Flatbed and Rotary Die-cutting

An update report by Daniel Brunton

Publisher of the magazine – International Paper Board Industry
(Contd. from last issue)

Die-cutting and stripping To ease maintenance, the machine is equipped with a

centralised motorised lubrication system and all main parts are
From Bao-Der Enterprise Corp of Taiwan comes the BD-
easily accessible for checking and cleaning. A service schedule
1050 C and BD-1050 CS (stripping). Features of these flatbed
is available with the machine and the first year’s service is
automatic die-cutters include:
included, along with a variety of first line spare parts.
– LCD screen dialogue window displays with recording and
The machine is naturally fully guarded and CE marked to
setting functions
comply with all UK safety requirements and as with all machines
– Maximum sheet size 1,050 x 750mm from ID Machinery is supplied delivered, installed and with full
– Minimum sheet size 400 x 370mm operator training as part of the package. With set up times of
under 5 minutes and speeds of up to 3,500sph, coupled with
– Steel cutting plates purchased from West Germany the full spares and service support, the machine is the ideal
– Handles from E flute up to 4mm corrugated choice for any plant looking to improve its die-cutting efficiency.
– Maximum machine speed 7,500sph
Two models
The company are currently seeking agents in Western Shanghai SR Pack Machinery Co Ltd of China market two
markets to continue their marketing strategy to increase exports automatic flatbed diecutters – models AD-1500 and AD-1650.
in the coming years. Both models (1500 x 960mm and 1650 x 1100mm) can
incorporate stripping. Other features include: lead edge feeder;
Sumo in the UK transfer table for corrugated and laminated board; maximum
pressure of 400 tons; quick set up with centreline and operate
Already well established for the supply of machinery from
at speeds of 4,000sph.
the Far East, having supplied over 100 TCY machines to the
European market, ID Machinery of Milton Keynes, England,
offer a semi-automatic die-cutter.
Modular WOOK IL
The WTNS series of flatbed die-cutters from WOOK IL
The MIDAS/SUMO machine is ideal for the short to have been further developed and improved over the last 12
medium run die-cut sector, traditionally catered for by the hand months and Andrew & Suter Ltd, the agent for the UK and
fed platen. With a maximum sheet size of 1820 x 1220mm Ireland, advise that the advances now made ensure that these
and a weight of 23 tons, the machine is manually fed making machines are amongst the best on offer.
it easy to feed both warped board and irregular sized board.
Versatility is the key word for the WOOK IL die-cutters.
From the automatic rising feed table, the operator feeds The Korean engineers with European help and additions have
the sheets in to a gripper bar assembly with double action produced a range of machines that will compete with any on
register for accurate feeding. The sheet is then transported in the market and there has been no compromise on the quality
to the die-cut station that is controlled by a robust crank of workmanship.
assembly providing up to 400 tons of diecutting pressure. The
forme is mounted via the traditional side loading system and is The WTNS range is available in six sizes, covering 1300,
quickly located with the centreline set. 1500, 1700, 1900, 2100 and 2500. The machines are
produced in four formats for each size, starting with the WTNS,
A full stripping station is included with the option of which is a semiautomatic machine without stripping. The
centreline 1 and 2 to facilitate even shorter set up times. The WTNS-S offers full male and female stripping other than the
die-cut sheet is then stacked in a non stop lowering delivery lead edge, with the WTNS-SS providing full stripping including
section with side squaring to ensure a well stacked pile. the lead edge. All of the first three formats are semi-automatic
The machine is fitted with three touch screen PLC’s at all with a pile delivery system.
operator points and includes full fault finding. All electrical and
electronic components are quality Japanese brands but can be The range is completed by the WTNSSSF version. This is
substituted for European brands if the customer prefers. a fully automatic machine with lead edge feeder for high

(cont. on page 23)

The Corrugator / Apr. - Jun. 2008 17

(cont. from page 17) servo motor. In addition to this, the vacuum transport, with
productivity that can be supplied either as a dedicated fully long lasting high friction belts provides consistent, accurate
automatic unit or as a dual automatic and semi-automatic board transport. Die-cutting accuracy is excellent and the
machine. In the dual state the automatic feed unit can be moved independent servo drives give the operator the ability to easily
back on rails, allowing the machine to then be used in a semi- fine tune the dimensions in case of tooling errors. As standard,
automatic mode. This is achieved by a quick release system the drives automatically adjust the speed of the anvil cylinder
and no parts have to be fitted. to compensate for the new diameter after grinding.

