Die Rebuilding and Remanufacturing Services

The die-cut products today depend on high-volume designs, raw materials, skilled production workers, and some form of rolling platform. A die cutting machine forms the approaching line of blanks into a scored and cut form at the core of the operation, a refined shape that requires another processing station to do the folding. All processing stations mesh nicely, but when the die-cutting heart fails, this entire line grinds stops. 

These are some of the common causes of failures:

  • Cutting Dies Breakage. The machine must be taken out of the service if the die is damaged or broken. Proper service is required and dies fracture must be fully welded and re-tempered.
  • Die lifespan Issues. Die failed repeatedly when the volume of the operation rises and works efficiently for only a short period of time.
  • Wear and Tear. Pressure applied by the anvil parts combines with the number of blanks passing through the die-cutting device to weigh heavily on the die, aligned die elements are knocked out of form and distorted by blank material hardness.
  • Cutting Results are Inconsistent. A worn die with a dull cutting edge produces unpredictable results of kiss-cutting, most of which are substandard. The inner system tears up expensive sheets of paper and countless blanks.

Rebuilding and Remanufacturing of used machines are essential to ensure they get the most use possible out their equipment. The entire machine and components cleaned and stripped bare also, inspected for defects, wear, and shortcomings.

What is Die Rebuilding and Remanufacturing Service?

Die Rebuilding Service is disassembling the existing die cutting machine. This method inspects all the parts while replacing those worn beyond repair. On the other hand, Die Remanufacturing Service is used when Cutting Die Machine involves replacing most of the entire system of the machine for about 80-85%.

When finished rebuilding Die Cutting Machine it is stored to the original OEM manufacturing specifications, and it’s the most economical choice available. And also, the machine is equal to good as new upon remanufacturing with new machine technology which exceeds current OEM Specifications. It’s an inexpensive alternative to purchasing a new machine. 

Rebuilding involves mechanical while remanufacturing involves rebuilding with some additional engineering upgrades, and can take considerable effort and time, months in some cases.

When things go seriously wrong call an expert for rebuilding or remanufacturing service, die-cutting is a unique resource and uses many moving parts and meshing forces that must always have consistent results.

ICD International Cutting Die manufacturer for all machine lines and recondition dies from any supplier. Our typical turnaround time is five business days, ICD extends your dies life, ensures proper functionality, and exceeds OEM specifications.

Contact us for further queries at 708-343-3333 or email your queries to info@icd-inc.com.

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Factors to Consider in Choosing the Right Die Supplier

Selecting the right supplier for your die includes scanning a number of price lists and searching for a quality that fits your standard. Your choice will depend on a variety of factors including value for money, quality, reliability, and service. 

By selecting the right ones, your emerging business will be able to equip itself with the tools needed to deliver a specialized service or align the shelves with great products that create sustainable margins.

Things to consider which will help you find the right kind of supplier:

  1. Expertise and Experience – Before deciding on getting a die cutting supplier, the first thing you should do is to research these things. Experience is a precious tool. The die supplier company you choose must have a considerable amount of field experience. An experienced company will easily be able to cater to your requirements, and even offer customized products and look after the installation. However, you should not just settle with the experience. Adequate knowledge along with a flair for innovation is also very essential. The company needs the latest tools available in the market, and an expert team to handle them.
  2. Products – What products are you looking for? An efficient and competent supplier will offer you a range of commercial products as well as industrial components. Some of a die cutting supplier’s most popular products are threaded rods, circles, disks, spacers, washers, insulators, seals, gaskets, and corrugated containers. Take a look at the portfolio of the company you choose. You will be able to know all about their products by reading the experiences of previous customers.
  3. Price and Performance – Cost-effectiveness also comes into play as an important factor. Die cutting requires accuracy and is a time-consuming and costly affair. Therefore, do not choose a supplier with die cutting whose price range is just too good. You must ensure that the service offered by the supplier does not compromise on the quotient of performance and quality. You need to find products at an economical rate, not only with a good final finish. Look for suppliers who will be offering affordable high-quality products.
  4. CNC Machining and Die Cutting – Computer-helped die cutting machine is a very popular trend these days. Form plastic die cutting to metal die cutting – computer-aided cutting designs are in use almost everywhere. It is a technique that attracts attention as the use of computer technology improves the accuracy of production. In this technique, the rate of productivity faces an upturn as dependence on manual labor decreases.

The most efficient suppliers are those offering products or services that match or exceed your business needs. So when you’re looking for suppliers, it’s best to be sure of your business needs and what you want to accomplish by buying instead of just paying for what suppliers want to sell you.

The type of materials you cut is very important to get your work done when choosing the right company. Every die cutting vendor you contact will have specific core skills. Make sure they have previous experience with your material and the right die cutting equipment to process the substrate most efficiently.

Here at International Cutting Die, Inc. we have a team of skilled professionals and known as the rising above current standards in the die supply industry.  We know if you speak with us about your project our experience, professionalism, and capabilities will convince you that we are that partner. Contact us at 708-343-3333 or email to info@icd-inc.com.

