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Rotary Die Cutting Equipment& Operations

11/03/2015 Parvesh Bravo 0 Comments

What Is Rotary Die Cutting?

Rotary die cutting is a type of die cutting process which uses a cylindrical die on a rotary press. It involves the feeding of a long web or sheet of material through a press into a “station”, which is an area that holds a rotary tool that will then make creases or perforations, or cut the web or sheet into smaller parts or specific shapes. A series of gears then makes the die rotate at the same speed as the press, to ensure that any cuts made by the die will line up with the printing on the material. Machines used in the rotary die cutting process often involve multiple “stations” that will die cut a particular shape into the material. Each station has one or more printing cylinders or geared tools. Some also will have automatic eye registration, which is utilized to ensure that the printing and/or cuts line up properly with one another, where precision is vital.

The dies that are used in the rotary die cutting process are adjustable dies, solid engraved dies, or magnetic plate tooling. Adjustable dies come with removable blades, which is useful if they need to be replaced due to wear and tear, or in order to cut a different type of material. Engraved dies are machined out of a solid steel bar (usually comprised of tool steel), and have a much higher tolerance. Magnetic plate tooling involves a cylinder with magnets on the inside, and an engraved metal plate wrapped or attached around the base of the cylinder, held in place by the magnetic forces.


Due to its versatility, die cutting is used in a wide variety of manufacturing processes for the purpose of cutting, forming, and shaping rolled and sheet metal. Because the process of die cutting is both relatively speedy, as well as highly precise, there are many custom types of die cutting. These include press, laser, flat bed, and rotary die cutting. Rotary die cutting is best suited to high volume projects, largely due to the fact that it features a quick turnover and produces very little waste compared to some other methods.

How Does Rotary Die Cutting Work?

The machines used in rotary die cutting consist of a heavy cylindrical anvil and a customized die. This die rolls over a flat surface which contains the female die features. Sheet metal, plastic, or paper, is then fed through the machine, typically from a spindle roll (or as flat individual pieces), which pass through the rolling die. This motion then works to cut or perforate the desired shape from the material. The Finished products are then deposited down the line, and waste material is caught and disposed of by a catcher.

As mentioned previously, rotary die cutting is normally sought after due to its high level of precision. Since the anvil can be controlled very precisely, the manufacturer can use it to determine the exact type and depth of the cut from the die. A specific example of the use of rotary die cutting is “kiss cutting”. This is where the cutting material does not have to come into contact with the fabrication liner.

In order to prevent wear and other damage to the steel dies within, it is best to only feed soft to semi-rigid materials through the rotary die cutting machines.

Applications of Rotary Die Cutting

While rotary die cutting is known well for the way it works on metals, it is also often used to cut plastic and paper. For example, rotary die cutters are used in the production of business envelopes, cardboard boxes, and even perforated tickets. Typically the items produced via rotary die cutting tend to be smaller items, due to the size of the machines and the precision involved.

Rotary die cutting is generally appropriate for projects that require:

- a high volume of products, all with a consistent cut

- very precise (low tolerance) cutting

- CNC application

- a quick turnaround

- multiple process projects (rotary die cutting can also be combined with embossing, lathing, coating, and other processes).

As mentioned before, rotary die cutting also produces less waste than other comparable methods, which is important for the conscientious manufacturer – and can lead to savings in terms of efficiency as well as being better for the environment.

Where To Get Rotary Die Cutting

One company that specializes in precision die cutting is Baril. Its operations include its multiple rotary die cutting machines, as well as its flagship machine, the Delta Crusader.

Baril’s precision die cutting operations and capabilities feature:

          Progressive die cutting (its machines are capable of registering multiple die cuts)

          The ability to cut intricate parts with multiple layers

          The ability to implement up to 8 webs in a single pass

          Excellent tolerances

          In-line machine vision inspection

          In-line laminating, slitting, and adhesive application available

Additionally, clean room rotary die cutting is also available, as is custom engineered production lines based on specific project requirements.

The advantages of Baril’s rotary die cutting services include its expert design, engineering, and material selection services. Baril works directly with clients from the beginning of the project right through to the end, ensuring that each project is able to deliver superior product functionality, as well as efficient economies of scale in manufacture and competitive economics. Baril’s consistent feedback from customers is that Baril product quality is the best in the industry; its track record of product durability and consistent quality is unparalleled among its competitors.

Baril’s multi-station, automated rotary die cutting presses have the capability to deliver high speed productivity as well as unmatched precision. Its rotary converting team ensures that all parts and components are manufactured effectively, by efficiently employing in-line laminating, slitting, multi-web capabilities and adhesive application.

While advanced engineering and creative design capabilities are crucial, Baril Corp views these capabilities as only one part of delivering top products to clients. To ensure that each customer project is successful, Baril is committed to delivering a premium quality program in the precision die cutting industry. To achieve this, the corporation has adopted extensive systems and quality processes, and its facilities have been ISO 9001:2008 and ISO 13485:2003 certified.