How to choose label die-cutting equipment? Keep these key points in mind!

Die-cutting is a crucial process in the production of self-adhesive labels. It can be said that most labels must go through die-cutting before they can be finally formed. Currently, there is a wide variety of equipment available in the market for die-cutting self-adhesive labels, making it difficult for label printing companies to choose. So, what are the advantages and disadvantages of the different types of self-adhesive label die-cutting equipment? How should label printing companies select these die-cutting machines when purchasing them? In this article, the author will discuss these questions with readers. Based on different working principles, the mainstream self-adhesive label die-cutting equipment in the market can be categorized into six types: rotary die-cutting, flatbed die-cutting, semi-rotary die-cutting, combination type, laser, and digital die-cutting. 01Rotary Die-Cutting EquipmentThe rotary die-cutting equipment uses die-cutting tools in the form of engraved rolls or magnetic knife sleeves attached to magnetic rolls. Since it is equipped with a rolling die rather than a flat die, when viewed from the side, the tool appears round. During die-cutting, the die roll and the impression roll come together, resembling two rolls pressing against each other, hence the name 'rotary die-cutting'.In fact, there is a tiny gap between the die roll and the impression roll, precisely the thickness of the backing paper of the self-adhesive material, while the face layer and adhesive layer are completely cut. Because the outer circles of the two rolls are nearly tangent during operation, this line-contact mode allows the relative movement between the plate roll and the impression roll to be controlled within 3 μm during operation, making the die-cutting pressure relatively stable. This method is especially suitable for labels that require high die-cutting quality. For example, labels that need to be automatically applied at high speed not only experience high pulling forces but also require that the backing paper not be damaged; otherwise, the labels may break during labeling. For such labels, rotary die-cutting is the optimal method. According to the operation mode, the mainstream rotary die-cutting equipment in the market today can be divided into two types: intermittent rotary die-cutting machines and full rotary die-cutting machines. Intermittent rotary die-cutting machines utilize reciprocating paper feeding (the equipment is equipped with a servo-controlled swing arm, which moves the material back and forth). When the plate roll reaches the die-cutting position, the material moves forward; when the plate roll reaches a blank position, the material moves backward.

The advantage of this design is that the same plate roller can be used to die-cut products of various lengths, provided that the maximum length of the product does not exceed two-thirds of the roller's circumference. Once this range is exceeded, the die-cutting speed of the equipment will drop significantly. Generally, intermittent paper-feed die-cutting equipment operates at speeds of 40 m/min to 60 m/min. Full rotary cylinder die-cutting equipment uses a continuous paper-feed, achieving speeds of 80 m/min to 150 m/min; however, when die-cutting products of different lengths, it is necessary to replace the roller with a corresponding diameter, which is costly.Although rotary-to-rotary die-cutting equipment maintains relatively stable die-cutting pressure and high die-cutting quality, the tool cost is also high. Currently, the price of magnetic dies on the market is usually between 250 and 350 RMB/m, and the cost of making a magnetic die can range from several hundred to several thousand RMB. The cost of making an engraved die roller is even higher, starting at 3,500–4,000 RMB. Therefore, rotary-to-rotary die-cutting is more suitable for large batches or products of different types but the same specifications (allowing shared dies).02Flat-to-flat die-cutting equipmentFlat-to-flat die-cutting equipment uses a flat plate die, with the die-cutting station consisting of two parallel planes. The die is generally mounted on the upper plane, while the lower plane serves as the die-cutting platform. During die-cutting, the two planes move vertically, and the adhesive material is moved by a traction motor or paper feed lever. When the planes press together, the die contacts the adhesive material and cuts through it. This equipment primarily relies on tracking sensors and its own computer program to ensure each paper feed is accurate, guaranteeing precise positioning of the die-cut pattern.The advantages of flat-to-flat die-cutting equipment include compact size, high speed, high precision, low noise, and minimal vibration. Mainstream flat-to-flat die-cutting machines on the market can operate at 400–450 impressions/min, with die-cutting accuracy controlled within ±0.2mm. Moreover, the cost of the die plates used in flat-to-flat machines is relatively low, generally only a few dozen to a few hundred RMB, which does not significantly increase costs for small batch orders.It should be noted that due to the design principles of the machine, flat-to-flat die-cutting equipment has lower stability compared to rotary-to-rotary die-cutting equipment. Occasionally, it may cut into the backing paper, especially at high speeds, making this problem difficult to avoid. Therefore, for products requiring exceptionally high die-cutting quality and very large orders, flat-to-flat die-cutting equipment has certain limitations.03Angled flat die-cutting equipmentAngled flat die-cutting equipment, also called inclined-back die-cutting equipment, has a certain tilt angle between the upper and lower planes. Its working principle is essentially the same as flat-to-flat equipment; it die-cuts by the vertical movement between two planes. When the planes press together, the die contacts and cuts through the adhesive material.The advantage of inclined-back die-cutting equipment is its high speed, high precision, and lower price compared to flat-to-flat equipment. Its disadvantages include a larger size, higher vibration, and noise, making it more suitable for placement on the ground floor of a production workshop. If placed on other floors, consideration must be given to whether the building's seismic strength can support such equipment, otherwise safety hazards may arise.Currently, although some leading die-cutting equipment manufacturers have made improvements to address the drawbacks of inclined-back die-cutting equipment, it still has the potential to be replaced by flat-to-flat die-cutting equipment.

