Key Solutions to Common Die Cutting Problems in Paper Box Packaging

September 11, 2020

Paper box packaging brings tons of benefits to both consumers and product manufacturers. It can help serve as a sustainable alternative for packaging products and attract customers in buying them since boxes can be reused and recycled. Paper box packaging can also fully protect the product whenever it is transported and display necessary information about the brand and its product. 

All the benefits of paper box packaging have pushed a lot of manufacturers to maximise paper boxes. However, all the work that needs to be done in conceptualising and finalising the packaging can be filled with some problems, particularly when performing die cutting. Paper boxes are typically created by die cutting, which is a process that places workpieces on the die cutting machine and cut them according to the preferred form or shape.

For your paper box packaging to be successful, here are some common die cutting problems and their corresponding solution that you can perform.

Low Die Cutting Accuracy

The low die cutting accuracy of a paper box packaging is usually caused by various factors. Your die cutting version body may have some problems that must be fixed right away. Printing problems may also cause low die cutting accuracy to paper box packaging. The working environment difference between the die cutting indentation and the printing process can also cause this specific issue.

In resolving this problem, you must choose an advanced die cutting plate making technology that will help improve die cutting plate accuracy. Both the die cutting indentation and the printing process must also be done in a working environment that has the same temperature, relative humidity, and other elements. Additionally, to minimise the impact of paper deformation due to die cutting inaccuracy, you must only perform die-cutting pre-treatment for the packaging once it has been polished or laminated.

Broken or Dark Lines

Another common die cutting problem that may occur in a paper box packaging is the presence of broken or dark lines. This specific problem is caused by the excessive pressure of the die-cutting indentation, surpassing the tolerance capacity of the paper or workpiece material. Dark lines are the unnecessary indentation lines that are caused by using an incompatible cutting plate and indention steel line. Poor choice of paper quality and the inconsistent direction of both the workpiece and the cutter may also cause these lines. Broken lines, alternatively, are caused by too large tensile force on the paper.

To solve these problems, you may want to pick an appropriate die-cutting plate, adjust the die-cutting pressure accurately, and improve the relative humidity of the die-cutting environment. Reducing the tensile force on the paper to avoid broken lines can likewise be done by reducing either the height of the indentation steel wire or the thickness of the bottom die strip. 

Occurrence of Fluffy Edges

Paper box packaging may also attain fluffy edges due to a blade that is not sharp enough to cut the material and provide a single clean stroke. Cutting with this type of blade will cause the edges of the paper box to be not smooth. 

As a solution, you must choose an appropriate due cutting blade for your paper box packaging. Your blade must have properties that can easily cut through the material without leaving unsightly fluffy edges. If your paper box has poor or thick fibre, then you must use a straight grain knife. Paper boxes with good fibre, alternatively, must be cut with a cross-grain knife.

Following these solutions to some of the most common die cutting problems in paper box packaging can help you obtain great packaging products as well as receive their associated benefits.

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