Understanding the Solutions to Die Cutting Waste Breakage

Die cutting is an essential process used in various industries to precisely cut and shape materials, such as paper, cardboard, or adhesive films. One crucial aspect of die cutting is the removal of excess material known as "die waste" or "trim waste", which is commonly referred to as "trimming" or "stripping" in the industry.

During the die cutting process, a die is used to cut the desired shape out of the material, leaving behind the final product and the surrounding waste. To ensure the quality and efficiency of the production process, it is necessary to remove this excess material. This step is known as "die cutting waste removal" or "trim waste handling".

Trim waste removal can be achieved through various methods depending on the nature of the material and the complexity of the die-cut shapes. In some cases, manual removal is performed by operators who carefully strip away the waste material from the finished product. This method is suitable for simpler die-cut shapes or smaller production runs.

For more complex or high-volume production, automated stripping equipment is employed. These machines are designed to efficiently remove the waste material by utilizing mechanical or vacuum-based methods. They can handle a wide range of materials and die-cut shapes, ensuring consistent and precise stripping without damaging the finished products.

Effective trim waste management is essential for maintaining the efficiency of die cutting operations. It helps minimize downtime, optimize production speeds, and ensure the accuracy and quality of the final products. By efficiently removing the waste material, die cutting processes can achieve higher productivity, reduce material costs, and improve overall workflow.

Die cutting waste removal is both a fundamental process in the production of adhesive labels and a segment where problems often arise. Today, I will provide you with answers to all the questions you may have regarding die cutting waste breakage.

Firstly, there are many factors that can contribute to waste breakage, and they can mainly be analyzed from the following aspects:

▍Raw Materials:

1. Heavy release force, material edges with burrs, cracks, or without silicon.

2. Weaker tear strength in the face material's machine direction (MD) or cross direction (CD).

3. Different types of adhesive: Water-based adhesives are easier to die cut than hot melt adhesives (which are more challenging to die cut compared to water-based and solvent adhesives).

▍Die Design:

1. Small R (radius) angles should be avoided, and right angles are best replaced by larger R angles, as larger R angles facilitate waste removal.

2. Choice of blade angle: Smaller blade angles result in higher sharpness but reduce the overall lifespan of the die.

3. Waste removal design: When the waste margin in the MD or CD direction is too large, adding a straight knife in the middle of the waste margin can help prevent excessive pulling force that leads to waste breakage in the opposite direction.

4. Die design: For straight knife lines, a slight inclination can be applied (combining the required terminus angle) to prolong the die lifespan and reduce the risk of waste breakage. When arranging irregular-shaped labels, an "H" shape layout is recommended to achieve a more even distribution of waste tension.

5. Dislocated waste removal.

6. Blade height: Magnetic and engraving blades should be adjusted according to the material to be cut to avoid insufficient blade height, which can cause incomplete cuts or damage to the substrate, resulting in waste breakage.

▍Tool Maintenance:

1. Adhesive residue on the blade should be promptly cleaned to prevent corrosion and rust, which can lead to notches on the blade edge.

2. Apply rust preventive before and after use.

▍Waste Removal Angle:

1. Straight waste removal: Adjust the waste removal angle to increase waste removal capacity.

2. Diagonal waste removal: Adjust the angle of the waste guide roller. It is recommended that the wider waste margin is on the side with a steeper angle (higher waste guide roller position).

▍Waste Removal Tension:

1. Properly increase the tension of the waste receiving paper tube during waste removal to prevent MD waste breakage caused by fast rotation due to a small paper tube size. The waste roll should be maintained neatly, with balanced forces on both sides. If necessary, a vacuum waste removal method can be employed.

▍Types of Die Cutting Waste Breakage:

Die cutting waste breakage can be classified into two types based on direction: MD waste breakage (in machine paper feeding direction) and CD waste breakage (across the width).

In addition to changing materials, there are many process-oriented solutions to tackle waste breakage.