Preface
SBL Machinery for over fifty years, SBL Machinery has been dedicated to the production of post-press equipment, with the three most well-known post-press machines being the”Die cutting machine”, “Folder gluer machine” and ” Hot Foil Stamping Machine “, and the theme shared today is ” Die cutting machine “, A die-cutting machine operates by using cutting tools or steel wires. The machine applies a predetermined pressure through an embossing plate to cut printed materials or cardboard into specific shapes. When the entire printed material is cut into individual shapes, it’s referred to as die-cutting. If it’s used to create indentations or folds on the printed material, it’s known as embossing or scoring.
The correct operation and setup of a Die cutting machine are crucial for increasing productivity. In this article, we will also share some industry-specific insights to enhance everyone’s knowledge in the Die cutting machine field and help customers achieve better paper production efficiency and cutting results. Without further ado, let’s dive into the three key techniques or factors to enhance Die cutting machine product efficiency.
1. Familiarity with the structure and operational procedures of a Die cutting machine
In fact, the same principle applies to any machinery. Being familiar with the machine’s structure and operational procedures is the initial and crucial step in improving product yield.
1-1. The structure of Die cutting machine
In general, apart from special Die cutting and hot stamping machines like SBL machinery, a standard Die cutting machine is composed of the following components:
1-1-1. The equipment's main body
The frame of the Die cutting machine serves as the primary structure of the entire machine, providing a stable working platform and support to ensure that the machine maintains stability and precision during high-speed operation.
1-1-2. Automatic Paper Feeding System
Automatic Die cutting machines are commonly equipped with an automated paper feeding system. This system can automatically feed paper into the Die cutting machine, ensuring a continuous and efficient production process. It typically comprises air suction nozzles, paper conveyors, sensors, and an automatic control system. Depending on various paper parameters such as size, thickness, softness, and more, it adjusts the appropriate height, position, angle, and air suction nozzles to accurately introduce the paper into the Die cutting machine.
1-1-3. Control System
Die cutting machines are equipped with sophisticated control systems for overseeing and regulating the machine’s operation. This system typically incorporates devices like a PLC (Programmable Logic Controller), a touchscreen user interface, and sensors, enabling automated control and fault detection. Operators can perform tasks such as parameter configuration, production monitoring, and troubleshooting through the touchscreen interface, thus improving production efficiency and operational ease.
1-1-4. Transmission System
The functioning of a Die cutting e relies on a dependable transmission system to propel the motion of its various components. This system usually comprises motors, gear reducers, transmission wheels, and gears, facilitating the transfer of power to different parts of the Die cutting machine. The design and calibration of the transmission system have a direct influence on the machine’s operating speed, precision, and stability.
1-1-5. Die-Cutting System
The die-cutting section of a Die cutting machine is primarily responsible for die-cutting the paperboard to create the desired shapes and structures. Die-cutting is the process of cutting paperboard into the required shape, typically accomplished using die-cutting tools.
The die-cutting section typically comprises the following components:
- Cutting tools
Cutting tools are the core components of the die-cutting section. They are usually crafted from hard materials, such as steel, with the necessary shapes and dimensions. Cutting tools can be customized to meet the design specifications of the paperboard, ensuring cutting precision and consistency.
- Die-cutting plate
The die-cutting plate serves as the supportive platform for the die-cutting tools. It is typically constructed from robust materials like metal, capable of withstanding the pressure and motion of the die-cutting tools. The flatness and hardness of the die-cutting plate are critical for the accuracy and stability of die-cutting.
- Pressure adjustment system
The die-cutting section often features a pressure adjustment system for fine-tuning the pressure applied by the die-cutting tools. Proper pressure ensures a close and precise contact between the die-cutting tools and the die-cutting plate, resulting in accurate cutting.
1-1-6. Safety Protection System
To ensure the safety of operators and the smooth operation of the Die cutting machine, a range of safety protection systems is commonly integrated. These systems encompass protective shields, safety switches, emergency stop buttons, and other mechanisms designed to promptly detect and respond to anomalies during machine operation. This, in turn, safeguards the well-being of operators and the integrity of the equipment.
1-2. The Die cutting machine operation process
While the functions and operations of each Die cutting machine may differ slightly, the fundamental operating procedure is largely similar. In general, the operational sequence for a Die cutting machine is as follows:
1-2-1. Power On
Ensure that the Die cutting machine is connected to the power source and in normal operating condition.
1-2-2. Adjust Speed
Adjust the machine’s operating speed according to the Die cutting requirements. The appropriate speed ensures precision and stability in box-making.
1-2-3. Load Paper
Place the paper to be used for Die cutting in the machine’s paper feeding system, ensuring smooth entry into the box-making machine.
1-2-4. Die-Cut Paper
Activate the Die cutting machine to pass the paper through its die-cutting section, completing the die-cutting paper process.
1-2-5. Check the paper cutting effect
After the paper cutting is completed, check whether the paper cutting effect meets the requirements. If necessary, further adjustments to position, angle, speed and other settings can be made.
1-2-6. Power Off
Once Die cutting is finished, turn off the Die Cutting machine and disconnect the power source.
2. Die-cutting tools
Of course, the selection of the machine and die-cutting tools for the Die cutting machine is one of the important factors affecting the product yield of the box-making machine. Taking SBL Machinery as an example, collaborating with local die-cutting tool manufacturers in Taiwan and partnering with the international die-cutting tool giant, Marbach, for the foreign part, is a crucial factor in achieving high product yield stability. Here is some information about the selection of die-cutting tools for box-making machines:
2-1. Cutting Tool Material
Selecting high-quality tool materials, such as high-speed steel (HSS) or hard alloy materials, ensures precision and durability in cutting. Of course, the choice of tool material is also related to the type and thickness of the paper. For instance, corrugated paper (thick paper) and cigarette boxes (thin paper) require different types of tool materials and designs.
