Left: Joe Fischer and Right: Wade Fouts

The proliferation of shorter print runs has necessitated innovation from all spectrums of the label and package printing industry. From press suppliers to die manufacturers, industry specialists must design new technologies to accommodate the latest trends. In the case of die manufacturing, flexible dies and solid dies both come with a list of pros and cons for specific jobs.

Wilson Manufacturing’s Joe Fischer and Wade Fouts spoke with L&NW about how converters can optimize their production efficiency with the newest die technology.

LNW: What emerging trends or changes are you currently observing within the industry?
Wilson: Digital printing and semi-rotary diecutting continue to grow and impact our industry. For die makers, rapid turnaround times are critical for our customers. Efficient production of shorter runs with minimized setup times enables printers and converters to address customer requests quickly, so die manufacturers must be responsive with expedited tooling solutions.

LNW:  What are common questions converters typically pose to their die maker?
Wilson: For Wilson Manufacturing, one of our customers’ primary concerns is choosing between flexible cutting dies and solid cutting dies. There are numerous factors to weigh when making this decision, so there is no one-size-fits-all answer.

In the past, the primary factor was whether the job fell into the “short run” or “long run” category. However, in recent years, the type of material being cut has become increasingly more important.

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. This limitation makes solid dies potentially more appropriate for thicker materials. Run length does remain a consideration, and flex dies have options that can prolong their lifespan.  Solid dies can be re-sharpened for continued use, though, and may have the advantage then for longer, repetitive runs.

The need for special features or customization can also influence the decision-making process. 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.

LNW: How can converters optimize their tooling to ensure reliable and efficient operation?
Wilson: Ensuring continuous operation with minimal downtime significantly impacts profitability. Converters can implement preventative actions as part of their standard setup procedures to mitigate common issues.

Material: Upon receipt, measure the stock to confirm that the substrate and liner meet specifications. Provide the die maker with the data sheets or micrometer measurements for each layer and the type of material to be cut to ensure proper die manufacturing specifications.

Adhesive: Most acrylic adhesives, as a general rule, do not affect diecutting, but cutting through rubber-based, hot melts, or stretchy adhesives may require customized manufacturing specifications. Provide adhesive specifications to the die maker to facilitate adjustments in blade angles, engraving settings, or the application of special coatings as needed.

Wear: Before operation, assess the die and anvil’s condition. Monitor bearer areas for signs of wear or discoloration. Clean and inspect the anvil surface thoroughly as an uneven surface can lead to
inconsistent diecutting.

Abrasives: Abrasives in inks, coatings, and materials can potentially dull cutting blades. It is crucial to closely monitor tool usage and proactively schedule re-sharpening or replacement of tooling in preparation of the next run.

LNW: What advice would you give to converters that would benefit everyone?
Wilson: It’s beneficial for all converters to stock their toolbox with accessories that enhance die life and minimize downtime.

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 help keep bearers clear of debris that can pit them and cause permanent damage.

Pressure gauges in the die station are essential. They simplify monitoring the tool’s performance to ensure consistent and accurate results.

Consider adding a stepped anvil to the tooling inventory.  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.