DIES
punching
The term applies to systems using a die with wooden ruler or tools for cutting hard materials, but other cutting systems on the market that can be seen in the screen. The various machines currently offered are classified into six general categories:
* clamshell die cutting equipment * equipment flatbed die cutting equipment rotary die * * kiss cutting equipment * * cutting plotters laser cutting systems
to work with relatively broad requirements with respect to search print cutting the clamshell die cutting equipment remain popular. These teams are generally hand fed, so the high tonnage are more desirable. The high tonnage allows more parts per cutting cycle last, which helps to counteract the work time associated with manual loading and unloading of substrates in the machine.
As clamshell equipment, equipment flatbed die cutting are also appropriate in situations where you need high production with registration requirements relatively low cut-to-print. These machines, some of which are compatible with automated feeding systems of materials, usually use steel rule dies with large format and can cut a large number of parts simultaneously. Requirements specific work (the type of material being cut, the internal features such as folds or perforations, perimeters of the parties, etc.) determine if equipment is required flatbed low or high tonnage.
rotary die cutting systems are designed to process feed material into sheets. The tools of these systems consist of a rotating cylinder and cut as the material is fed between the cylinder and the surface of the machine. While rotating systems can offer very high cutting speeds, cutting accuracy is also limited by the fixed nature of the tools.
When tolerances are narrow court records, the image distortion due to irregularities in print (for example, stretching of the screen for printing) or dimensional changes in the substrates (material stretch or shrinkage due to processing or environmental conditions) make it almost impossible to get the required precision cutting teams in large-format die. For these jobs, precision die cutting equipment using electro-optical recording technology and digital cutting systems that do not require fixed die (ie, laser cutting plotters) are the favorite teams.
laser cutting machines and cutting plotters are often the path chosen to carry out work cut circulation, or companies that need an effective solution for prototyping. The main advantage of these machines is their repeatability in terms of accuracy of cut. However, unless systems incorporating visual record, these teams have no way to compensate for image distortion or material and measure where they are cutting in relation to the printing area. These machines also have other disadvantages compared with conventional stamping equipment, in that they can not do folds in material and are more limited in the variety of materials that can be cut (adhesives, for example, are a challenge for them) .
Mechanical equipment Precision stamping optical recording employing either steel rule or hard tools are hybrid systems that combine the speed of the die with the accuracy of a digital court system. Precision equipment offer high tonnage cut a narrow clearance between the rotating head and the bed of the machine.
Unlike clamshell equipment or flatbed, the precision die-cutting have a more limited area and cut far fewer pieces per cycle (usually 2 to 4 pieces). However, when these machines are equipped with electro-optical sensors and systems for fully automated material handling (Fig. 1), offer labor costs minimum operating savings equivalent to conventional stamping equipment. Precision equipment optical record not only provide more accuracy, but also much more flexible in terms of the variety of materials that can handle and special features that are able to create, such as folds, highlighted areas and drilling.
The term applies to systems using a die with wooden ruler or tools for cutting hard materials, but other cutting systems on the market that can be seen in the screen. The various machines currently offered are classified into six general categories:
* clamshell die cutting equipment * equipment flatbed die cutting equipment rotary die * * kiss cutting equipment * * cutting plotters laser cutting systems
to work with relatively broad requirements with respect to search print cutting the clamshell die cutting equipment remain popular. These teams are generally hand fed, so the high tonnage are more desirable. The high tonnage allows more parts per cutting cycle last, which helps to counteract the work time associated with manual loading and unloading of substrates in the machine.
As clamshell equipment, equipment flatbed die cutting are also appropriate in situations where you need high production with registration requirements relatively low cut-to-print. These machines, some of which are compatible with automated feeding systems of materials, usually use steel rule dies with large format and can cut a large number of parts simultaneously. Requirements specific work (the type of material being cut, the internal features such as folds or perforations, perimeters of the parties, etc.) determine if equipment is required flatbed low or high tonnage.
rotary die cutting systems are designed to process feed material into sheets. The tools of these systems consist of a rotating cylinder and cut as the material is fed between the cylinder and the surface of the machine. While rotating systems can offer very high cutting speeds, cutting accuracy is also limited by the fixed nature of the tools.
