Efficiency and precision are non-negotiable in label printing, but traditional methods, while generally reliable, often fall short in meeting the soaring demand for rapid turnaround times and high-quality finishes. Semi-rotary die cutting is transforming the way that labels are printed and produced, offering printing businesses greater control over customisation, cost, and production times.
In this article, we’ll explore the advantages of semi-rotary die cutting and its impact on the label printing industry.
How does semi-rotary die cutting work?
Semi-rotary die cutting combines flatbed and rotary die cutting technology to achieve greater precision, versatility, and cost-efficiency while reducing turnaround times and waste. Unlike full rotary die cutting, in which the die continuously rotates and requires exact synchronisation with the substrate speed, semi-rotary systems use a single magnetic cylinder and interchangeable flexible die tools. The web moves in a start-stop motion, allowing the die to cut different shapes and sizes without the need to switch the tools for each job. 
Flatbed and rotary die cutting technology to achieve greater precision, versatility, and cost-efficiency while reducing turnaround times and waste. Unlike full rotary die cutting, in which the die continuously rotates and requires exact synchronisation with the substrate speed, semi-rotary systems use a single magnetic cylinder and interchangeable flexible die tools. The web moves in a start-stop motion, allowing the die to cut different shapes and sizes without the need to switch the tools for each job.
These are a few of the benefits for label printing businesses
- Enhanced versatility: Semi-rotary die cutting is adept at handling a range of substrate materials and sizes, including paper, film, and foil. This versatility makes the method ideal for short runs, customised shapes, and fast job changes, providing printers with the agility to meet their customers’ different needs and expanding the portfolio of services they are able to offer. At Focus Label, semi-rotary systems are an option on our Reflex & dFlex digital hybrid printing and finishing systems, as well as the Proflex & eFlex full converting lines.
- Cost-efficiency: With no need for a large inventory of expensive rotary dies tools for each specific printing job, semi-rotary die cutting is highly cost-effective, relying instead upon a flexible die which is cheaper and quicker to produce. This significantly reduces setup times and costs, making the technique economically viable for both short and long runs.
- Exceptional precision and quality: The start-stop motion of semi-rotary die cutting ensures that each cut is perfectly aligned and consistently accurate. The high level of precision is crucial for intricate designs and complex label shapes, ensuring high-quality outputs every time. Also, the magnetic cylinder maintains a stable die position, further enhancing the accuracy of each cut.
- Reduced waste: Efficiency in material use is another critical advantage of semi-rotary die cutting. By minimising waste by optimising at the cutting process, the technique ensures that the maximum number of labels can be produced from a given amount of material. As well as reducing costs, this also supports businesses in their drive to deliver sustainable printing.
- Faster turnaround times: With reduced setup times and the ability to quickly switch jobs, semi-rotary die cutting significantly shortens production cycles. Printers can respond to orders more quickly, enhancing their ability to meet tight deadlines and increasing productivity.
How is semi-rotary die cutting impacting the printing industry?
The adoption of semi-rotary die cutting is revolutionising the label printing industry. Especially for finishing of digital labels & pre-printed webs. Printers can now offer more customised solutions, cater to a broader range of applications, and achieve higher profit margins. Above all, the technology empowers businesses to remain competitive in a challenging market in which speed, quality, and cost-effectiveness are crucial to their success and longevity.
Find out more
For more information about our semi-rotary die-cutting machines or to request a free, no-obligation quotation for your business, please call Focus Label today on 0115 824 5486 or send our team an enquiry.
