Are these two major "headache" issues present in irregular die-cutting? This way to solve it!!

The die-cutting of self-adhesive adhesive belongs to special die-cutting, and usually after die-cutting, unnecessary waste edges need to be removed for easy labeling and labeling. The irregular label mentioned in the article refers to the label with irregular shape. The difficulty of the die-cutting process lies in the waste disposal process, and in actual production, some problems often arise due to its irregular shape. This article will introduce some common problems and solutions in the die-cutting process of self-adhesive shaped labels.

01 Broken discharge edge

The fracture of waste edges in die-cutting is a common problem encountered in adhesive die-cutting processing, and many factors can affect it. The common influencing factors include surface material strength, waste edge width, die-cutting tools, waste discharge tension, and irregular labels. Here, we mainly discuss the reasons and solutions for the broken waste edges caused by irregular labels.

The reason for the fracture of the discharge edge: The special shape of the irregular label results in irregular discharge edges. As the number of discharge edges on the discharge roller increases, the diameter of the area with more discharge on the discharge roller will also be larger than that of the area with less discharge, which inevitably leads to uneven tension of the discharge edge and is easy to cause discharge edge fracture.

Solution: (1) Add a balance pressure roller to the waste discharge roller and balance the diameter of the waste discharge coil appropriately with external force; (2) Add appropriate lining paper to the winding position with fewer waste edges to balance the tension of the waste edges; (3) Before die-cutting, a pre stripping process is used to appropriately reduce the release force of the material. The greater the release force, the greater the tension on the material during waste discharge, which is not conducive to smooth waste discharge, especially for irregular labels; (4) By enhancing the tensile strength of the waste edge through processing technology, increasing the tensile strength of the surface material through surface coating, and adding a back knife device for die-cutting the base paper at the die-cutting station, the waste edge becomes a double-layer structure of the surface paper and the base paper, and its tensile strength is greatly enhanced.

02 Label warping during waste disposal

The common phenomenon of labeling during the adhesive die cutting process refers to the label being lifted off the bottom paper by the waste edge during the die cutting process, commonly known as "flying label". The warping angle is the prelude to the flying beacon, and the usual influencing factors include: die-cutting quality, waste disposal method, material peeling force, and environmental temperature.

Due to its unique shape, irregular labels often have a raised edge during die cutting and waste disposal, resulting in the label being unable to roll and label properly, resulting in a high scrap rate. This phenomenon often occurs in areas where the contour angle of the label is very small, such as the five corners of a pentagram label. During normal waste discharge, if the area is too small, the relative peeling force will also be very small, making it easy for the waste edge to pick up the rear corner.

Solution: When designing labels, try to avoid right or acute angles as much as possible. The larger the angle, the more conducive it is to waste disposal; In order to increase the angle of waste discharge, the waste roller can be modified into a waste steel ruler; Add foam to the label position on the die cutting blade plate; Add a certain thickness of sponge roller to the label position of the thinner waste roller.