2-2. Cutting Tool Arrangement Design
Based on the specifications of the Die cutting machine and the product design requirements, a suitable tool template is designed after discussions with the tool manufacturers to ensure precision and consistency in cutting. The arrangement design of the tools depends on the shape of the product, whether it’s circular, square, with chamfers, irregular, etc. It also takes into account the product’s specific needs, such as cutting shapes (sharp blades) or creasing and folding (round-tipped blades). This involves arranging different tools, buffers (foam), and angles accordingly. Choosing the appropriate tool arrangement design not only enhances product yield but also prolongs the lifespan of the tools.
2-3. Lifespan of Cutting Tool
When considering the lifespan of cutting tools, a longer tool life can lead to improved production efficiency and product yield. The tool’s lifespan is influenced by the following factors:
- Tool manufacturer
Cutting tools from reputable European or American manufacturers tend to be more durable. - Tool material
Different metal materials have varying hardness and durability. - Tool design
When designing tools for paper or box shapes, it’s essential to consider the overall layout space utilization to ensure a balanced distribution of force on the tool. This requires detailed discussions with the tool and mold experts.Average operating speed and time duration of the die-cutting machine.In theory, to enhance the lifespan of cutting tools on a die-cutting machine, it’s similar to driving a car. Firstly, try to maintain a consistent speed during operation and avoid sudden speed fluctuations in a short time. Secondly, avoid prolonged operation at the machine’s maximum speed.
- Machine brand of the die-cutting machine
In general, well-known brand die-cutting machines not only have a longer lifespan but also feature superior overall designs, including the transmission system and the die-cutting system driven by a camshaft. Their cam motion curves are smoother, resulting in more even force distribution. This, in turn, leads to higher product yield and a longer average tool lifespan.
2-4. Cutting Tool maintenance and repair
Make sure to regularly maintain and repair your tools, including cleaning, sharpening, and calibrating them, to keep them in their best condition and performance.
3. Key components related to yield
In the context of a Die cutting machine’s mechanism, it’s important to note that certain components are intricately linked to product quality and efficiency. This section will focus on these crucial components, serving a dual purpose: firstly, as a guide for inquiring about vital aspects when purchasing such equipment from manufacturers, and secondly, as a resource to understand how to select, adjust, and configure these components to enhance product yield.
3-1. FEEDER
In the Die cutting machine industry, there’s a famous saying: “When paper is fed smoothly, the machine delivers color; however, if paper feed isn’t optimal, the output appears in black and white.” This statement underscores the significance of a crucial component in Die cutting machines – the feeder. The primary role of the feeder is to accurately and flawlessly guide paper or cardboard into the box folding machine. This process demands exceptional precision since even the slightest deviation can affect the final product’s quality. The design and precision of the feeder mechanism directly influence the paper transport process and the quality of box folding.
Taking SBL Machinery as an example, the reason their feeder component is highly favored by a broad customer base is its adaptability to different paper types, such as thick, thin, large, or small, through adjustments in nozzle styles, angles, positions, and ranges. The new generation SBL 1060SEA model’s feeder movement design, in combination with coordinated actions between nozzles and pressure foot, along with well-timed air valve control, ensures a stable paper-feeding performance, significantly boosting overall yield.
3-2. Gripper bar
The gripper bar in the Die cutting machine is another critical component with the primary role of accurately guiding paper into the machine, ensuring precise positioning and angles. Through precise control and adjustments, the gripper bar effectively prevents paper misalignment or folding, thereby guaranteeing the quality and efficiency of box folding. Furthermore, the gripper bar allows rapid fine-tuning of paper positioning to meet the demands of high-speed and high-volume production.
SBL’s latest technology features a 7-piece gripper bar with a unique design of a large-angle intermittent drive system, facilitating high-speed operation and providing maximum production speed. Made of carbon fiber material, the gripper bar is designed for lightweight and high durability, offering a long service life.”
3-3. Die cut steel plate
In a Die cutting machine, the back of the die-cut steel plate often features a die-cut frame for securing the cutting tools. Does the die-cut steel plate have any relationship with product yield? One can consider this by understanding that the machine requires pressure for its up-and-down cutting and folding actions. The desired shapes or creases are achieved through the die-cut frame on the back of the steel plate. If the steel plate is subjected to prolonged stress and lacks the necessary durability or strength, it may be susceptible to deformation or warping. In such cases, the steel plate’s resilience becomes crucial. As an example, SBL Machinery uses German TSH steel plates to ensure long-lasting stability and product yield.
3-4. Suction or blowing device
The primary purpose of the air blowing or suction device in a Die cutting machine is to ensure the paper remains stable as it is fed into the machine, preventing any misalignment or folding due to air influence. During the paper feeding process, powerful and consistent airflow effectively presses the paper, preventing it from moving or flipping during insertion, ensuring each sheet enters the box folding machine with precision. Additionally, the air blowing or suction device can preheat the paper, enhancing its flexibility and pliability, further improving the quality of box folding and product yield. Therefore, the air blowing or suction device in a Die cutting machine plays a crucial role in enhancing product yield.
As an example, in SBL Machinery‘s SBL 1060SEA model, there are paper tail suction devices in the waste removal and separation sections, as well as air blowing mechanisms in the die-cut frames, aiding in maintaining paper stability and thereby increasing yield.