Flat Knife Die-cutting VS Round Knife Die-cutting, Who Is Stronger? Compete With The Advantages And Disadvantages, Let You See At A Glance!

Die-cutting is an important post-press link in the manufacturing process of self-adhesive labels, especially most roll self-adhesive labels need to be die-cut after printing. At present, there are many die-cutting methods on the market, such as flat knife, round knife, laser, digital die-cutting, etc. Among them, flat knife and round knife die-cutting are currently the more mainstream die-cutting methods. So, what are the advantages and disadvantages of these two die-cutting methods? What is the most concerned about the cost and life of label printing companies? In this article, the author will discuss and analyze it with you, hoping to give readers some help.

Analysis of the working principle and advantages and disadvantages of flat knife die-cutting

Flat knife die-cutting working principle

Flat knife die-cutting, as the name suggests, is a way to flatten die-cutting using flat knife templates. Specifically, the plate and pressing mechanism of the flat flattening die cutting machine are flat-shaped, the plate table and the pressure plate are vertically flat, the knife template is attached to the pressure plate, and the printed label material passes between the plate table and the pressure plate. When the die cutting machine is working, the vertical movement between the plate table and the pressure plate, the material is pulled forward by the traction motor, and when passing between the plate table and the pressure plate, the plate table and the pressure plate are pressed, and the die cutting knife attached to the pressure plate is in contact with the material surface and cuts the material.

According to the different trajectory of the pressure plate, the mainstream flat knife die-cutting equipment on the market can be divided into two categories: diagonal back type and flat pressing type. The diagonal flat knife die-cutting equipment has a certain inclination angle between the plate table and the pressure plate during operation, while the flat flat knife die cutting equipment moves vertically up and down the plate and the pressure plate during operation. Relatively speaking, the structure of flat flat knife die-cutting equipment is more advantageous, because of its fast speed, small footprint, and light vibration, while the diagonal flat knife die-cutting equipment is also light The floor space is large, and the vibration is large, and the noise during operation is relatively large.

Analysis of the advantages and disadvantages of flat knife die-cutting

(1) The cost of flat knife die-cutting knife plate is low. At present, the price of flat knife die-cut blade is generally calculated by the length of the knife strip used in this blade, generally speaking, the price of domestic knife blade is 50~60 yuan / linear meter, less than one along the meter is charged at about 60 yuan basic knife fee; The price of imported knife strips is 90~100 yuan / linear meter, and the basic knife fee is charged at about 90 yuan for less than one meter. In addition, if the production of the knife plate is difficult, the fee ranging from 30~80 yuan will be charged according to different situations. Generally speaking, the cost of making a flat knife template is between tens and hundreds of yuan, which can greatly save the cost of the knife mold, improve the success rate of receiving orders, and is more suitable for small and medium-sized orders with low profits

(2) The life of the knife plate of flat knife die-cutting is relatively low. Generally speaking, die-cut paper materials, its service life is between 20~300,000 times; Die-cut film materials, their service life is less than 100,000 times.

(3) Compared with round knife die-cutting, the die-cutting speed of flat knife die-cutting is low. Under normal circumstances, the die-cutting speed of round knife die-cutting equipment is 80~150m/min, the die-cutting speed of traditional flat knife die-cutting equipment is 20~40m/min, the die-cutting speed of the mainstream high-speed flat-knife die-cutting equipment on the market is 40~60m/min, and the die-cutting speed of high-speed flat-knife die-cutting equipment can fully meet the die-cutting needs of small and medium-sized orders, but when making large orders, its die-cutting efficiency is still not as good as that of round knife die-cutting equipment.

(4) The die-cutting pressure is unstable.Flat knife die-cutting equipment in the die-cutting process pressure will gradually become larger or smaller, need the operator to pay attention to observe the die-cutting effect at any time and make corresponding adjustments, the use of flat knife die-cutting equipment for products with high die-cutting indentation requirements will have certain risks. Although the stability of the die-cutting pressure of the high-speed flat knife die-cutting equipment launched on the market in recent years has been greatly improved, the limitation of the design principle of the flat-knife die-cutting equipment itself cannot completely solve this problem. Although flat knives can also achieve high-precision die-cutting, the expensive cost of engraving knives and corrosion knives makes them less common.

Analysis of the working principle and advantages and disadvantages of round knife die-cutting

Working principle of round knife die-cutting

Round knife die-cutting refers to a way of pasting a magnetic knife skin on a magnetic roller or using a carving knife roller to die-cut. Since the knife roller is round, and the matching imprint roller is also round, this die-cutting method is a die-cutting method of circular pressing circle. The circular die cutting equipment adopts the principle of line contact, and the upper and lower rollers will be pressed together during die-cutting, and the knife die will contact the material and cut off the material. This line contact method makes the die-cutting pressure relatively stable, more suitable for processing products with particularly strict requirements for finished product indentation, such as products that require high-speed automatic labeling, due to the fast labeling speed, the label backing paper is subjected to a large tensile force per unit time, it is easy to break, if the round knife die-cutting method to process such products, you can do the base paper without indentation, This ensures that the liner will not be pulled off during the high-speed labeling process.

Analysis of the advantages and disadvantages of round knife die-cutting

(1) The cost of round knife die-cutting is high, and it is not suitable for small and medium-sized orders. At present, the price of magnetic knife skin on the market is generally 250~350 yuan / m, and the cost of making a round knife ranges from hundreds to thousands of yuan. If it is to do the engraving knife roller cost is higher, the current market price is 600~800 yuan / m, the lowest starting price of the cost of a carving knife is also about 3500~4000 yuan.

(2) The service life of the knife plate cut by the round knife die-cutting is related to the material cut Generally speaking, the thermal paper material is cut by die-cutting with a hard-coated magnetic knife skin, and its service life is between 70~100 times; Die-cut film material, its service life is about 50~600,000 times. The service life of the same kind of material die-cut with a magnetic knife skin without hard coating is only 1/2~2/3 of that of a hard coated magnetic skin. In addition, the engraving knife roller can not be hard coated on its surface, so its service life is similar to that of the magnetic skin without hard coating, but the engraving knife roller can be repaired 2~3 times.

(2) Round knife die-cutting equipment can be used independently or online with the printing machine 。 At present, the mainstream independent round knife die-cutting equipment on the market is divided into batch and continuous two, the main difference between these two equipment is that the intermittent round knife die-cutting equipment can be intermittent paper feeding, so that a knife roller can be used to die-cut products of different lengths, and the continuous round knife die-cutting equipment is continuous paper feeding, so the knife roller corresponding to the number of teeth must be replaced when die-cutting products of different lengths, the cost of the knife roller is higher than that of intermittent round knife die-cutting equipment, but its speed is also higher than that of intermittent round knife die-cutting equipment. Generally speaking, the speed of continuous round knife die-cutting equipment is 80~150m/min, and the speed of intermittent circular knife die-cutting equipment is 40~60m/min.

(4) The die cutting pressure of the round knife is stable and the die cutting accuracy is high. In general, the runout range between the two rolls of the round knife die-cutting equipment is within 3 μm. This fluctuation range can well ensure the stability of die cutting pressure and die cutting accuracy, and product round knife die cutting with high requirements for die cutting accuracy is the best choice.In general, round knife die cutting is characterized by fast speed, high precision, and relatively long service life of the knife plate, but the cost of the knife die is also relatively high, which is more suitable for some order production with high requirements for die cutting accuracy and large number of die cutting.