The combination option gives the user one of the most Because the machine is not only a first class die-cutter but
versatile machines on the market as it can be used to die-cut also a high graphics flexo printer, customers have specified it
all grades of corrugated from micro flute up to double wall as with up to eight print units. In addition to a number of highly
well as plastic corrugated, solid board, cartonboard, foam sophisticated machine options, the Evolution can be equipped
backed materials and many more. with any type of sheet dryer and an ejection unit allows sample
sheets to be removed on the run.
This combination option provides the converter with the
choice of being able to purchase a WTNS-SS version and to In combination with the zero-feedinterrupt stacker EVO-
add the automatic feed unit at a later date, when the work mix Stack, (which is available either for bundles or stacks), Göpfert
requires this choice. Options are also available to enhance the is able to provide a bottleneck free die-cutting line. Machine
machines and these include, automatic or semi-automatic pre- reliability is ensured through the company’s high standard of
loaders, batch delivery system instead of the pile delivery unit, engineering and the use of internationally known component
cameras with monitors to help the operator view the board suppliers. Spare parts are readily available all over the world.
passing through the machine, a touch screen with full diagnostic Remote diagnostics with a 24 hour Hotline service, a large
system and finally an automatic pallet dispenser unit. spare parts store and multilingual staff means that plant
managers can be sure of maximum machine availability.
ROTARY DIE-CUTTERS
Accuracy, flexibility and performance
Gold award for Göpfert
Martin (Bobst Group) has developed a complete range of
The new G pfert double die-cutting unit for the direct driven innovative and productive in-line corrugated rotary diecutting
RDC Evolution-HBL was awarded the Gold Award for solutions offering short set-up times and high quality
Innovation by a jury of the European Federation of Corrugated flexographic printing. More than 365 Martin DRO lines are
Board Manufacturers (FEFCO) who were impressed by the now running worldwide.
solid German design and the innovative machine concept.
DRO 1628 GT (66"): the ‘plug and play’ DRO solution,
Two complete die-cutting and anvil cylinders are mounted featuring feed-belt feeder, high performance bottom flexo
in a large rotating support drum. This is the logical extension printing units with vacuum transfer and a 66 x 110" gear train
of the HBL principle, which already offers set while running rotary die-cutter. Ideal for long run orders. Quick and easy to
on the print units. During production, the die for the next install.
order can be pre-set by the operator in a safe position from
the factory floor. The die is changed at chest height while the DRO 1624/28/32 NT (66"): high performance mobile
material flow of the current order runs at a height of 2.20m. DRO with independent drives, a servo driven machine with
The changeover to the pre-set die-cutting cylinder takes only excellent register accuracy and precise die-cutting. Designed
two minutes and is fully automatic, once it is activated. Five of for high graphics applications, it includes in-line varnishing
these double die-cutters are already running successfully in and drying. It also features a new direct drive feeder, full vacuum
production and three more are on order.

The success of the Evolution (over 140 installations so far)

is due to its true direct drive concept. Every axis has its own

Göpfert high board

line die-cutter. Martin DRO 1628 NT HBL.

The Corrugator / Apr. - Jun. 2008 23

transfer, extended transfer space between flexo units, closed
Rapidex (Bobst Group), is dedicated to the design of large size flexo
inking circuits and dust collection system.
converting machines with in line slotting and rotary die-cutting.

Based on the same technical platform as the DRO NT

machine, Martin has developed a fixed machine concept
allowing shorter set up times. The DRO 1624/28/32 NT
Rapidset (66") is a high performance Rapidset DRO with pit.
A real Rapidset concept (set up during the run) is achieved,
thanks to pits under the flexo units offering easy and quick
access to the printing units.

