensure consistent and accurate results.  

“Consider adding a stepped anvil to the tooling inventory,” he adds. “It can often allow a dulling die to finish the current job before needing re-sharpening. It can also compensate for dies not cutting deep enough due to liner variances or changes in material specifications. Regularly audit magnetic cylinders and anvils to ensure their surfaces are smooth, even, and ready for the next run. This helps maintain optimal performance and extends the life of tooling.”

Quest for sustainability

Much like other segments of the label and package printing market, sustainability is firmly entrenched in diecutting. Maxcess, for example, has seen considerable demand for solutions that promote sustainability.

“Our customers are looking for solutions to minimize waste and scrap, increase recycling, and reuse tooling,” comments Maxcess’s Laakko. “There is also significant attention on continuous improvement in production processes to optimize output and yield, especially given the recent price pressures and inflation issues.”

According to Kocher+Beck’s Morris, as consumers choose more products manufactured from sustainable materials, production methods must change to cope with materials that are becoming thinner and more challenging.

“At Kocher+Beck, we are seeing a shift toward more sustainable and eco-friendly manufacturing practices due to advancements on presses and substrates, which are becoming thinner and more recyclable in the converting industry,” says Morris.

Take your pick

Nowadays, converters have numerous options when deciding on the diecutting method for their labels. Whether dealing with flexible dies, solid tooling, or laser diecutting, the main considerations are material being converted and run length.  

“Flexible dies are more economical for shorter to medium runs and longer runs on standard materials,” states’ Laakko. “Solid tooling is better for very long runs, thicker materials, and abrasive materials. Also, if you are running the job multiple times, solid tooling may be better as you can repair, resharpen, and refurbish the solid die for longer life. Many solid dies can be resharpened up to five times, saving converters money.  

“Performance coatings can help prolong die life, as well, on flexible and solid tooling to combat the effects of abrasive materials, inks, and challenging adhesives,” Laakko continues. “While laser cutting is an option for intricate or complex labels, flexible dies have closed the gap and are usually more cost-effective versus lasers. Lasers remain expensive, can break down, and they tend to run at a slower speeds than rotary tooling.

When choosing between flexible dies, solid tooling, or laser diecutting, converters must consider other factors like production speed, material type, and desired precision. “Flexible dies, such as Wink’s SuperCut line, excel in versatility, speed and efficiency, particularly for intricate shapes but also with standard labels,” explains Wink’s Gysbers. “For most label applications, they are the best choice and most cost-effective tooling. Solid tooling is still an option for heavy-duty applications and very long runs, while laser diecutting offers an advantage for prototyping and ultra-customized designs in small digital runs. However, laser cutting requires machinery investments and comes with many limitations like some materials are not suited for laser cutting at all.”

Flexible dies can be manufactured more quickly than solid dies, but they are also limited on blade height due to the undercut of the magnetic cylinder, remarks Joe Fischer, technical manager, Wilson Manufacturing. “This limitation makes solid dies potentially more appropriate for thicker materials. Run length does remain a consideration, and flexible dies have options that can prolong their lifespan. Solid dies can be re-sharpened for continued use, though, and may have the advantage for longer, repetitive runs.  

“The need for special features or customization can also influence the decision-making process,” Fischer adds. “Certain materials may require specific blade angles that can only be achieved with a solid die. Removing small or precise waste areas may require a solid die equipped with pin ejection, air ejection, or vacuum waste removal capabilities. Cost is, of course, a significant consideration. Flexible dies are generally significantly less expensive than solid dies, and they will be the most cost-effective when the converter already possesses the corresponding magnetic cylinder size in inventory.”

These criteria have not changed much in recent years, though. “Despite all the changes and challenges we have discussed, the criteria for using solid, flexible, or laser diecutting has changed very little,” explains Kocher+Beck’s Morris. “Solid dies are ideally suited to cutting thick materials and/or long-running jobs. However, the higher initial cost, storage requirements, and shipping costs should be considered.   

“Flexible dies are one of the best options for converting a wide selection of materials,” adds Morris. “They are ideal for short and long runs, are easy to store, have a fast turn time, and have a favorable price point. Laser diecutting is a good option for extremely short runs or prototyping. However, the significant initial investment cost and high running costs associated with it require consideration of ROI.” 

New products

There are a host of new products available to the market, many of which were launched at Labelexpo Americas 2024.

Kocher+Beck has prioritized automation with its newest product releases. Automated systems, such as the GapMaster EM and the new VGS (Variable Gap System) from Kocher+Beck, allow users to record and easily recall specific jobs, providing consistent results quickly and accurately with minimum downtime, says Morris. “These systems avoid data duplication and simplify production monitoring by the press operator via an intuitive user interface. This increases productivity with less time spent on repetitive tasks and fault-finding exercises.”

At the heart of the VGS is the ability to regulate the gap independently or synchronously with the cylinders. “The VGS utilizes the pressure between the cylinders to ensure constant regulation, guaranteeing consistent precision, regardless of external influences,” notes Morris. “The control system is continuously loaded with the required force and is not affected by fluctuations in the cutting force. Another key feature of the VGS is its adjustment movement: The gap adjustment is a 100% linear cylinder movement without horizontal deviation; the control is also linear and can be operated electronically through an HMI or manually. This means that uniform steps can be altered regardless of the position in the adjustment range.