When tolerances are narrow court records, the image distortion due to irregularities in print (for example, stretching of the screen for printing) or dimensional changes in the substrates (material stretch or shrinkage due to processing or environmental conditions) make it almost impossible to get the required precision cutting teams in large-format die. For these jobs, precision die cutting equipment using electro-optical recording technology and digital cutting systems that do not require fixed die (ie, laser cutting plotters) are the favorite teams.
laser cutting machines and cutting plotters are often the path chosen to carry out work cut circulation, or companies that need an effective solution for prototyping. The main advantage of these machines is their repeatability in terms of accuracy of cut. However, unless systems incorporating visual record, these teams have no way to compensate for image distortion or material and measure where they are cutting in relation to the printing area. These machines also have other disadvantages compared with conventional stamping equipment, in that they can not do folds in material and are more limited in the variety of materials that can be cut (adhesives, for example, are a challenge for them) .
Mechanical equipment Precision stamping optical recording employing either steel rule or hard tools are hybrid systems that combine the speed of the die with the accuracy of a digital court system. Precision equipment offer high tonnage cut a narrow clearance between the rotating head and the bed of the machine.
Unlike clamshell equipment or flatbed, the precision die-cutting have a more limited area and cut far fewer pieces per cycle (usually 2 to 4 pieces). However, when these machines are equipped with electro-optical sensors and systems for fully automated material handling (Fig. 1), offer labor costs minimum operating savings equivalent to conventional stamping equipment. Precision equipment optical record not only provide more accuracy, but also much more flexible in terms of the variety of materials that can handle and special features that are able to create, such as folds, highlighted areas and drilling.
Fig. 1 TEAM OF HIGH PRECISION PUNCHING: The team of high-precision die cutting, as this mechanical model, has a smaller cutting area than conventional flat bed equipment and die clamshell. Gap systems equipped with automatic optical registration mechanisms can compensate for irregularities in material or image and maintain accurate punching positions in relation to the location of the graphics.
court system selection and length of the run
considerations when a machine ready for operation, associated with each of the different court systems, may have a significant effect on the type of equipment to be selected a printing workshop. However, these considerations are often overlooked by screen printers.
When applications do not involve difficult substrates or adhesives and the runs are short, and digital laser cutting plotters clearly provided the best return on investment. However, as the run lengths increase in these systems, the costs of inputs (spare blades and head of the laser plotters) can become uneconomical, and slower operating speeds of these machines may begin to impede productivity. For longer run lengths, punching equipment or precision flatbed represent the best value.
By focusing on punching systems, our main economic interest has to do with the cost of making adjustments to the dies and maintain lengths to run to offset these costs. Many times, the problems associated with the adjustment of the tools screen printers arise when working with materials that have not used before or recently. Adhesives, for example, can cause unpleasant surprises when first cut and can cause significant downtime to clean and readjust dies repeatedly to achieve the appropriate court. In some cases, adjustments become so dramatic that it is necessary to re-make tools.
For its part, teams in smaller format precision of these adjustments are substantially easier, because the tools have far fewer cavities than dies de sistemas tipo almeja y cama plana con formatos más grandes. Mientras que estos sistemas mayores pueden tener 40 cavidades, el equipo de precisión más pequeño puede tener sólo entre 2 y 4. Igualmente, la característica de registro óptico de los equipos de precisión más sofisticados asegura que la posición del troquel siempre sea exacta, lo cual significa que es necesario hacer ajustes a las herramientas con menos frecuencia, y cuando ocurren, no hay que repetirlos. Una vez se ajustan las herramientas, los talleres que usan estas máquinas pueden manejar fácilmente órdenes periódicas a corto plazo del mismo trabajo y no deben preocuparse de tener que repetir sus ajustes para alistar las herramientas.
Overcome bottlenecks in production systems
All manual power failure are likely to cause bottlenecks in production resulting from the amount of time it takes to feed and download the materials, and remove the cut pieces of leaves and rolls. This process is usually slower than screen printing, which produces printed material in profusion. For workshops using cutting equipment manual, the only way to avoid such delays is to make sure there is enough manpower available.
For high-volume production equipment flatbed die cutting, rotary and precision, the best option is to incorporate automated material handling that feed and discharge material removed while the cut parts (Fig. 2). The collection of parts and their separation into groups can also be automated.
court system selection and length of the run
considerations when a machine ready for operation, associated with each of the different court systems, may have a significant effect on the type of equipment to be selected a printing workshop. However, these considerations are often overlooked by screen printers.
When applications do not involve difficult substrates or adhesives and the runs are short, and digital laser cutting plotters clearly provided the best return on investment. However, as the run lengths increase in these systems, the costs of inputs (spare blades and head of the laser plotters) can become uneconomical, and slower operating speeds of these machines may begin to impede productivity. For longer run lengths, punching equipment or precision flatbed represent the best value.
