Die Cutting Column | What Is The “nemesis” of Round-to-round Die Cutting Burrs? Seven Solutions Will Help You Get Twice The Result with Half The Effort!

1. Material batch differences

A medium-sized label printing company used the same brand and model of self-adhesive material when producing a batch of pharmaceutical labels. However, during the production process, it was found that some of the labels had burrs on the edges. After careful comparison and analysis, it was found that the material used this time was different from the previous batch. Although the material parameters such as thickness and viscosity were within the standard range, the internal structure and performance of the material were different from the previous batch, resulting in poor label die-cutting results.

When encountering such problems, label printing companies should actively communicate with material suppliers to understand the reasons for the differences in material batches and require suppliers to strengthen material quality control. At the same time, label printing companies should adjust die-cutting process parameters in a timely manner when using this batch of materials, such as appropriately reducing die-cutting speed, adjusting tool edge height, increasing die-cutting pressure, etc., to adapt to the characteristics of the new batch of materials. After many tests and adjustments, the die-cutting burr problem was finally completely solved to ensure the quality of this batch of label products.

2. Die cutting speed and material adaptability

A label printing company undertook the production of a batch of electronic product labels. The thickness of the self-adhesive material used was 0.12mm, the thickness tolerance was ±0.005mm, and the adhesive strength was 700g/25mm. At the same time, the die-cutting equipment used had a tool hardness of HRC71 and a cutting edge angle of 60°. In the early stage of production, the quality of the label products was normal, but as the production progressed, burrs began to appear on the edges of the labels. After careful observation and analysis, it was found that the operators gradually increased the die-cutting speed of the die-cutting machine in order to improve production efficiency. When the die-cutting speed was less than 60m/min, the quality of the die-cut label products was relatively perfect; when the speed exceeded 60m/min, burrs appeared on the edges of the labels. The root cause was that the cutting edge of the die-cutting tool could not completely cut off the material instantly when die-cutting the self-adhesive material, resulting in burrs.

For such problems, improvements can be made in two ways: tools and equipment. In terms of tools, the supplier's technicians need to readjust the tool edge angle parameter to 50°. In terms of equipment optimization, the die-cutting equipment needs to be fully inspected and repaired to ensure the high-precision and high-efficiency operation of the equipment. At the same time, it is necessary to communicate with the material supplier to understand the performance of the material at different die-cutting speeds in order to better adjust the production process parameters. After adjustment, the die-cutting speed was increased to 90m/min, and there was no burr phenomenon. The product qualification rate reached more than 99%, and the burr problem was effectively solved.

3. Impact of ambient temperature and humidity

Temperature and humidity control in the production workshop has always been the top priority of production environment control for label printing companies. A label printing company in the Pearl River Delta region produced a batch of self-adhesive labels in the summer, and the label edges were burred. The material used is a special self-adhesive material with a material thickness of 0.18mm, a thickness tolerance of ±0.006mm, and an adhesive strength of 750g/25mm. After analysis, it was found that the high temperature and high humidity in the production environment affected the performance and die-cutting effect of the self-adhesive material, resulting in increased fluidity and viscosity of the material, making it easy for the material to adhere to the edge during die-cutting, causing the residual glue on the edge of the label to produce burrs, rather than the real burrs of the material surface material.

Combined with practical experience, it is recommended that the printing company add more temperature and humidity adjustment equipment in the production workshop to control the ambient temperature at 22℃~25℃ and the relative humidity at 50%~60%. At the same time, the materials need to be dried and pre-treated before entering the production workshop to reduce the humidity of the materials, and the warehouse also needs to carry out material storage and processing in different areas. In addition, according to the suggestions of the tool supplier, the printing company also adjusted the process parameters of its die-cutting equipment, added nano-anti-adhesive coating, and improved the anti-adhesive ability of the cutting edge. By implementing the above measures, the problem of residual glue on labels was solved and product quality was effectively guaranteed.

4. Tool material and maintenance

A large label manufacturer found in the long-term production process that even after adjusting various process parameters and equipment status, the burr problem of some labels still existed and the problem was still not completely solved. After in-depth analysis, it was found that although the parameters of the tools from different suppliers were similar, the material hardness, edge roughness and toughness were completely different, and the tool maintenance requirements were also different. During long-term storage, the tools were prone to pitting corrosion on both sides of the edge, coating damage, etc., and burrs were easily generated during die-cutting on the machine.

Label printing companies need to choose tool suppliers with stable quality to cooperate with. Suppliers should regularly send technicians to conduct on-site die-cutting knowledge and technology training to explain equipment use and maintenance methods, as well as how to check tool wear. At the same time, the accuracy of the die-cutting equipment is regularly tested and worn parts in the die-cutting unit are replaced in a timely manner. Through the joint efforts of suppliers and operators, the problem of label burrs can be significantly improved and production efficiency improved.

5. Material storage and handling

A small label printing company found burrs on the edges of labels during production. Analysis showed that the self-adhesive materials were improperly squeezed and collided during storage and handling, resulting in deformation and uneven thickness of the materials. Due to the uneven thickness of squeezed and collided materials, burrs are very likely to occur during die-cutting.

In the face of such problems, label printing companies need to strengthen the management of material storage and handling, and use special shelves and handling equipment to avoid squeezing and collision of materials. At the same time, before using the materials, they need to be carefully inspected and screened to remove deformed and unevenly thick materials.

6. Improper design issues

A label printing company found that burrs appeared on the edge of a special-shaped electronic label when die-cutting it. After analysis, it was found that the shape of the label was too complicated, with many sharp angles and small corners, which made the force of the tool on these parts uneven during die-cutting, resulting in the problem of die-cutting burrs.

The problem of unreasonable label design requires direct communication between the printing company and the customer to optimize the label design from the perspective of printing technology. Try to change the sharp angle to an obtuse angle, reduce the number of small parts, and simplify the shape of the label. At the same time, adjust the die-cutting process parameters, and use special tools and die-cutting methods to adapt to the new design. After the improved and optimized design, the burr problem was effectively solved and the product quality was also improved.

7. Equipment maintenance is not timely

A large label printing company found that the problem of burrs on self-adhesive labels increased gradually after a period of continuous production. After inspection, it was found that the key parts of the die-cutting equipment were worn and loose due to long-term operation and untimely maintenance. For example, the bearings of the die-cutting roller, bottom roller, and support roller were worn, causing the roller to be non-concentric during operation, affecting the die-cutting accuracy; the tool fixing device was loose, causing the tool to produce burrs during the die-cutting process.

Enterprises need to develop strict equipment maintenance plans, regularly ask suppliers to conduct comprehensive inspections and repairs on die-cutting equipment, replace worn parts in a timely manner, and clean and lubricate various parts of the equipment regularly every week. At the same time, regular training for equipment operators should be strengthened to increase attention to equipment maintenance and operating specifications. When the equipment operates stably, the burr problem will naturally be effectively controlled, and production efficiency will be significantly improved.

In summary, the problem of burrs in the round die-cutting of self-adhesive labels is a complex and comprehensive problem that needs to be analyzed and solved from multiple aspects. In actual production, enterprises should strengthen the monitoring and management of the production process, discover problems in a timely manner and take effective measures to solve them. At the same time, they should continue to learn and draw on advanced technologies and experiences, improve their own technical level and production capacity, and ensure that the die-cutting quality of self-adhesive labels can meet the needs of the market and customers.

Hans He

Whatsapp/WeChat:+0086 13676974117

Email：sales07@dtpapergroup.com