Some markets are demanding even more flexibility and

higher printing quality (anilox roll change from one order to
another). To answer these demands, the company has
developed a High Board Line machine, the DRO 1624/28/
32 NT HBL (66"). It offers set up while on the run and easy
access to printing units (convenient for large printing stereos).
This machine offers greater flexibility in terms of board grades
as a result of the automatic anilox roll changeover system. Position and speed of the slotting shafts and the die-cutting
cylinder are controlled. After the first die-cut, the die cylinder
Martin prefeeders, palletising solutions, and peripheral slows down to let the board pass through the machine and
equipment are available to maximise the performance of all then reaccelerates to die-cut a second time in register at the
Martin DRO lines. same tangential speed as the sheet. Furthermore, Extendo
technology applied on two independent slotting shafts enables
Extendo for Jumbo substantial make ready time saving. There is no need to open
the machine to change the knives to modify the slot length.
Rapidex (Bobst Group), is dedicated to the design of large
All tools are positioned automatically.
size flexo converting machines with in line slotting and rotary
die-cutting. These flexo folder gluers and printer slotter die-
cutters have been developed for producing big boxes, made New generation
from the heaviest grades of corrugated board. The new generation Isowa FD-71 rotary die-cutter is well
respected for its high productivity, trouble-free running and
The Jumbo machines (Advanced and Rapidset NT) are production of high quality print and diecut boxes. The die-cut
available from 1600 x 4100mm (66" x 161") to 2200 x unit is independent from other units and is driven by its own
5500mm (86" x 210") with a wide range of finishing options – independent motor. Features of the line include:
die-cutting, folding, gluing/taping/stitching.
Isowa Rotary
Meeting a growing demand to process ever larger sheets, Diecutter.
all Rapidex Jumbo lines are available with full machine speed
Extendo features. This technology, using independent servo
motors, enables slotting and die-cutting of sheets up to 100"
depth on a 86" Jumbo format. Each slotter shaft is equipped
with one independent servo drive, as is the rotary die-cutter.
Therefore, the Jumbo is able to produce at a speed of 6,000sph
in Extendo Mode.

The Corrugator / Apr. - Jun. 2008 25

– Instant ink recovery and washing time. traditional gear train machines, and in 1676mm repeat with
– Chamber doctor blade with automatic viscosity controller working widths of 2400 and 2800mm for the new Direct Drive
function series.
– Steady sheet travel without skew, thanks for vacuum transfer
system Two versions
– High production speeds
Avon, Ohio-based EMBA Machinery Inc offers a complete
– Independent direct drive of the die-cut unit
line of McKinley rotary die-cutters in both the traditional track
opening style and the latest open architecture, high board line
Available as 2100 x 2700mm wide, these bottom print
design.
die-cutters can be supplied with up to four colours, offering
quality print to meet the demand for point of sale and value
The McKinley ColorStar™ is the company’s high board
added packaging. The FD-71 is designed to be most efficient,
line offering, consisting of fixed and separated vacuum transfer
saving valuable man hours in all aspects of setup, clean-up
printing modules, and designed especially for high graphics
and maintenance, while being fully computerised to control
and high output. It utilises independent electronic servo drives
the short time-set-up. As an optional feature, a dryer unit is
and has a fixed height board line of 84" (2.133 m) with a full
available for the last print unit.
67" (1.7 m) of separation between print stations. This ensures
that sheets are in contact with a single print section at a time.
Direct Drive version is new In addition to ensuring superior registration, this spacing also
The Curioni ‘Plus Series’ rotary die-cutters are proving to facilitates drying between print stations and provides ample
be an excellent choice for box makers around Europe. Over space for third-party IR dryers.
the last two years, more than 10 machines have been
successfully installed. Productivity and printing accuracy are The ColorStar™ is recommended for 100-line+ process
key features shared by all printing. In addition, the fixed station design and high board
Curioni machines and this is line makes unused print sections available for set-up and anilox
ensured due to the heavy duty, changes while the machine is running. It is available in 50"
accurate, construction of the (1.27m) or 66" (1.67m) cylinder sizes, with machine widths of
machines. The company’s latest 80" (2.28m), 110" (2.79m), and 130" (3.30m). The machines
development is the introduction are capable of producing high graphics at speeds up to
of a Direct Drive series of rotary 9,000sph.
die-cutters.
EMBA’s line of McKinley Premier™ rotary die-cutters are
The SUN Automation Extend-O-Feed, widely acknowledged conventional open/close track operated machines. Offered in
as one of the best feeders available, has been installed as a a broad range of standard cylinder sizes and machine widths,
standard on Curioni machines for nearly 20 years now. The including flexo folder gluer die-cutting modules from 24" x 78"
improved Raffaello printing units can be supplied with a choice to 88" x 210", McKinley has a size to fit most needs. All
of inking options – traditional roll to roll, reverse angle doctor machines are modular in design, allowing custom configuration
blade or closed chamber doctor blade. Whichever option is and later expansion as needs develop. These configurations
chosen, precision of shafts and rolls comes as standard. can include multiple flexo printing units, scoring capability,
and a creaser/slotter section. Among many standard features
The precision of print register, which is critical on machines are True Zero™ digital registration, EMBA ServoFeed™ lead
designed to run multiple colour jobs, is further enhanced by edge feeder system and variable speed cutting anvil. Optional
the proven Suction Grip vacuum sheet transport system, which equipment includes vacuum transfer sections, automatic wash-
also prevents board crushing and provides kiss-touch printing up system, computerised set-up, and complete servo-driven
performance. The sheet transport system is integrated and electronic line-shafting.
completed by a wide Split Process section, which prevents
marking of the sheet generated by the cutting die and provides
enough time for ink drying.