By focusing on punching systems, our main economic interest has to do with the cost of making adjustments to the dies and maintain lengths to run to offset these costs. Many times, the problems associated with the adjustment of the tools screen printers arise when working with materials that have not used before or recently. Adhesives, for example, can cause unpleasant surprises when first cut and can cause significant downtime to clean and readjust dies repeatedly to achieve the appropriate court. In some cases, adjustments become so dramatic that it is necessary to re-make tools.
For its part, teams in smaller format precision of these adjustments are substantially easier, because the tools have far fewer cavities than dies de sistemas tipo almeja y cama plana con formatos más grandes. Mientras que estos sistemas mayores pueden tener 40 cavidades, el equipo de precisión más pequeño puede tener sólo entre 2 y 4. Igualmente, la característica de registro óptico de los equipos de precisión más sofisticados asegura que la posición del troquel siempre sea exacta, lo cual significa que es necesario hacer ajustes a las herramientas con menos frecuencia, y cuando ocurren, no hay que repetirlos. Una vez se ajustan las herramientas, los talleres que usan estas máquinas pueden manejar fácilmente órdenes periódicas a corto plazo del mismo trabajo y no deben preocuparse de tener que repetir sus ajustes para alistar las herramientas.
Overcome bottlenecks in production systems
All manual power failure are likely to cause bottlenecks in production resulting from the amount of time it takes to feed and download the materials, and remove the cut pieces of leaves and rolls. This process is usually slower than screen printing, which produces printed material in profusion. For workshops using cutting equipment manual, the only way to avoid such delays is to make sure there is enough manpower available.
For high-volume production equipment flatbed die cutting, rotary and precision, the best option is to incorporate automated material handling that feed and discharge material removed while the cut parts (Fig. 2). The collection of parts and their separation into groups can also be automated.
AUTOMATION PUNCHING Fig. 2: For maximum cutting efficiency, the team flatbed die cutting, rotary, high accuracy can be configured with mechanisms automated material handling, including roll feed, units collected and selection systems. Similar accessories are also available for automatic handling of substrates in leaves.
Try to accommodate each application with its own blade size to optimize use of material is not an effective method for punching. Variations in the size of the sheet (or roll) lead to excessive tool settings and other changes to prepress and printing, all of which increases downtime and undermines productivity. A better strategy is to guide the entire production of the plant to a minimum number of standard sizes of sheets or rolls, and plan production so that should change the size of material the least amount of times possible. The less downtime this method provides offset any resulting increase in costs waste.
Bottlenecks in production can be avoided later if you plan to work with your entire team die cutting in mind. This means that all printed materials must include proper registration marks that apply to all die cutting equipment in their operation. With this kind of standardization, always have the option of working on two or more machines to meet delivery schedules. These standards also allow you to optimize the ability to make changes or simply to find die-cutting machines that work best for work with special needs.
art departments also need to know how to group images, and otherwise create designs to maintain a minimum level of waste in all computers in the workshop. Schemes design standards should include requirements for waste smaller area around the perimeter of a sheet and between the parts for all cutting equipment workshop and not only for certain machines. Art departments generally are not aware of what punching machine will be used for a particular job, graphic design artists should include the major areas of waste required by your computer.
die inventory management
few printers that handle high volumes can meet their needs only laser cutting and / or cutting plotters, and most have some form of punching solution available. Those who do use the die face the common challenge of ensuring that the dies are right at hand when needed.
The problems of availability of tools are a common cause of bottlenecks. On the one hand, the tool is not delivered on time, or the tool has a problem that becomes evident when production begins, making it necessary to replace the punch. Strengthening good relations with manufacturers of dies will help you get the correct dies when needed and greatly facilitate the adjustment of dies at the last minute. In some operations, screen printing, die volume required can be large enough to justify the creation of an internal department and contract manufacturing of stamping die manufacturers full time.
matter where you do the punches, printers who have developed systems to maintain inventories of die production plobemas face less than those with poor management policy dies. Some users find that the steel rule dies are relatively inexpensive and discarded shortly after each job, despite the fact that many of the dies can be reconfigured and reused for other applications. Maintain a collection of dies can help avoid the expense of having to continually buy new tools. Collections or die storage areas can be organized in a certain sequence number for work and / or client. The workshops employ more sophisticated bar code systems in dies with scanners to ensure selection of the proper die. Some sophisticated precision presses are equipped with memory features that allow you to enter a number of die to enable the system to automatically bring to mind all the calibrations that are used with the die, minimizing much of the preparation time.
