The Rotary Die Cutter Process and Its Benefits

Interested in using a rotary die cutter? It’s no wonder. This machine empowers you to work with many different materials, providing a level of flexibility you won’t find with other options. However, it’s important that you know the basics behind rotary die cutting before starting. Check it out!

What is a rotary die cutter?

Let’s get into the simplest part first: what exactly is a rotary die cutter? This machine utilizes a specialized die cutting process. It relies on cylindrical die cuts to carve shapes out of different types of material. The machine moves in repetitive circular motions, with blades cutting out your desired shapes positioned around the entirety of the cylinder. That’s what makes the machine so efficient: it creates many identical shapes as it rotates, without any need for a pause.

What a rotary cutting machine does require, however, is an adjustment. Such adjustments aren’t big, but you typically will need to make them before starting the process. This means that the setup time for this machine may be somewhat longer. However, the speed of the cutting dies makes up for that setup. In the long run, you’re usually saving time when using a rotary cutting die machine compared to alternative options like flat bed die cutting machines.

How fast is a rotary die cutter?

The speed of a rotary die cutter can vary depending on the project, the calibration of the machine, and the size of the sheets of material you’re using. Some machines quote speeds as low as 200 sheets per hour, while others offer speeds as fast as 5,000 sheets per hour. However, the speeds do not exist in a vacuum, and you–or a third-party rotary die cutter manufacturer–may have some degree of control over how quickly a machine works.

At points, manufacturers make changes to the machines and their processes in order to increase the speed of the production. These may include investing in equipment upgrades with regards to your machines or rotary die cuts, adding in retrofits, or altering your full line system. Needless to say, these alterations and upgrades can be somewhat daunting for business owners. Fortunately, it is possible to outsource your projects to a United States manufacturer. This third-party handles production for you, ensuring the die cutting process works as fast as possible.

Not only does this take the trial and error out of the question for you–it also decreases your prep and production time. You’ll have the products you want, the way you want them much faster. Additionally, you won’t have to invest in a rotary die cutting machine, or for that matter cutting dies. You won’t have to take the time to hire or train operators, either. It’s no wonder that so many business owners outsource processes like die cutting.

What are the advantages of rotary cutters?

Let’s explore why we often select a rotary die cutter over other machines and processes. While you’ll find several alternatives, it’s clear that a rotary die cut machine offers certain advantages that are hard to duplicate.

Less waste. When it comes to manufacturing, less waste is always an advantage–because when waste is minimal, you cut down on expense. Another perk: if you’re trying to operate a more sustainable and environmentally friendly business, less waste is more beneficial.

Ease of use. The easier a die cut machine is to use, the better for the business owner. A rotary die cutter can cut through a wide variety of different materials easily. Think everything from foam to metal, as well as cork, paper, and magnets.

Speed and efficiency. When you’re scaling up, speed and efficiency equal money saved. An industrial die cutting machine has a built-in cutting pattern, which means that you don’t have to adjust it between cuts. That equals far greater efficiency compared to the rest of the competition. Additionally, this empowers a die cutter manufacturer to offer a quick turnaround time.

They’re multipurpose. What if you had a machine that could do it all? A rotary die cutter may be what you’re looking for, as it can perform kissing cutting, laminating, embossing, inline packaging, and more.

They’re durable. Keep in mind: the longer a machine lasts, the less money you spend in the long term. Because the rotary die cutting process is so straightforward, there’s less potential for wear and tear. Therefore, the machine lasts longer.

Precision. The key to that straightforward process is precision cutting. This rotary die cutting machine replicates precision cuts over and over. It’s the most accurate precision cutting process available, yielding identical results—which is exactly what you want!

Summing Up Rotary Die Cutting:

So, you know you need to use a rotary die cutter. Does that mean you need to invest in your own machine? Not necessarily. It’s possible to use third-party manufacturers like Conversion Technologies International. Although we’re located in Ohio, we can work with clients throughout the country.

The great thing about working with a third party is that you don’t have to go invest in a machine you may use for a limited time. There’s no need to rent a facility, and you won’t have to hire permanent employees as operators. Additionally, we know what we’re doing—there isn’t a learning curve, and you can move forward with confidence, knowing you’ll receive the results you need.

Want to learn more about rotary die cutting and working with a third-party manufacturer? We’re here to help. Contact us here or call us at 419-924-5566. Let’s get this process started!