Adjustment to the 1 mm-System

Before we start thinking about using the 1 mm system let us introduce this specific way of working to you.

Most of the details are not new for the packaging industry, because the system is used for more than a decade but we think it is important to explain it again.

Of course we have to start in the early beginnings of all die cutting processes. Originally a hard (50 - 52 HRC) 4, 5 or 6 mm cutting plate was used. That means the hardness of the die rule was roughly the same as the cutting plate (~50 HRC). Millions of strokes of the die rule on the plate influenced the cutting quality in a negative way in the long run as the tips of the knives wear out.

By taking a close look on this process two main disadvantages were figured out. First to be mentioned is the weight of the original cutting plates, especially with regard to the bigger formats for corrugated board. More physical effort has to be put in for preparing new jobs as the plates are quite heavy. Second is the higher setting time as only a few cutting plates were stored and so all creasing matrix had to be removed and put on for each new job. That´s why the 1 mm system was invented.

You have the choice between four different hardness that suite best for your jobs. Due to the thickness of only 1 mm the weight is just a fraction of the weight of the original plate, so mainly all jobs can be prepared by just one person. Additionally the wear of the knives and rules is less as you can choose between soft and medium hard cutting plates.

So touching the plates with the knives is more or less intended to make sure to have a clean cut without any damage on the rules. As a positive side effect less “Angel hair” is a result of this system, too. But more than that, it mesh perfectly with the changings in the packaging industry. In the past order volumes may have been a quarter of a millions packages. To save money and stock capacities packaging manufacturers as well as end users prefer splitting these orders now and rather place smaller orders more often.

So it is a repeat job for the die cutting company. The 1 mm system turned out to be just perfect for this system as the plates are stored together with the die tool and the make ready sheet. All phenolic or creasing matrix will be kept on the plate. Set up times are reduced to a minimum and along with that down time of the machine, too.