The heavy duty design of the rotary die-cutting unit suits

the most demanding requirement of multiple shift production,
even when running double wall board. It is also equipped with
Synchro Drive, (a positive rotation control of the anvil), a
grinding device for the polyurethane blanket and a fast die
mounting system. A computer controls the machine and a
large memory allows for pre-setting of the machine in an
efficient manner.

The company’s RDCs are available in 1350 and 1676mm

repeat length with working width from 2200 to 3700mm for

The Corrugator / Apr. - Jun. 2008 27

Established partners it’s class and the ability to extend die cutting beyond the set
format to a staggering 3m x 6m for RSC’s and wraps.”
Dong Fang is one of China’s leading manufacturers of
printing and rotary diecutter machinery and one of the most
The RotacuT also handles a variety of materials without
respected companies in the Asian corrugated industry. In a
any additional adoption needed. This modern die-cutter shares
relatively short space of time, thanks to the proper focus on
little with conventional rotaries and is at the forefront of the
market needs, Dong Fang has become a reputable, privately
latest work on ‘adjustable plywood dies and off machine make
owned company. It is owned by the Tang family, with Victor
ready’.
Tang being President.

The most important machine series for international

Rotary as well
markets are the Topra and Apstar models, (top and bottom Joining the range of flatbed machines produced by UK-
printing respectively). Both machine series come with many based Crosland VK is a newly introduced rotary die-cutter that
technical developments from the company’s technical partners, offers high speed, flexible die-cutting that is ideally suited to
SUN Automation. As a result of this collaboration, the machines volume production. Up to six flexo units can be added allowing
are fitted with SUN lead edge feeder, MicroGrind, vaccum printing and die-cutting to be done in one operation. Both top
transport and the dual doctor blade systems. Both models can and bottom print is available. High performance is combined
be supplied with up to five colours, with air dryers. with user-friendly features.

Second generation
EMBA Machinery GmbH of Lübeck Germany reports
continued strong market interest in its second generation of
Easy.Up programme – upgrades and retrofits for converting
machines. The Servofeed is available for all machine types
and will improve output as well as product quality. It provides
more vacuum surface, better capability to run warped board
and is easier to install than mechanical systems.
New from UK-based Crosland VK.
Easy.Up also includes a new vacuum transport system that
provides accurate board transfer for perfect register from the
Dong Fang has quickly developed its international markets,
front to the back of the machine. The system requires no set-
mainly with the successful Apstar series. These machines are
up for order change yet provides perfect adaptability for each
equipped with European-standard parts, as well as remote
individual job.
control cabinet, touch screen and modem for remote technical
troubleshooting. They have a well established sales network,
The Harmonic Drive register gear box upgrade is now
(with international sales accounting for over 50 per cent of the
available with a digital B&R Servo drive that makes register
annual production) and representatives with after sales offices
accuracy easier to control and memorise. After completing an
around the world, like Warak Consulting for Southern Europe
upgrade with a ServoHarmonicDrive and their new Vacuum
and the Middle East, Goettsch for US, Latin America and Asia-
Transport System, almost any rotary die-cutter can hold
Pacific areas and M&K Trading for the UK. Dong Fang is in
registration to within ± 0.5 mm.
the process of manufacturing a new, high quality, modular
printing machine that will be available in the first quarter of
Other components in the programme are ink-control-units,
2008.
chamber blade systems and complete computer control
upgrades.
Largest in class
Tony Sullivan, Managing Director of UK-based Corserve
Ltd comments, “The RotacuT all servo engineered rotary
diecutter continues to replace conventional flatbed die-cutters
in significant numbers for the manufacture of die cut corrugated
sheets. The reason is that
the patented technology
adopted gives a number of
advantages for the
boxmaker such as
excellent no edge trim
registration accuracy,
rotary speed and trim
separation, a format size
much larger than others in