04Modular Die-Cutting EquipmentAs the name suggests, modular die-cutting equipment refers to devices that, in addition to die-cutting functions, also integrate other functions such as flexographic printing, coating, lamination, and cold foil stamping. This type of all-in-one post-press equipment is more appropriately called a post-press processing center. It can meet diverse and personalized customer needs, allowing companies to select the combination units that best suit their orders. Furthermore, some special functions can be added to the modular die-cutting equipment to achieve unique capabilities not available in other devices.This modular die-cutting equipment has many advantages. Companies can choose the appropriate die-cutting method based on the characteristics of the product, either rotary die-cutting or flatbed die-cutting, or even combine both methods in one machine. The drawback is the high equipment cost; the price of a single modular die-cutting machine ranges from several hundred thousand to several million yuan. Specific functions need to be customized according to the company's needs, and small-scale label printing companies with limited financial resources often cannot afford to purchase such equipment.05Laser Die-Cutting EquipmentLaser die-cutting equipment is a type of device that uses computer-controlled laser beams to cut materials. The advantage of this equipment is that no die is needed, and the shape of each label can be varied. Since digital printers also have variable printing capabilities, laser die-cutting equipment is the perfect companion for digital printing, suitable for ultra-short runs as well as small batch and personalized orders. In addition, compared to traditional die-cutting equipment, laser die-cutting equipment can also cut complex patterns, such as maps with intricate die lines.The disadvantages of laser die-cutting equipment are its high cost. A high-quality laser die-cutting machine typically costs around one million yuan. Additionally, as the laser generates heat when cutting materials, it can cause issues with soft thin-film adhesive materials, such as white PE, potentially leading to edge shrinkage or yellowing during cutting.06Digital Die-Cutting EquipmentDigital die-cutting equipment is a new type of die-cutting device that has emerged in recent years. This equipment uses computer-controlled robotic arms with blades to cut the required shapes from materials. The advantages include the ability to perform variable die-cutting, low tool costs, and a cold die-cutting process that does not generate heat, thus preventing shrinkage or yellowing of film materials. However, the main drawback of mainstream digital die-cutting equipment on the market is its relatively slow speed, making it suitable only for small batch orders.

Above, the author has introduced the advantages and disadvantages of six mainstream die-cutting machines on the market. So, how should label printing companies choose the die-cutting equipment that suits the characteristics of their products? Ultimately, it comes down to selecting based on the company's order situation and product structure.If a company mainly handles large-volume orders and requires high die-cutting quality, it is recommended to choose rotary die-cutting equipment; if the company mainly handles medium to small-volume orders and has relatively lower die-cutting quality requirements, high-speed flatbed die-cutting equipment can be considered; if the company mainly receives ultra-short or personalized orders online, digital die-cutting equipment is recommended; if the company primarily engages in digital printing, it would be worth considering laser die-cutting equipment; if the company mainly produces products with complex processes and has long or complicated post-printing procedures, combination die-cutting equipment is recommended.Today, many label printing companies own more than one or even more than one type of die-cutting machine, and can choose the most suitable equipment according to the specific order during production. It can be anticipated that with the continuous development of self-adhesive label production technology, combination die-cutting equipment will become the main die-cutting equipment for label printing companies.