Die-cutting is a manufacturing process that is popular in the packaging industry. However, only packaging experts may have a solid idea of the die-cutting process. Die-cutting originates from the letterpress printing process. Over the years, it has evolved into a more specific manufacturing process. In the packaging industry, the process utilizes a die for cutting materials into different shapes, patterns, and designs for custom die-cutting packaging solutions.
It’s mostly used to manufacture folding carton packaging. These packaging solutions are tailored to meet the brand’s narratives and create an excellent customer experience. It’s a valuable process offering an easier, faster, and more affordable way of producing custom packaging in bulk.
What Is Die-Cutting?
Die-cutting is a process where a manufacturer uses a machine to produce large numbers of cut-out shapes, similar to a giant cookie cutter. Interestingly, die-cutting can be used in the factory or at home. It’s commonly used for mass cutting in the packaging industry, as die-cutting packaging offers several benefits. There are currently three types of die-cutting machines which are:
- Digital die-cutting machines
- Manual die-cutting machines
- Industrial die-cutting machines
The digital die-cutter is an advanced and user-friendly die-cutting machine. It’s easy to operate and can be used at home. The digital die-cutter is powered by electricity and works by relying on computer cartridges that have pre-loaded images. The digital die-cutter has a sharp blade for cutting materials rather than a steel die.
The manual die-cutting machine, as the name implies, is operated manually, unlike the digital die-cutter. It’s designed with an easy cranking lever for activating steel dies used to cut materials. The manual die-cutters are often smaller than other types of die cutters, making them perfect for craft tables at home.
Industrial die-cutters are more advanced than manual die-cutters. They’re designed to withstand rigorous usage and are used in the manufacturing industries for large-scale production. For instance, they’re used in the packaging industry to produce large-scale die-cutting packaging. Industrial die-cutters use electricity like digital die-cutters. Also, the processes it uses for cutting materials are automated, ensuring that more shapes are produced at a faster rate.
The three types of die-cutters are fitted with either a rotary cutter or a flatbed cutter. The rotary cutter uses pressure applied to a rounded anvil to form the shapes that cut down onto the die. In contrast, the flatbed cutter cuts the material into shapes when they are passed through a hydraulic press. An advantage die-cutters have over scissors is that they cut the shapes into the same measurement every time. This makes them perfect for the production of custom die-cut products and packaging.
Which Materials Can A Die-cutting Machine Cut?
A die-cutting machine can cut several materials like thin wood, metal, paper, foam sheets, thin plastic, and fabric. However, it’s important that manufacturers, even die-cut foam manufacturers, cut only thin materials with die-cutting machines. This ensures that nothing gets broken during production. Other materials that can be cut with a die-cutter include adhesives, chipboard, rubber, corkboard, leather, vinyl, and sponge.
Benefits Of Using Die-cutting Machine In The Packaging Industry
Die-cutters have helped die-cut packaging manufacturers improve product quality, production speed, and customer satisfaction over the years. This has also helped them manage the increasing demand that comes to a rapidly growing business. Some of the reasons why many manufacturers have adopted die-cutters for their process include the following:
- They can be used to cut multiple materials
- They improve accuracy
- They reduce wastage
- They speed up the production rate
They Can Be Used To Cut Multiple Materials
As stated above, die-cutting machines can be used to cut a variety of materials. This offers manufacturers in the packaging industry absolute flexibility for the production of die-cutting packaging solutions.
They Improve Accuracy
Another benefit of using die-cutters is their ability to cut materials into the exact shapes and patterns needed. This high level of accuracy provides manufacturers the ability to remain uniform during production.
They Reduce Wastage
The ability for die-cutters to cut different materials into the exact shape, size, designs, and patterns needed also helps to reduce wastage. The more accurate manufacturers can cut their production materials, the fewer waste products they will have.
They Speed Up The Production Rate
Industrial die-cutters used in the packaging industry are automated and designed for large-scale production. They are very fast and can cut hundreds of pieces in minutes. This fast-cutting rate helps to improve the production rate when manufacturing packing products. It also helps a manufacturer achieve better efficiency during production.
Do you need a reputable die-cut packaging manufacturer that can meet your packaging needs? Contact RipplePak today for the best quality die-cut packaging in Canada. We’re a packaging company that uses the principles of thermodynamics and the appropriate raw materials to design functional and effective packaging and insulation products. We’re dedicated to providing innovative products and services to our customers, which include cold chain solutions, moving supplies, packaging material, and Insulapack Insulation.