The Corrugator / Apr. - Jun. 2008 29

 The Deltastack, the current generation of die-cut stripper Wingrinding device can be supplied as an additional component
stacker, is also part of the upgrade products for rotary diecutters, for a new machine or as a retrofit on existing installation.
increasing productivity as well as print quality. All upgrades
for rotary diecutters and flexo printer slotters are manufactured Wintek SpA is also the exclusive distributor in Europe for
in Germany. the range of Wintek Sunrise converting machines that include
Casemaker Series 37 (available in sizes of 950 x 2200 –
Steel to Steel 2500mm), Casemaker – Flexo Printer Slotter Series 50
(available in the sizes of 1270 x 2700 – 2900mm), Rotary Die
The range of rotary die-cutters from TCY of Taiwan is well
Cutter Series 66 (available in sizes of 1676 x 2000 – 2800 –
established – whether for specialist die-cut work, conventional
3300mm) and Flexo Printer Slotter Series 66 Large (available
die-cuts and vegetable trays or displays. Machines are available
in sizes of 1676 x 3600 – 4000 – 4300mm).
in sizes of 1600 x 2500mm, 1600 x 3000mm and 1600 x
3600mm.
These European concept machines are the result of a
technical and industrial alliance between Wintek and Sunrise
The company also markets a rotary die-cutter using the
Pacific of Taiwan. All machines are of solid construction and
concept of steel to steel die-cutting. Features of the machine
are equipped in their standard version with Sun Automation
include:
‘Extend-O-Feed’, vacuum transport through the print sections,
bottom flexographic printing system with dual doctor blade,
– Heavy-duty construction to avoid vibration
vacuum transfer unit between the print section and the die-cut
– Sun Lead Edge Feeder with sheet cleaner
section, variable speed anvil for die-cut accuracy in the rotary
– Printing units with vacuum transfer
die-cutter and computer control.
– Vacuum transfer unit between last print unit and die-cutter
to avoid vibration and ensure good register. The result is
Machines are manufactured partly in Taiwan by Sunrise
clean cut blanks.
Pacific based on European specifications and partly in Italy.
The casemaker range is completed with a folder gluer and
Retrofits and new counter ejector section that is manufactured in Italy.
Based in Italy, Wintek SpA markets a range of retrofit
upgrades for existing converting machines (casemakers, rotary Offering a quick return on investment, the complete range
die-cutters, printer slotters and printing lines). Aimed at of machines is manufactured to satisfy the requirements of the
optimising the performance of most makes of converting European market both in performance and technical/safety
machine, these retrofits can be completed on site at the standards. Installation, start-up, training and after sales service
customer’s facility. Installation, commissioning, training and activities are carried out by Wintek skilled engineers with a
technical assistance are carried out by skilled engineers. The long experience in this specific market.
most successful retrofits include Winair and Wingrinding. The
Winair vacuum transport system for existing print units Robust construction
eliminates use of pull collars and sheets guides. Advantages
The YSF rotary die-cutter is of proven design and has
are:
continually evolved over the last 20 years. It has been designed
to be economic to purchase, yet still provide all the features
– set up time reduction at order change (it is no longer
necessary to produce a modern die-cut blank in an ever
necessary to adjust the pull collars and sheets guides, caliper
increasing competitive environment.
and positioning)
– more precise and fast sheet transport even with warped
corrugated board
– printing quality improvement (printing pressure reduction,
elimination of any colour streaking)
– printing register improvement
– sheet lateral trim saving
– ease of operation
– quick return on investment.

The Wingrinding device (based on a reliable solution

successfully applied for a number of years on standard Wintek/
SUNRISE converting lines) allows grinding of the RDC anvil
cylinder to be undertaken quickly – during the time necessary
for an order change or with the machine running. More
frequently removing a minimum of polyurethane across the
full width of the anvil cylinder results in extended blanket life,
while keeping die-cutting quality and precision constant. The

