Die cutting for corrugated box

Die cutting for corrugated box

Die-cutting is one of the post-printing processes. Once the printing is done, the next step in box making is to crease and cut the box blank. Paperboard is processed through a die-cutter in order to get the desired box style shape. Die-cutter is a machine which uses a cutting dies to crease and the cut the box blank in a desired style and shape.
A die is flat or curved plywood surface, generally, embedded with two types of steel rule: the cutting and creasing rules. Creasing rules have a function of putting crease on the box. It has a top round which crushes the flutes of the box and creates a crease so that a box can fold easily. The cutting rules have sharp edge which cuts through the box blank and separates the unwanted area of the blank. On the adjacent side of rules, a closed cell rubber strip is glued which acts as the ejection rubber. The rubber strip is greater in height than the creasing and cutting rule. When die cuts the blank, the pressure from the rubber keeps the scrap away from the die. For special purposes, special kind of rules can be added on the plywood surface of die such as perforation rules.
Depending upon the shape of the plywood surface, die-cutters can be categorized into two types:
2.6.1 Flatbed Die-Cutter
2.6.2 Rotary Die-Cutter
2.6.1 Flatbed Die-Cutter
As the name suggests, it is made on a flat plywood die. The shape of the box is incised in the plywood by using a laser or a saw. Creasing and cutting rules are then cut to the required
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length and fixed into the plywood surface. Die-cutting is performed by pressing the die against the blank. Pressure from the mechanically assisted die process the blank and a die-cut finished piece is received at the delivery side.
Flatbed die-cutting is a simple process used to process complex shapes where great detail and accuracy is required, such as point of purchase displays. However the speed is slower than the rotary die-cutter.
2.6.2 Rotary Die-Cutter
Rotary die-cutters are high speed die-cutting machines and normally used for higher volume jobs. The die is made up of a curved plywood surface concentric with the die mounting cylinder. Creasing and cutting steel rules are also curved in shape so that it can be properly embedded in the plywood surface. Nip pressure is provided by a supporting cylinder running along with the die mounting cylinder.
Rotary die-cutters are generally installed in-line with a flexo-folder gluer machine however flatbed die-cutter is usually a separate machine and process the litho-labeling and litho-lamination box blanks.
In the die-cutting section, die cost is an upfront cost to the customer. Just like printing plates, a customer has to pay for the dies as well.

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