only high quality and expensive die-cutters have historically been able to produce these results. “Many of our customers who have purchased our die-cutters had found that they were sending large amounts of revenue out the door since most commercial printers don’t have a die-cutting service,” Train says. “Our customers found that with the purchase of the Duplo DI CUT range of rotary die-cutters and the PFi Blade, they could keep the work in-house – controlling costs and the time frame for the jobs – keeping the quality of the products high. “Another really important benefit is that customers have been able to break through to different markets that stand apart from their usual customer base and to support their existing customer base with more services. The end result is that more revenue is generated with a cost-effective solution.” With this, Train warns of the dangers of underinvesting, saying this can lead to lower quality machines that do not adjust skew or do not include X & Y sheet registration. This, he says, will mean that the print will not consistently match the shapes being cut. “Die-cutting is reserved for premium printed products, and these details noticeably stand out,” Train explains, adding: “Traditional die-cutting is a very labour intensive process to make the dies up, but with rotary die-cutters job changes are a fraction of the time even if the dies are slightly more expensive. For the digital cutting tables, the software is key. “Most cut files can be found easily online or designed quickly, but transferring these designs to the cutting table using stock software is almost impossible. Duplo has developed a suite of software packages we call Duplo Connect, to take the pain out of this process. With materials libraries and our usual Duplo PC driven automation, creating new cut files that work first time has become as easy as moving a file into a folder.” Train goes on to outline some of the solutions available from Duplo, beginning with the PFi DI CUT 310, the replacement machine for the 300 model. A high-speed rotary die-cutter, it delivers packaging and print marketing applications in distinctive shapes and sizes to help printers stand out from the competition. Running up to 4,000 sheets per hour, the PFi DI-CUT 310 utilises a magnetic cylinder and flexible dies that process paper, laminates, self-adhesive, and synthetic stocks up to 400 gsm. “We had a lot of success with the older model, and so we listened to our customers and have improved and refined the 58 “The SC5000 combines ultra-reliable feeding with an instant job retrieval system and flawless high-speed cutting,” Hillhouse says, adding: “This automatic sheet cutter is perfect for both digital die-cutting and creasing lightweight packaging and pointof-sale card and paper projects, as well as kiss-cut sheet label production.” Also from Morgana is the AeroDieCut, which, developed by Uchida, is billed as the next step up for printers needing longer runs of die-cut product. Described as traditional meets digital, this machine uses regular cutting and creasing forms, combined with a patented system of moving press rollers that provide the pressure necessary to cut through and score the substrate, all housed in a relatively compact unit. Other features on the AeroDieCut include a patented ‘Tri-suction feeder’, which Hillhouse says ensures consistent paper feeding. The feeding unit is equipped with an ultra-sonic sensor for double feed detection, and a cut-mark sensor to compensate for any image shift. Feeding is carefully controlled when the step-and-repeat mode is employed. The AeroDieCut can accommodate cutting formes of up to 350 x 550mm, with a die board thickness of up to 18mm, and a cutting rule height of 23.3-23.8mm, while the unit can accommodate paper sizes up to 365 x 515mm with a maximum finished size of 310 x 485mm. Finally from Morgana, and suitable for longer runs, the Rotary Die Cutter (RDC) features a cutting system composed of an upper magnetic cylinder, holding the cutting matrix in place, and a lower counter cylinder. A pin register system on the magnetic cylinder helps the operator to install the cutting matrix accurately, while side-alignment of sheets is managed by email: news@printmonthly.co.uk Issue 341 - March / April 2023 adjustable straps allowing the machine to maintain accurate sheet position. “The top sheet, air suction deep pile feeder ensures reliable sheet feeding and can accommodate up to 400mm of printed sheets, whilst an 8” touch screen user interface provides for fast and efficient job changeovers,” Hillhouse says. “Maximum sheet size for the RDC is 368mm x 508mm, with a maximum die-cutting area of 361mm x 472mm. Material thicknesses of up to 400gsm can be cut. Running speeds of up to 6,000 sheets per hour make this the ideal unit for printers that anticipate regular long runs.” Keep work in-house Another leading manufacturer in this sector is Duplo. Martyn Train, managing director of Duplo UK, says the whole point of die-cutting is for consistent precision, and Duplo distributes the PFi Blade B2 and B3 machines, which, as digital die-cutters, do not need dies to produce intricate shapes Factoid ▲ Morgana’s AeroDieCut is suitable for shortto-medium-run work BACK TO BASICS / DIE-CUTTING ▼ Duplo’s diecutting equipment can be used to produce intricate shapes and applications
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