There are numerous factors for converters to consider when exploring diecutting. The right equipment and tooling can make or break the process – impacting the quality of the label. Kevin Harfst, Mari Werner, and Zach Janowski are three members of Wilson Manufacturing’s dedicated sales team who provided insight into this critical converting segment.

LNW: How has technology evolved in recent years?
Wilson: A need for the highest precision with full repeatability has become a requirement for our industry. With proprietary equipment designed and built by Wilson Manufacturing in-house, machine sharpening has become the norm. Where before it was new and innovative, now it has become necessary to meet the advanced requirements of new projects. With eyes on the future, Wilson has already expanded capacity for these custom-designed machines in preparation for an increase in demand.

LNW:  What trends is Wilson seeing in the diecutting and tooling markets?
Wilson: We see the material to be cut as a driving factor in the most recent trends. The properties of the stock directly affect how the die is manufactured, as it can determine the blade angle, steel type, coatings,
settings, and more. Inks and coatings on the material can affect manufacturing, as well. Some have abrasive factors that accelerate die wear, and some may need special blade angles or blade heights in order to cut successfully.

Recently we have seen adhesives having an increased role in the manufacturing specs. High tack, rubber-based, or weather-resistance features can also be more abrasive or require special keener blade angles. Existing tooling made for other materials may not work the same on these types of adhesives, and stripping the waste may need to be done right at the die or at a tight angle over a stripping bar. Each material can be different, but it helps to be aware of potential challenges before they become obstacles.

Probably the most notable trend coming out of the pandemic would be the evolution of 40# liners. The thickness on a 40# liner used to average .0024″, but the new normal is that 40# liners can be anything from .0020″ to .0024″.  This makes a difference in diecutting the material, though, as a die tooled for the traditional 40# liner thickness may not cut well for that thinner liner or, at best, experience a substantial reduction in die life.

The easy solution to this, however, is communication. More information is better than less. Advise the material specs, and the type of adhesive, indicate the liner thickness instead of weight, and advise of any coatings or inks to be cut through. Supply the die maker with the technical data specs from the material manufacturer and ensure the die is made to match the needs of the material.

LNW:  What can you tell converters when they have the job on press and it’s not running as expected? What should they do first?
Wilson: First off, establish what is happening – or is not happening. There may be a temporary solution or even a quick fix, so identifying the issue first will help to clear a path to the best solution. One example is labels lifting. It could be wear, blade damage, a change in material, or aggressive adhesive, to name a few. If the die was running and stopped, it is often just the blades getting dull, and a stepped anvil may help finish the job before sending the die in for retooling or reordering. For a flex die, a thin layer of paint sprayed on the back or even permanent marker ink on the back where the blades aren’t cutting deep enough might do the trick. We also offer thin film “shims” that can fit between the mag cylinder and the flex die to make the blades cut deeper. If the waste won’t strip or keeps breaking, try reversing the web direction of the die, as this might overcome “directional wear” on the blades or make stripping the waste easier. If one area or cavity is the culprit, try adding open cell foam to that area to see if it will help keep the part down when the waste is stripped. If the tool is brand new, though, first check the specs of the material it was ordered for against the material that is in use. If they aren’t the same, the stepped anvil may help. For flex dies, double-check the overall thickness of the material to confirm it is not too thick for the plate/blade height.

LNW: Is there one topic that has been a continuous source of questions?
Wilson: Yes, we are frequently asked, “What is a ‘standard perf’ to use?” But the answer is that there isn’t a “one size fits all.” So many factors work together to decide the perfect perf spec that it can take a little bit of testing to figure that out. Fan-folding usually requires a spec that folds easily, but that same spec may tear too easily for most label applications, so the first question is, “What will the perf be used for?” After that, other factors that determine the perf that works include the material thickness, the tension it will be under, and the end use – the best suggestion with a new project is to send in some of the material and make samples for evaluation.