Due to the large number of dies that workshops may be available, they must have procedures in place to review the art of a given job has not changed. One of the problems of production that occurs most often is to prepare the tools for a job that seems to be a repeat order, when in reality, the customer has made minor revisions to the design, making it necessary to change the tools as well.
also be implemented procedures to ensure is that the dies are properly handled and stored. The hard rule dies are subject to nicks with relative ease. The hard tools also need to be properly stored, inventoried, and controlled with respect to wear. If you force a tool to a too long without sharpening properly, one day, in the middle of a print you will find that the tool does not cut sharply. A reinforcement strategy successfully used by many printers for hard tooling is to have a steel rule die or extra hard tool, which can be used as a booster if you need to renew or substantially change the main tool.
die Successful management also includes making decisions. cost-effective on the type of die to use with certain jobs. For example, should take into account the lifecycle costs of various types of dies because the entry price is usually a poor indicator of the total costs of the life cycle of the tool.
Typically, the offer dies with hard tools can throw two options that include a sophisticated punch and a lower cost. Assuming identical die configurations, although the sophisticated may have a price tag that doubles the cheapest, can hold 3 million cycles before requiring sharpening and can be reground between 12 and 15 times during its life cycle. For its part, the die may also be less expensive regrinding between 12 and 15 times, but require the process after only January 1 million cycles. So to double the initial cost, the more expensive die bear three times the number of cutting cycles that the least expensive option. However, if you do not expect to use the die more than 15 million cycles, would be an unnecessary expense to buy the most expensive tool. Maintenance and training
always pays to follow the maintenance procedures recommended by the manufacturers of the equipment and dies. Most of these procedures require very little maintenance time and costs when compared with the downtime of a machine, its value is negligible. One of the basic maintenance habits you should adopt stamping equipment is to keep track of the number of cycles of operation of the machine. You can set routine maintenance such as sharpening of dies, based on the number of machine cycles, similar to how we schedule the maintenance of your car based on the total distance.
When selecting equipment, it must also consider how long it takes to make the repairs and if the manufacturers have replacement equipment available. The modular equipment enabling manufacturers to provide replacement modules that help ensure continuous service time when the repair of equipment is needed. Also, it is advisable to keep parts important parts for the equipment on the premises.
For its investment in cutting equipment to produce full performance, it is practical to adequately train employees in operating the machines. Some users believe that the management of the cutting involves a little more than turning on / off button. The fact, however, is that when the screen printing companies devote time to train workers to operate the equipment properly, see more production and fewer problems with the equipment. Before committing to a new court system, find out what kind of training options offered by the equipment manufacturer.
The best court decision
Whether you want to support their new products or improve current production process, the perfect system is waiting. It could be a flat-bed die cutting, a cutting plotter economic, or a sophisticated precision optical registration features. To meet their needs with the right piece of equipment, pay special attention to their current goals and future plans for production. Make sure the computer you select offers the level of speed, accuracy and flexibility you need to help your business become profitable and grow. By understanding all the options of cutting technology and the advantages and disadvantages of each, will be able to ask appropriate questions to find the machine that is perfectly suited to his workshop.
Try to accommodate each application with its own blade size to optimize use of material is not an effective method for punching. Variations in the size of the sheet (or roll) lead to excessive tool settings and other changes to prepress and printing, all of which increases downtime and undermines productivity. A better strategy is to guide the entire production of the plant to a minimum number of standard sizes of sheets or rolls, and plan production so that should change the size of material the least amount of times possible. The less downtime this method provides offset any resulting increase in costs waste.
Bottlenecks in production can be avoided later if you plan to work with your entire team die cutting in mind. This means that all printed materials must include proper registration marks that apply to all die cutting equipment in their operation. With this kind of standardization, always have the option of working on two or more machines to meet delivery schedules. These standards also allow you to optimize the ability to make changes or simply to find die-cutting machines that work best for work with special needs.
art departments also need to know how to group images, and otherwise create designs to maintain a minimum level of waste in all computers in the workshop. Schemes design standards should include requirements for waste smaller area around the perimeter of a sheet and between the parts for all cutting equipment workshop and not only for certain machines. Art departments generally are not aware of what punching machine will be used for a particular job, graphic design artists should include the major areas of waste required by your computer.
die inventory management
few printers that handle high volumes can meet their needs only laser cutting and / or cutting plotters, and most have some form of punching solution available. Those who do use the die face the common challenge of ensuring that the dies are right at hand when needed.
