Semi-rotary die cutting is an important technological innovation in the field of label and package production. Although not a new process it has taken on a new life in recent years with the increase in popularity of digital printing and low volume production runs.
In this article, we will explain five of the main efficiency benefits of semi-rotary die cutting that can make a big difference to your operation.
What is semi-rotary die cutting?
Semi-rotary die cutting is a process used in the printing and packaging sectors to cut items such as stickers, labels, and packaging into precise shapes. The technology combines elements of traditional rotary die cutting with greater flexibility that makes it more suited to short-to mid-sized print runs and variable data requirements. The main difference is that the main tool is fixed with the unique cutting form supplied as a flexible plate mounted to the die tool. The main Tool moves in partial rather than full rotation, enabling the same tool to handle different lengths and designs without needing replacement or adjustment between jobs.
Benefit one: less wastage
Semi-rotary die cutting gives you both precision and flexibility in your cutting processes, wasting less material during the initial set-up process if compared to full rotary equipped machines. The Die forms are easy to change and less costly than a full rotary die forms and will reduce your overall tool inventory.
Benefit two: quicker turnaround
Semi-rotary is also faster to change than full rotation systems because they require less regular switching of the main tool between jobs. This can significantly reduce setup times when changing the design form, substrates, or tools, minimising downtime and enabling faster print finishing cycles.
Benefit three: cost savings
Another benefit of being able to use the same tool for multiple applications is money saved on tooling. Without the need to purchase bespoke rotary dies tools for each product or design, semi-rotary systems are cheaper and more cost-effective to set up, while also allowing you to serve a more diverse range of markets and manage multiple design changes.
Benefit four: precision and consistency
Semi-rotary die cutting systems can also be more precise and consistent than rotary systems, helping you maintain higher levels of quality in your label production processes. The cutting output of modern semi-rotary systems is incredibly accurate, delivering perfect alignment on each unit, even when working with intricate shapes and complex designs. Furthermore, once your machine is set up, it can create runs of thousands of identical units without any variation, with a very low risk of misaligned cuts and uneven edges.
Benefit five: Short runs and personalisation
The demand for hyper personalisation and small batch sizes are some of the most important developments in the global print management sector, forcing suppliers to increase the flexibility of their services. In this regard, semi-rotary die cutting is perfectly optimised for short production runs and variable designs, giving you the agility to respond quickly to market changes and customer requests.
Find out more
Get in touch with Focus Label today to discover how our range of printing & digital finishing machines and semi-rotary die cutting can transform your operations and increase profitability.
Image source: Canva