The Corrugator / Apr. - Jun. 2008 31

 As with all YSF machinery, the die cut units are of a robust ANCILLIARIES AND RETROFITS
and strong construction with the die drum ground, polished
and fully chromed. The anvil life and accuracy is prolonged Wide range of tooling
with lateral oscillation and machines can be supplied with either Northampton, England-based Mansfield Board Machinery
anvil synchronisation or equalisation. Anvil life and accuracy is Ltd. provide a range of tooling to support die-cutting
further enhanced by optional anvil trimming systems – two applications. These include polyurethane rotary die-cut anvils,
systems are available, either knife or abrasion. die cut hand hole tooling for printer slotters (Dovey), diecut
stitch flap tooling for printer slotters (Tabtool) and chase plate
The die drum can be offset laterally ± 20mm. This protection sheets. With specialist knowledge of the industry,
adjustment enhances register control and reduces the need to MBM can design tooling to suit most machines and applications.
remount the cutting die. All models are supplied with internal The Dovey handhole equipment offers rotary die-cutting with
pin stripping as standard – however, conventional ejection simple formes while attached to the slotting shafts of a printer
rubber stripping can also be utilised. slotter. Hand holes, vent holes, special shapes and perforations
can easily be fitted. This increases the type of orders that can
Linear encoders are used to control die-cut pressure and be run on a simple printer slotter.
register is also CNC controlled. Both these axis are adjustable
to within ± 0.1mm. CNC control is via touch screen PLC and The Tabtool is also designed to fit printer slotters and
on the Super S type machine can also be controlled via a casemakers to give die-cut quality edge to the stitch/glue flap
central PC touch screen station. of a box. Replacing the standard upper and lower knives, the
system operates as a continuous slot and flap cut, using serrated
Elan accuracy rule blades, while cutting against a polyurethane anvil cover.
The Mitsubishi second generation ELAN is a 66" rotary Results are a clean cut with no waste tags.
die-cutter that can handle the most intricate shapes and the
smallest cut-outs and can even make reverse matrix scores at High performance
high speeds of up to 12,000sph. The large cylinder, 1,675mm Spanish company Rodicut have been supplying rotary die-
in circumference, provides strength to help minimise cylinder cutting dies and polyurethane anvil covers for over 25 years.
bend from the weight at die-cutting. It therefore combines the The extensive range of products helps operators of rotary die-
die-cutting accuracy and scoring capability of a flatbed with cutters achieve similar levels of accuracy expected of flat bed
the set-up ease and speed of a rotary system. A stainless steel die-cutters.
sheet, mounted on the anvil cylinder in combination with the
cutting die, eliminates the need for the extensive set-up Over the last 8 years, the company has developed a series
necessary with the traditional steel anvil designs. Using the of maintenance programmes and training programmes to help
semi-hard anvil and cutting die together allows reverse scoring extend the life of their die products. The company claims that
to be pre-set. its products can help increase productivity on the diecutter by
as much as 40 per cent whilst saving 90 per cent on usual
Sheet feed is accomplished by a lead edge feeder. Smooth consumption rates for polyurethane products. Rodicut’s
sheet feeding ensures that double wall, soft sheets, E-flute and polyurethane covers have also been developed to allow for a
even cross corrugated board is handled at high speed. Vacuum certain amount of stretch whilst a job is being run. The company
pulls each sheet on to a bottom grate and feeder wheels. The also claims that with a 3kg blanket, over 1 million sqm of
feeder wheels accelerate to reach the same speed as the feed board can be die-cut before it needs to be replaced.
roll and the sheet is then fed. The lead edge feeder eliminates
slippage caused by the corrugator score as well as slippage at Global appeal
start-up. Paper dust removal is standard within the feed unit.
Vacuum removes paper dust from the surface and the cut edge SUN Automation Group specialises in maintaining and
of the sheet, effectively preventing problems during printing, improving the productivity of a box plant by providing parts,
resulting in sharper printing and less downtime for clean up. A service and upgrades to existing rotary die-cutters. It offers
vacuum belt type transfer conveyor is available between the conventional rebuilds on most machines with OEM quality parts.
printing and die-cut unit. The company can modernise machines by adding SunTrac
vacuum transfer, RainbowGraphics chambered doctor blade
Ink is dried as it passes between units eliminating ink smear, ink systems, digital harmonic registers, Extend-O-Feed lead
smudging and soiling in the high-speed die-cutting process. A
4 wide vacuum belt system provides stable transport. A bottom
printing system achieves top quality accurate printing even at
high speeds. A dust purge system blows air into the hopper
encasing the ink roll to prevent dust from degrading the printing.

The Corrugator / Apr. - Jun. 2008 33

 Dicar offers a complete line of diecutting products that meet
high speed, high precision die-cutting needs including the
Equalizer anvil system, Anvilok III glue tab and hand hole
systems and complete lines of urethane components and
diecutting and die-making supplies.

High performance stackers

The Geo. M. Martin Company’s line of rotary die-cutter
stackers are designed to match the maximum performance of
any rotary die-cutter. They all feature fast set-up, low
maintenance design, reliability and the latest modern operator
and safety controls.

