How to Effectively Improve the Quality of Die-cutting？

The correct choice of pressure sensitive adhesive material effectively improves the quality of die-cutting in several matters needing attention.

1. Do not use die-cutting paper material die cutting plate ie cutting film material because the blade has been worn, and is not suitable for die-cutting film.
2. Flat pressing dies cutting, as far as possible to reduce the die cutting area, especially full plate small label, because the board is large, row knife, quality is difficult to ensure.
3. Flat pressing flat dies cutting plates to often replace, especially processing long plate live, because the cut mark will affect the quality of the new format label die cutting.
4. Flat pressing die cutting, die cutting strength should be just right, this is the master’s knife technology, and sometimes prefer to cut some shallow.
5. Often check the quality of die cutting, especially automatic labeling labels. To avoid mass quality problems. The specific detection method is to smear the release paper with a signal pen to check the penetration of the cut marks on the release paper.
6. Die-cutting large areas, and complex patterns of labels, to professional manufacturers to make die-cutting plates, so as to ensure the precision of die-cutting.
7. To keep the blade sharp, establish a file, and record the use of each die-cutting plate, in order to replace the blade in time. To use small angles, high hardness of special blade die cutting film pressure sensitive adhesive materials, especially PE materials.

Effect of adhesive on die cutting

There are 4 types of adhesives commonly used in pressure-sensitive adhesive materials:

1. Acrylic water-based pressure sensitive adhesive
2. Rubber hot melt adhesive
3. Ssolvent rubber
4. Acrylic adhesive

Due to the different raw materials and formulations of adhesives, the physical and chemical properties are not the same. Water latex is composed of tiny capsules, relatively small cohesion, and easy separation between the film.

In the die cutting pressure sensitive adhesive material, if the die cutting is not in place, either the label and the waste paper edge together are stripped, or the release paper is cut through. Because the hot melt layer can only be completely cut off (or most of the cut off) to normal waste, otherwise not cut through the film will be stripped together with the label, improving the difficulty of die cutting.

Therefore, it is relatively easy to die-cut latex pressure sensitive adhesive materials, and hot melt adhesive pressure sensitive adhesive materials have higher requirements for die-cutting technology. This is also the processing of hot melt adhesive material consumption, the main reason for low production efficiency.

The influence of the substrate of pressure sensitive adhesive material on die-cutting

The main factors affecting the quality of die cutting are the type of substrate, strength, and thickness.

1.  The type of substrate

The substrate can be mainly divided into paper and film two categories. The cutting principle of ordinary paper is slightly different from that of film materials. Based on the die-cutting characteristics of paper materials, and taking into account the wear of the blade, the Angle of the flat die-cutting blade is usually specified as 52 degrees, if the Angle is large, the extrusion deformation of the material is large, that is, the horizontal separation force will make the material fracture separation phenomenon intensified.

The die-cutting of thin film materials is simply the process of completely cutting through. Because thin film materials are mostly ductile and will not break naturally, it is not suitable to cut through two-thirds. It is necessary to cut through completely or four-fifths of the thickness, otherwise the product will be stripped together during waste discharge.

Die cutting film material blade is too sharp, high hardness, to use a small Angle die-cutting knife, the blade Angle is usually 30°~ 42°. If the use of a large Angle dies cutting knife, not only die cutting is difficult, and if the blade is not sharp there will be substrate cutting not through, release paper fracture, or the edge of the die-cutting product flanging phenomenon, resulting in gluing.

In short, the precision of die-cutting film is higher than that of paper materials, so die-cutting film materials have certain requirements for equipment accuracy, die precision, and release paper.

2. The strength of the substrate

The strength of the substrate and substrate thickness, fiber (polymer) structure, and its own humidity. In the die-cutting process of pressure sensitive adhesive materials, the factor related to the substrate is the waste removal speed. The greater the humidity of the environment, the weaker the strength of the material after moisture, so that it is easy to break, or even unable to discharge waste.

Layout design, according to the strength of the material, through the test reasonable arrangement of die-cutting product waste size and waste speed, which can not only improve production efficiency but also reduce material waste.

3. The thickness of the substrate

The thickness of the material directly affects the depth of die cutting, the thicker the material, the easier it is to die cut. Because the thicker the material, the greater the die-cutting tolerance, and the less chance of cutting through the release paper. Relatively thin material, easy to cut through the release paper failure.

So die cutting thin substrates, must be carried out on high precision equipment, as far as possible to reduce the die-cutting area (especially small products), the use of professional die manufacturers of the die.

The thickness of the substrate is proportional to the strength, which directly affects the discharge rate. Can respectively use 80g/㎡ and 60g/㎡ material to do a waste comparison test, the result is that the former than the latter production efficiency increased by 20% to 30%.