“The VGS is a groundbreaking, patented innovation focused on the OEM market,” he adds. “It fulfills the requirements of the current demanding printing environment and is fully equipped for future Industry 4.1 developments.”

Meanwhile, Maxcess has designed numerous products under the  RotoMetrics brand, as well as many of the company’s other brands. For example, the RotoMetrics AccuAdjust adjustable anvils allow for independent or simultaneous bearer adjustment for versatility. Plus, converters can easily upgrade to automated solutions and data analytics for improved performance. 

Additionally, RotoMetrics’ new flexible dies have been re-engineered and remanufactured for greater consistency, durability, and longer running rates. “RotoMetrics flexible dies run two times longer than the competition,” explains Maxcess’s Laakko. “RotoMetrics’ award-winning RotoRepel Performance Coating keeps dies running longer and protects the blades from abrasive inks, challenging materials, and difficult adhesives, too.  

“Our Fife guiding products improve efficiencies and run rates while reducing waste,” adds Laakko. “And Tidland slitting solutions bring increased automation, data/job recall, and improved operator safety to narrow web applications. Finally, Componex and Webex Plasma Coatings improve release and can be delivered in one week versus industry standard timing of up to three weeks.”

Wilson Manufacturing has engineered several state-of-the-art tooling solutions, including pin eject, air eject, vacuum, and custom insert dies. These advanced waste management products are designed to boost production and promote sustainability.   

Additionally, Wilson Manufacturing has launched an expanded line of accessories. Highlights include the Cylinder Inspection Tool, designed for the precise measurement and assessment of magnetic cylinders and anvil rolls. Also featured is the magnetic-base bearer wipers. These wipers are easy to install, require no machine modifications, and feature a built-in oil reservoir for continuous lubrication, promoting enhanced tooling performance and longevity.

Wink manufactures a comprehensive portfolio of premium precision tools, including flexible dies for a wide range of applications, featuring improved cutting angle geometries for efficient cutting on thin liners; MCR coating for extended tool life; new and improved non-stick coatings for flexible dies and rotary dies; the latest generation of rotary cylinders, particularly highlighting the OptiMag magnetic cylinders; and rotary tools with various ejection systems. Wink also offers high-performance flatbed tools. According to Wink, its tools are individually configured with the utmost precision, speed, and
reliable delivery.

Wink has also integrated enhanced etching and engraving technologies to cater to ultra-thin liners and intricate designs. The drive for sustainability is also influencing product development, with an emphasis on optimizing materials for minimized waste and
enhanced longevity.

“At Wink, we recognize that successful outcomes depend on close collaboration with our customers. Our ‘You cut, we care’ philosophy drives us to engage directly with clients, understanding their specific needs and challenges,” says Gysbers. “This commitment ensures our products meet the precise requirements of converters worldwide. Our team also offers consultation, maintenance, and training services, fostering lasting partnerships that help customers stay ahead in a competitive market.”

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– SPONSORED CONTENT –

Maxcess: Elevating Integrated Performance for Converters

In today’s fast-paced converting industry, label converters are under constant pressure to improve efficiency, reduce waste, train a new generation workforce, and optimize performance. Maxcess’s unique position as a global leader in innovative converting solutions empowers converters to meet these challenges by offering an integrated and automated approach to unwinding, tension control, guiding, diecutting, and rewinding.

At the core of this constructive interaction lies Maxcess’s portfolio of trusted brands. MAGPOWR products ensure precise tension control, a critical factor for maintaining consistent press speed to ensure quality and minimizing material waste. Paired with Fife guiding systems, converters gain unmatched web alignment accuracy, allowing for smoother operations and fewer operator errors. Tidland’s unwind and rewind shafts further enhance efficiency by enabling quick roll changes, less core damage and secure handling of materials, reducing downtime and ensuring seamless operation. Finally, RotoMetrics’ diecutting solutions deliver unmatched precision and durability, enabling converters to achieve high-quality output at faster speeds.

Maxcess doesn’t just provide products; it delivers support. With decades of experience and a commitment to customer success, Maxcess collaborates with converters to design tailored solutions that align with their production goals. This partnership approach ensures that each element—from tension to guiding to diecutting—works in harmony, creating a streamlined process that maximizes speed, output,
and profitability.

By leveraging Maxcess’s comprehensive solutions, label converters can confidently tackle today’s demands while positioning themselves for future success. Together, Maxcess and its customers are setting new standards for performance and sustainability in the industry, turning challenges into opportunities for growth and innovation. 2025 solutions helping converters work better, faster, and smarter include:

• Tidland RD AutoScore – Automated back scoring solution

• RotoMetrics AccuAdjust Anvil and Flexible Dies – Versatility and 2X durability

• Tidland SmartSlit – Narrow web automated slitting solution

Find out more at maxcess.com.