The Valu-Stak® LCS series RDC stacker offers an

edge feeders, MicroGrind anvil accuracy systems, or PrintPrep economical, reliable, high performance solution for most
sheet cleaning systems. Print stations, die-cut stations and dwell diecutting applications. Standard features include 3-across by
stations are also available for most machines. 4-up capabilities, auto tracking drives to match changing press
speeds, quick adjust snubbing wheels, accurate high
These upgrades can be added individually to solve a specific performance counter, auto jam detection, proportional
problem, such as poor registration or too much scrap, or can hydraulics, 127mm stacking deck belts and the Vari-Stack
be retrofitted as a group to transform a machine into one hopper system.
capable of higher production and quality thus enabling entry
to new markets. The Select®-LCS series stacker is designed to meet the
most demanding 24/7 die-cutting operations. Its fast setup,
With the recent acquisition of Deritend, SUN are now in a high performance operation and multiout capabilities maximise
position to support existing Deritend customers with parts and die-cutting line efficiency. Standard features include the Smart-
service to original specifications. The company also stocks a Stak order entry system for fast and repeatable set-ups,
large selection of parts for Ward Models 866, 166, 11500, extended nip layboy arms, spring loaded carriage-style snubbing
12000, 13000, 15000, and 16000 machines. Many of these wheels and the Pozi-Stack front end with access backstop which
parts have been re-engineered for improved performance and handles a wide range of products while providing the operator
longer life. SUN Automation Group Europe supports sales for a full view of the stacking process.
equipment, parts and service through its Bristol headquarters
and sales office in Holland.

Extended wear
DuraBlue anvil covers are the latest innovation in Dicar’s
line of precision, long wearing urethane covers. Users of
DuraBlue will quickly realise the benefits including extended
wear, easy rotation and fast mounting.

DuraBlue enhances the

Boltless™ design with a ‘dove-
tail’ shaped lock-up which Standard on all stackers is the patented LCS-LG safety
allows the removal of both system, which provides optimum protection while allowing the
the male and female ends of stacker to automatically cycle without operator attention.
the cover in one simple Designed to European and USA standards, the fully integrated
motion. Advantages of the safety system includes automatic self-testing and redundant
design include reduced controls.
installation, rotation and
removal times which can be translated to reduced downtime The Select and Valu-Stak are available with a full range of
and increased productivity. The lock up design ensures perfect options to match specific production requirements. The
edge alignment and eliminates the potential for cover skew company also offers a complete line of material handling
that is often an issue with standard mounting lockups. The equipment including bundle separators, load formers, and a
design, which offers enhanced flexibility making them easier full complement of Pozi-Lock components.
to handle, store and wrap around the cylinder, is as durable as
it is easy to use and will withstand hundreds of rotations while
providing the same secure lock-up and edge alignment
precision. (cont. on page 39)

The Corrugator / Apr. - Jun. 2008 35

(cont. from page 35) operation. Interstation flexo dryers make it possible to dry each
or selected colours before the next is applied, eliminating
Under three minutes ghosting, smearing, optimising colour brightness and gloss with
increases in productivity and product value. Final flexo dryers
CUE Inc is a leading manufacturer of urethane anvil covers increase productivity by drying over-print varnish or a final
for rotary diecutting. The company traces it roots to the colour prior to die-cutting and or finishing operations;
pioneering days of cast urethanes in 1957 and manufactured eliminating offsetting onto anvil covers, marking and smearing
one of the first urethane anvil covers for rotary diecutting in on transportation belts, optimising colour brightness and gloss
1962. Today the company is ISO 9001-2000 certified. with dramatic increases in productivity and product value. The
company’s UV flexo curing systems increase productivity,
The company’s Timesaver™ anvil covers provides product offerings and product value. The systems make it
converters with a consistent urethane die-cutting surface. possible to cure UV over-print varnishes at maximised machine
Timesaver’s design starts with a solid-steel backing that ensures speeds providing extreme scuff, rub and water resistance, box
a precise fit and dimensional stability throughout the life of the strength and ‘wet look’ gloss levels.
blanket. Next, a solid steel hold-down angle and an exclusive
solid steel lock bar are welded to the metal backing in a
Positive feedback
proprietary process that ensures a precise fit. Highest quality
urethane is chemically bonded to the metal backing and the Following Sandvik DieCutting Products’ launch of its range
cover surface is then ground to a consistent thickness and of special hard edge coated rules, designated Sandvik Dieflex
trimmed to an exact width. Platinum, feedback from customers is extremely positive. All
trials and customer orders are supporting the claim that,
It’s exclusive solid steel lock bar fills the die-cutter keyway although initially more expensive, the longer life of Dieflex
with metal, providing a consistent cutting surface for the entire Platinum proves the life cycle cost argument. It makes the new
circumference of the cylinder. The operator can then use rules a real alternative for high volume, quality applications,
minimal die impression depth for clean cuts – one of the primary such as food packaging and the
ways of maximising product quality and blanket longevity. coated boards of top of the range,
high end packaging.
The Timesaver was designed to minimise machine
downtime during blanket rotations without modifying the die- As the coating is very thin, there
cutter in any way. There are no systems to buy, so there is no is no rounding of the edges. Sandvik
capital expenditure required. A video is available demonstrating Dieflex Platinum cuts tougher
a complete Timesaver Anvil Cover rotation on an unmodified materials at a lower cutting pressure
die-cutter in under three minutes. with improved release properties.
This reduces dusting problems and
High Efficiency dryers at the same time gives excellent and
even cutting results on long runs.
High quality and high production diecutting operations Yet, even combined with the edge
continue to turn to the high efficiency flexo drying and curing and body coating hardness, it retains its extreme bendability.
systems of JB Machinery. Specifically designed for the
corrugated industry, these IR drying and UV curing systems Also new from Sandvik is an anticorrosion coating across
continue to gain worldwide acceptance – currently JB has over its range of flatbed and rotary die-cutting products. The special
500 installations in 27 countries around the world. lacquer-based formula, the result of a substantial investment
by the company, protects the product both during shipment
Combining optimised to customers and throughout its operational life, eliminating
per for mance with an the risk of rust formation.
ergonomic design to offer
greater accessibility, easier
New exit line
maintenance and enhanced
safety, JB gives users the Para of Italy has developed a new product – a fully automatic
ability to run faster, reduce exit system for diecutting lines. Two installations are already
multi-pass jobs to a single working well in Italian boxplants. One has been installed at a
pass, provide higher quality factory in Italy that produces board for fruit boxes – the
graphics and create value for their customers. Drying also automatic RDC exit line includes breaker, 180° layer turner
maximises the ability to use high holdout substrates like clay and palletiser and it is fitted behind a Martin DRO. The other
coated, high-graphics sheets, without compromising run system has been installed at a plant owned by a multi-national
speeds. group, located in northern Italy, running behind a Corpart
rotary die-cutter. Both installations have been in place for 12
These high efficiency IR inter-station flexo dryers and final months and are operating well.
flexo dryers increase productivity, provide higher quality
graphics options and expand the capability of the flexo

