Post-press die-cutting tape technology that printing practitioners should know

With the rapid growth of modern industries such as mobile phones, electronics, and electrical appliances, the packaging tape industry has evolved to meet specific demands. This has led to the development of specialized die-cut tapes used in roll-shaped packaging. As a result, post-negative die-cut technology has emerged, enhancing precision and efficiency in the production process. Die-cutting is one of the most common techniques used in packaging tape manufacturing. It involves using a die cutter to create a cutting plate based on the design specifications. Under pressure, the tape or other material is shaped into the desired form. In addition, creasing is an essential step that uses a crimping knife or die to press lines onto the material, enabling it to fold at precise locations. This allows for accurate and clean folding during the final product assembly. The die-cutting and creasing process typically combines both cutting and embossing tools within the same template. This integrated approach, known as die-cutting, streamlines the production workflow. The main steps involved are: setting up the upper version, adjusting pressure, determining spacing, applying the rubber strip, testing the pressure, performing the formal die-cutting, removing waste, inspecting the finished product, and finally packaging it. Before proceeding with mass production, the die-cut version must be proofread to ensure it aligns with the original design. Key factors to check include the accuracy of the steel wire (crimping knife) and steel knife (die-cutting knife) positions, whether the slotted and holed cutting lines are continuous and smooth, and whether the curve transitions are rounded. To make cleaning easier, adjacent narrow waste edges should be connected with additional parts to form a single piece. Any sharp corners or misaligned lines should also be addressed. If any issues are found, the plate-making team should be notified immediately to avoid delays and waste. Once the die-cut version is approved, the plate is installed in the die-cutting machine, and its position is adjusted accordingly. Next, the pressure is fine-tuned. The pressure of the steel knife is adjusted first, followed by the application of padding. After starting the machine and pressing several times to level the blade, a larger cardboard sample is used to test the pressure. Based on the cuts made, the pressure is gradually adjusted until uniform pressure is achieved across all cutting lines. Typically, the steel line is set 0.8mm lower than the knife line, depending on the type and thickness of the corrugated cardboard being used. The backing paper thickness is calculated based on the material's thickness, ensuring that the rubber bullet can function properly. The rubber bullet strip should be placed on either side of the main steel knife, allowing it to push the cut material away after each cut. Ideally, the rubber band should be about 1.2mm higher than the blade, with a 1–2mm gap between the rubber and the blade. This prevents the material from being pulled sideways before being fully cut, reducing the risk of paper fibers and improving overall quality. After the setup is complete, a trial die-cut is performed to ensure everything works correctly. Once the sample passes inspection, full-scale production begins. Throughout this process, the operator plays a crucial role. They should be well-trained and perform regular self-checks, comparing the output with the original proofs to identify and resolve any issues promptly. Following the die-cutting, excess edges are removed, and the burrs are smoothed out to ensure a clean finish. The finished products are then inspected, defective items are discarded, and the remaining ones are labeled, packaged, and stored. As the industry continues to evolve, the integration of information technology is expected to further improve efficiency and accuracy in the packaging tape manufacturing process.

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