Common Die Cutting Problems in Cartons and Boxes

April 30, 2018

Die cutting is a somewhat dated, but it is still very useful medium for processing large bulks of paper, pasteboard, cardboard, and even some varieties of plastic and metals into uniform lengths. Thanks to die cutters, it has become possible to uniformly cut a large number of materials quickly and efficiently.

Still, some die cutters do experience mishaps, and there are a lot of problems that occur in a typical run than most people are unaware of. These issues are not always a mark of an outdated die cutting machine however, since any type of machinery that is in constant motion is bound to have problems, every now and then.

Here are some of the most common die cutting problems that occur when processing cartons and boxes:

  • Misaligned blades – oftentimes, the blades of a die cutting machine can become misaligned due to extensive repetitive movement. In those instances, the cuts which would otherwise be even and clean will become crooked or misaligned. In the worst case, it will be unable to cut through a single stack and will leave sheets of carton or cardboard that have not been cut at all.
  • Warped or dented blades – sometimes, the thickness of a stack may be too much for the die cutting blade and it can warp or dent, which results in either uncut sheets or rough, uneven cuts that sometimes leave the material in a condition that can no longer be completely repurposed.
  • Burst-lines and dark lines – burst lines occur when the pressure of a die cutter is too much for the tolerance capacity of the material. This occurs in spite of the sharpness of the blade. Black lines, on the other hand, are caused by improper blade alignment, lack of pressure, or inappropriate die indentation, which leaves a clear crease on the material, instead of cutting through it.
  • Fluff – more common on paper than on cardboard, but nevertheless still frequently experienced in improperly maintained die cutting machines, fluff happens when a blade isn’t sharp enough to cut a material, but not sharp or forceful enough to provide a single clean stroke. The remainder of the material that is cut leaves edges which are ‘fluffy’, making for an unsightly and wasteful result.

Whatever the dilemmas you may be having with die cutting machines, in the hands of experts at Triforme, who know how to properly employ, maintain, and repair die cutters, these issues are easily worked out.

If you’re looking for a die cutting service that can handle a wide range of materials, and deliver the best possible results, contact us here at Triforme today.

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47 Vinter Ave. Croydon
VIC 3136
Phone: +61(3)9723 4400

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