The Corrugator / Apr. - Jun. 2008 39

Breaker III is new
The Bundle Breaker III from Alliance Machine Systems
International has been updated to provide box makers with
the increased performance demanded by today’s latest rotary
die-cutters. Updated controls, with improved position sensing,
allow greater overall line performance. Machine motions have
been specifically optimised to reduce overall platen travel during
the break cycle, resulting in faster machine cycle times.
(besides electrical power), can be used such as steam recovered
The Bundle Breaker III is constructed with durable from the corrugator, hot water, diathermic oil or gas.
components to provide years of reliable performance under
the continuous, high speed operation found on today’s finishing The final system in the Dry-Board series is a UV unit. The
lines. An improved colour touchscreen interface is intuitive installation of UV systems produces many advantages such as
and reduces setup times. It takes only minutes to set up the immediate curing for quick passage to successive treatments
Bundle Breaker III. and high gloss on varnish. These units are high power systems
(up to 200 W/cm).
The Bundle Breaker III also offers a smooth plastic infeed
and exit conveyor surfaces for added bundle control stability.
Introducing Propel
This helps to preserve bundle quality and allows the handling
of slippery and unstable bundles. The latest innovation from US based Monroe Rubber &
Plastic is Propel, a new, high performance ejection rubber for
Dry-Board series rotary die formes. Due to the new materials compact
construction, the height of the ejection rubber is lowered, which
The Giardina Dry-Board the company claims will allow for an increase in productivity
series of IR dryers are suited and performance from the die-cutter. With virtually no
to the drying of water-based compression set, the need for surplus rubber over knife height
inks and varnishes and can be is eliminated.
installed on machines for both
top and bottom printing. The Additionally, with the reduced rubber height, the machine
company’s dryers have been operates closet to design pitch diameter and less blanket wear
designed with the operator in is encountered. The company also explains that its product
mind. Complete with high efficiency quartz tube radiators, they offers improved scrap ejection, is easy to set-up and allows for
produce quick drying of printed sheets. a cleaner cut without crushing the board. The new material is
equally well suited for flat bed die formes.
The Dry-Board Hot Air system is a more traditional drying
system. To heat the air inside the exchange unit, other sources, (Reprinted with the permission of the author from
International Paper Board Industry, September, 2007)

The Corrugator invites Product Writeups and

Original Articles along with the Photographs

Please send your editorial contribution to:

The Editors,
FEDERATION OF CORRUGATED BOX
MANUFACTURERS OF INDIA
e-mail: nalanda@vsnl.com

The Corrugator / Apr. - Jun. 2008 40