Pre-Press and On-Press: Fundamentals of Folding-Carton Die Cutting That Will Help Cut Cost

May 26, 2017

Today, die cutters understand the need for efficiency in their folding-carton die cutting processes in order to obtain the highest level of profitability from their efforts. Each day, converters need to perform their functions in the most cost-effective ways possible. The real issue facing converters, though, is not how fast and efficient the operator runs a particular job, but what happens prior to the operator's role in the folding-carton die cutting process.

Elements That Affect the Efficiency of the Folding-Carton Die Cutting Process

1. Carton design contributes 20 percent to the efficiency of this process. By keeping the carton design as simple as possible, die cutters can streamline the production. The need to analyse the design to decide what is necessary and what is unnecessary to the design. At times, changing the scoring is more efficient than adding elaborate details that slow down production.

2. Production layout contains following five different aspects that together can contribute up to 30 percent to the efficiency of the folding-carton die cutting process:

  • Layout should be included in the design or estimate stage of the process and needs to be approved by cutting before the quote is finalised.
  • Input from the blanker operator is a must and all who are involved in the order-taking process should consult with the operator to prevent issues from arising.
  • Die cutters need to visualise the layout or sheet throughout each step of the cutting press to picture how it will move through the stripper, if the female stripper required a carrier rule and more.
  • Preparation prior to the actual cutting may be necessary when non-blankers or blankers are involved in the process.
  • Turning to double-knifing and utilising the paper's grain direction will assist with blanking and eliminate the need for internal stripping.

3. Die and tooling makes up approximately 30 percent of on-press makeready, but contributes 75 percent to the pre-makeready and pre-press efficiency rating. The die cutter needs to do his homework, place timely orders, know when laser tools are better than universal or hand tooling is and understand the types of tools to order for a job.

4. Pre-press set up makes up at least 10 percent of the efficiency of this process and at times, up to 25 percent. An assortment of equipment is necessary at this stage, including such things as a counter-transfer machine, extra storage cassettes, a hoist, one Easy-Set table and a humidity-controlled systematic storage area.

5. On-press makeready affects approximately 10 percent of the final stages of the folding-carton die cutting process. Job-setting histories, using a pit-stop concept, keeping the necessary tools on hand and utilising the right tooling and machine alignment techniques are the important factors that die cutter should concentrate on during this stage along with utilising a Quicklock system and performing the proper preventative maintenance.

For further facts about this topic, contact Triforme. We are experts in all areas of die cutting.

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47 Vinter Ave. Croydon
VIC 3136
Email: design@triforme.com.au
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