DDIN Library

Flatbed vs. Rotary Die Cutting

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Written by Robert Larson

Why would a converter prefer rotary diecutting over flatbed diecutting? I think that the most basic reason is economic. When you consider the costs of diecutting component parts of a product, if you have large volumes of parts to be diecut such as labels or corrugated boxes, rotary diecutting can provide a lower per cut piece cost vs. flatbed diecutting. Initial equipment costs and tooling costs for rotary diecutting tend to be more expensive for rotary diecutting vs. flatbed diecutting.

John Ward's development of the first rotary diecutting press system in 1962, introduced a whole new segment of the diecutting process developed in the narrow web printing process. Today with in-line printing, diecutting and stripping, many items like labels could be printed and diecut very fast and economically over previous flat die techniques.

Utilizing rotary cutting dies, the speed of rotary diecutting increased productivity for long run diecutting applications. For example, in the label industry whereas labels used to be die cut on flatbed presses, today almost all labels are produced on rotary die cutting press systems. We will explore this area more in future chapters. Whereas most all steel rotary anvil dies were the standard for rotary tooling, today magnetic cylinders with chemically etched magnetic dies are taking over in many rotary applications. For example, in a recent report on diecutting, it was stated that in North America, 25% of rotary applications are using magnetic flexible dies while 75% of applications are still using hard anvil or segmented rotary dies. In contrast in Europe, 75% of rotary applications use magnetic flexible dies and only 25% of rotary diecutting applications use hard anvil rotary tooling.

There are several methods of rotary diecutting in the marketplace to include hard anvil rotary diecutting, soft anvil rotary diecutting and magnetic flexible rotary diecutting. We shall go into more detail on each of these systems of rotary diecutting in Part 3 of this book.

When considering using rotary diecutting vs. flatbed diecutting many converters used to flatbed diecutting may have the following concerns.

1. Cost of tooling is too high

2. Cost of equipment is too high

3. Problems cutting thick, hard materials

4.The lack of knowledge of the process (fear of the unknown)

Tooling Costs

When comparing the cost of tooling between the two processes, there is no doubt that the rotary tooling had usually been more expensive. However, the usable life of a rotary die will be much longer than that of a steel rule die cutting the same material. Die life can now be extended even further with tougher steels and new coating processes. In the past 10 years magnetic flexible rotary dies have entered the rotary diecutting scene. Magnetic rotary dies are far more economical than their hard anvil dies. Also soft anvil steel rule rotary dies for use in diecutting corrugated boxes, for example, are more economical than their hard anvil counterparts.

Rotary Diecutting Equipment Costs

The rotary die cutting process in many cases is much faster than flatbed diecutting with line speeds running up to 200 feet (or more) per minute. When comparing the cost of die cutting equipment for the two processes, I don’t think that there is much of a debate. Both types can vary all over the map. Depending on the bells and whistles the costs can easily be $250,000 and over for more for a flatbed diecutting system. Having said that, there is also a great deal of used rotary equipment available in the $25,000 to $50,000 area.

Again, this is an area that may require some outside advice. For example, if your products tend to be on the “difficult to die cut” end of the spectrum, you would be ill advised to purchase equipment used for flexographic printing and die cutting. Buying the right equipment will save you money and headaches in the future. The type of material that you need to diecut often determines whether you need to use flatbed diecutting or rotary diecutting.

Cutting Thick or Hard Materials

Another common question of owning rotary diecutting equipment has been the perception that many materials that a converter wants to diecut are too hard, too thick or too abrasive etc., etc. Unless you’ve been involved in the rotary die business within the last five years, you would be amazed at the progress that has been made as far as extending die life and the “difficult to die cut” materials that are now being processed on a more profitable basis.

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