Global Web Finishing offers industry proven and accepted rotary die cut tooling, which has been used for decades in industry proven and accepted machinery designs.

In some printing segments and many other industries, die cutting is the same process on the same materials every day. Identifying the correct die tooling and machine design is relatively simple.

Steel to steel die cutting for web finishing in the high volume direct mail segment is different. There is very little chance for a one size fits all approach. Prior to purchase, your specific die cutting needs should be evaluated so that the correct machine and tooling are purchased. This is GWF’s specialty in rotary web print finishing die cutting.

And although rotary die cutters are relatively simple designs in terms of cylinder configuration, etc., these machines require high levels of design integrity and know how due to the precision nature of the die tooling, variety of paper types, and print product format applications for consistent high performance steel to steel die cutting.

GWF builds the highest quality machinery designs for the two types of recognized die tooling used in our industry segment today.

First for photochemically etched; shallow relief or “flexible” steel dies normally .021” (.533mm) to .040” (1.0mm) in gauge. These dies are most often mounted to a magnetic cylinder and likely designed originally for the pressure sensitive label industry.

These dies are generally only good cutting through a woven web of single thickness. Product formats well suited to these dies include envelope windows, integrated stickers/labels, dry peel kiss cut cards, and sculpted edge cutting of the web.

Next GWF builds die cutting couples designed to use “solid” type dies which are formed and shaped die rule steel blades molded in plastic for support. These are commercially available and normally designed at .375” (9.525mm) or .625” (15.875mm) in height per die cylinder undercut.

GWF machines designed to use “solid” die tooling will produce the same aforementioned products that the “flexible” dies produce, albeit at a greater expense. The same is not true, however, going the other way. Solid dies are made for heavy duty cutting of multiple thickness plies of woven web and will absorb punishment that “flexible” dies will not.

Other strong considerations for die cutter type selection involve required location(s) of equipment which is again based on desired production needs.

Many requests for GWF die cutters are for portable machines. Portable die cutters often serve double duty as an “inserter” for “closed end mailers” or “multi-ply paper card” products inside inline finishing systems. The drawback remains that portable machines are most often only partial (half) web width. Some die cut applications must take place on a full width flat web before ribboning or folding, while other product applications require the web to be processed into a specific format before die cutting takes place.

Die cutters are not a one size fits all situation and it is prudent to discuss your specific requirements with someone who cares as much as you about the outcome. GWF has ideas and industry proven equipment designs for any and all of your die cutting needs.

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