The problems of availability of tools are a common cause of bottlenecks. On the one hand, the tool is not delivered on time, or the tool has a problem that becomes evident when production begins, making it necessary to replace the punch. Strengthening good relations with manufacturers of dies will help you get the correct dies when needed and greatly facilitate the adjustment of dies at the last minute. In some operations, screen printing, die volume required can be large enough to justify the creation of an internal department and contract manufacturing of stamping die manufacturers full time.
matter where you do the punches, printers who have developed systems to maintain inventories of die production plobemas face less than those with poor management policy dies. Some users find that the steel rule dies are relatively inexpensive and discarded shortly after each job, despite the fact that many of the dies can be reconfigured and reused for other applications. Maintain a collection of dies can help avoid the expense of having to continually buy new tools. Collections or die storage areas can be organized in a certain sequence number for work and / or client. The workshops employ more sophisticated bar code systems in dies with scanners to ensure selection of the proper die. Some sophisticated precision presses are equipped with memory features that allow you to enter a number of die to enable the system to automatically bring to mind all the calibrations that are used with the die, minimizing much of the preparation time.
Due to the large number of dies that workshops may be available, they must have procedures in place to review the art of a given job has not changed. One of the problems of production that occurs most often is to prepare the tools for a job that seems to be a repeat order, when in reality, the customer has made minor revisions to the design, making it necessary to change the tools as well.
also be implemented procedures to ensure is that the dies are properly handled and stored. The hard rule dies are subject to nicks with relative ease. The hard tools also need to be properly stored, inventoried, and controlled with respect to wear. If you force a tool to a too long without sharpening properly, one day, in the middle of a print you will find that the tool does not cut sharply. A reinforcement strategy successfully used by many printers for hard tooling is to have a steel rule die or extra hard tool, which can be used as a booster if you need to renew or substantially change the main tool.
die Successful management also includes making decisions. cost-effective on the type of die to use with certain jobs. For example, should take into account the lifecycle costs of various types of dies because the entry price is usually a poor indicator of the total costs of the life cycle of the tool.
Typically, the offer dies with hard tools can throw two options that include a sophisticated punch and a lower cost. Assuming identical die configurations, although the sophisticated may have a price tag that doubles the cheapest, can hold 3 million cycles before requiring sharpening and can be reground between 12 and 15 times during its life cycle. For its part, the die may also be less expensive regrinding between 12 and 15 times, but require the process after only January 1 million cycles. So to double the initial cost, the more expensive die bear three times the number of cutting cycles that the least expensive option. However, if you do not expect to use the die more than 15 million cycles, would be an unnecessary expense to buy the most expensive tool. Maintenance and training
always pays to follow the maintenance procedures recommended by the manufacturers of the equipment and dies. Most of these procedures require very little maintenance time and costs when compared with the downtime of a machine, its value is negligible. One of the basic maintenance habits you should adopt stamping equipment is to keep track of the number of cycles of operation of the machine. You can set routine maintenance such as sharpening of dies, based on the number of machine cycles, similar to how we schedule the maintenance of your car based on the total distance.
When selecting equipment, it must also consider how long it takes to make the repairs and if the manufacturers have replacement equipment available. The modular equipment enabling manufacturers to provide replacement modules that help ensure continuous service time when the repair of equipment is needed. Also, it is advisable to keep parts important parts for the equipment on the premises.
For its investment in cutting equipment to produce full performance, it is practical to adequately train employees in operating the machines. Some users believe that the management of the cutting involves a little more than turning on / off button. The fact, however, is that when the screen printing companies devote time to train workers to operate the equipment properly, see more production and fewer problems with the equipment. Before committing to a new court system, find out what kind of training options offered by the equipment manufacturer.
The best court decision
Whether you want to support their new products or improve current production process, the perfect system is waiting. It could be a flat-bed die cutting, a cutting plotter economic, or a sophisticated precision optical registration features. To meet their needs with the right piece of equipment, pay special attention to their current goals and future plans for production. Make sure the computer you select offers the level of speed, accuracy and flexibility you need to help your business become profitable and grow. By understanding all the options of cutting technology and the advantages and disadvantages of each, will be able to ask appropriate questions to find the machine that is perfectly suited to his workshop.
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