by Melissa Donovan
The digitally printed corrugated industry is in its infancy. There is much potential in this portion of the market—including printing hardware, the software that drives it, and the subject of this article—finishing.
Traditional die cutters are still used for cutting corrugated board, but dieless devices are efficient in their own way. There is a place for both, depending on the volume and type of items being cut.
Ideal for Corrugated
Both die cutters and dieless cutting devices are considered for digitally finishing corrugated board.
According to Beatrice Drury, communications manager, Zund America, Inc., digital, dieless cutting/finishing systems are positioned to meed demands for faster turnarounds, shorter runs, and increased versioning.
“While dieless systems may not be able to match the raw throughput attainable with traditional die cutting technologies, advanced digital, integrated workflow automation enables flexibilities and speeds in terms of file preparation, job setup and switchovers, adjustments on the fly, end-to-end data flow and job tracking, and other previously unimaginable benefits,” continues Drury.
Daniele Gallucci, president, Elitron America, says that in most cases die and dieless customers are complementary, however they both come with advantages and disadvantages.
“Die cutters are efficient at cutting a predetermined shape quickly. They require a cutting die to be made, which can be expensive and timely to make. This is why they are ideal for mass production to offset the cost of the die,” explains Mark de Guzman, marketing manager, Vision Engraving & Routing Systems.
Die cutters offer affordability for large volumes, as well as speed for high-volume production runs, states Gallucci. However, they are disadvantageous in regards to setup time and cost. Meanwhile, a dieless cutter provides flexibility and time to market for small and medium runs.
“Dieless cutters are flexible and can be programmed to cut virtually any type of shape without having to create a new die. They are very cost effective for cutting one-offs and can also perform low or high-production applications. Dieless cutters can’t stamp out cuts at a high rate like die cutters can, but dieless cutters offer higher application flexibility and adaptability,” adds de Guzman.
Speed Up
Finishing devices must keep pace with speedy printing devices. Today’s finishing solutions for corrugated achieve this in number of ways.
As Josh Hope, director, marketing, Mimaki USA, Inc., states, “the build quality of industrial cutting systems delivers products that are fast and precise.”
“Key manufacturers increase cutting speed via different cutting technologies or improved motion systems. Some companies also provide solutions to automate different processes within their cutting system to increase productivity and capacity, reducing labor cost,” shares Gallucci.
And it’s all connected. Not just the linear drive system pushes speed to new heights, but what Drury says is “innovative engineering at all levels.” This includes the “advanced electronics and algorithms to control the movement of the individual component as well as a linear drive system. But for those specifications to translate into real productivity and return on investment they also require redesigned vision and registration systems to capture and retrieve the appropriate cutting data and make sure the cut perfectly matches the print.”
Precision Matched
While speed is essential, precision is equally important. This is achieved in a number of ways.
An unprecise cut can produce unwanted flaws in the final product, admits de Guzman. “To achieve a quality precise cut, Vision builds highly rigid machines with minimum flex. It also incorporates high-quality heavy-duty motors and precision parts. Other factors to consider for a precise cut are tool condition and alignment, material type, and the correct cutting parameters should be set for the particular application.”
Another example, the Mimaki CFX Series flatbed cutting plotters employ a ball screw on the Z-axis, which allows for not only high pressure, but also highly accurate cuts with less breakage over multiple cuts, notes Hope. “As we are defining accuracy in hundredths of a millimeter it is critical to ensure that the equipment is manufactured with accuracy in mind.”
“To achieve these previously unattainable speeds without sacrificing precision requires technological advances in the drive system and in controlling the movement of the beam(s) and cutting head(s)/modules as well as a stable base to counteract the forces inherently involved in moving the beam and cutting head/modules,” shares Drury.
Similar to speed, precision is connected to other elements of the entire finishing process. “It requires all components and their characteristics, down to the sophisticated geometries of the cutting blade/router bits working together, to control all movement and ensure a perfect match between cut and print even if, for instance, the substrate is imperfectly printed or misaligned as it is fed onto the machine for processing. Even seemingly basic features, such as the material hold down, play an important role in maintaining the stability of the substrate and ensuring clean, precise cuts,” adds Drury.
Corrugated in Style
Single face as well as single/double/triple wall are used in corrugated for packaging today. In this regard, finishing devices must be equipped to handle the media properly.
“All kinds of corrugated materials are being used, depending on the application, from the lighter single face to heavier triple wall,” admits Gallucci.
Drury says single- and double-wall corrugated are more common in most packaging environments, however Zünd can offer individually tailored cutting solutions for every type of packaging application, including for processing related materials such as protective foams.
Fall into Corrugated
Dedicated to the corrugated packaging industry, SuperCorrExpo takes place in September 2024. The event brings together professionals, suppliers, manufacturers, and experts worldwide to showcase the latest technologies and equipment, exchange knowledge and resources, and foster new business partnerships. It takes place every four years and is organized by TAPPI and AICC.
We look forward to witnessing what’s next in corrugated finishing at SuperCorrExpo.
Jun2024, DPS Magazine