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Your Guide to Cutting Die Reverse Engineering

Consumers requirements and business approaches are ever changing. Reverse engineering plays a crucial role to keep pace with these changes and ensure continued development, especially in the production process. But, what does this process entails? How can it help? Here is your quick guide to cutting die reverse engineering. 

Reverse engineering looks into the physical components and functionality of a thing to create a duplicate or to recreate it. Similarly, this special engineering with your cutting dies involves duplication of existing component and redesigning the same to make new ones to comply with new conditions. 

International Cutting Die (ICD) has state-of-the-art machinery to conduct quality reverse engineering processes that produce quality outputs. Our seasoned engineers are capable not only of duplication, but also of creating or adding new features to the new components. It is advantageous for the introduction of new product specs or requirements. 

What happens during the process?

We make use of your existing components that needs upgrading or recreating as part of your maintenance or change in the business requirements. The key to a successful and quality process is a thorough reproduction. It entails a comprehensive or detailed examination and analysis of your existing tools. Once the examination is satisfactorily done, our engineers and designers will lay out a plan for an accurate duplication of your die and stations. 

Why go for cutting die reverse engineering?

  • Update outdated equipment

The business backdrop is always changing, requiring businesses to adapt to the shifting needs. Reverse engineering is a fast and relatively easier solution to keep up with the transformations in the industrial environment. That is,  it enables you to update or reconstruct your outdated equipment to accommodate business changes. 

  • Discover machine flaws

The reverse engineering process gives you the opportunity to intensively check into your cutting die. It provides an opportunity to examine the flaws and vulnerabilities of the die, which is useful to ensure that the reverse-engineered component is devoid of these faults. This likewise brings your attention to your other cutting dies to check whether they have the same issues. 

  • Cost-effective innovations

One of the biggest advantages of reverse engineering is that it supports inexpensive innovations. The process helps you create innovative machineries without the expensive capitalization needs as you don’t actually have to start from scratch. You can utilize the existing components to create new ones that are specific to your needs. 

Know more about our cutting die services. Reach to us! 

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What is the Importance of Cutting Die Maintenance?

Well-maintained dies are one of the most important aspects of the cutting die industry. It’s essential for dies to have regular maintenance in order to produce good parts without delays — and dies that do not function correctly are unacceptable!

Dies are assembled from parts that must work together and should be designed correctly since safe performance begins with good design. Careless operation and poor maintenance will cause great difficulty in spite of the designer’s best efforts.

What is Die Maintenance?

Die maintenance is sharpening cutting sections because of normal wear, replacing springs before their expected life cycle, periodically cleaning the dies and inspecting them for loose dowels or sections, and resurfacing and lubricating components as necessary.

Most likely, the problem is that the die used in the spring has designed improperly or that the spring deflects far beyond its most effective rate. Also, new dies may have design problems that must be corrected to assure smooth operation.

How to Extend the Life of Your Die?

  • Sharpening. Part defects such as burrs, safety issues, and feeding problems, etc. are results of the cutting sections and punch edges break down over a period of time. Die sections and punch should be sharpened periodically. Use the right grinding wheel that breaks down and does not load up during grinding small metals that are very hard to cut. Wheels that load up and burn during the process results in softening, heat checking or cracking of the die section or punch. Grind the proper cutting shear, so the cutting angles are balanced reduces the necessary cutting force, and helps quiet down the die. Correct cutting shear reduces the shock loading of the die and press prolonging and die life.
  • Shimming. Maintaining the timing of each die station is essential for shimming procedures. Should use fewer thicker shims, an excessive number of thin shims placed under a die section creates a section of spongy die, which may tend to breathe and move more. Also, there must be sufficient clearance for screws, slug drop holes, and dowels. Inspect all pierce holes to ensure that there is no shim interference in the slug drop hole. Avoid crooked shimming of die sections, and avoid overhanging shim on die sections. Remove all burrs from your shims and before mounting, make sure all sections and shims are free of debris.
  • Inspect and Clean. Look for loose fasteners, missing dowels pins, galled die sections, broken springs, know why it’s broken, replace springs if they’re already close to the end of their normal life cycle, inspect wear plates and cam surfaces, regrind and fit as necessary, check for dulled, chipped, or cracked die sections and replace if needed, ensure that all screws are tight, all necessary mating die surfaces must be lubricated, inspect die to ensure that all safety guards are in place, all debris like slugs, slivers, and lubricant buildup from the dies must be cleaned, make sure to dry die so it will not rust and all cutting punches are secure in their retainers.

A regular schedule for die maintenance is very important and necessary activity. Without die maintenance, parts of the machine may fail, and repairs can be more costly and time-consuming.

International Cutting Die (ICD) know the importance of keeping machines and dies maintained and best way to keep it maintained is to contact (ICD), we make sure that we extend the life of your dies, ensures proper functionality, and meets OEM Specifications!

Click here to see more of our services: www.icd-inc.com/services/

Contact us at (708) 343 3333 or email info@icd-inc.com for further queries.

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Why You Should Choose ICD for Cutting Die Rebuilding?

When the majority of business operations relies on machines, a piece of non-performing equipment poses risks of operational disturbance and loss. Most sites with cutting dies cannot afford a broken or ill-functioning station because it can affect other phases of the entire production or process. When having your cutting dies for repair, rebuilding or reconditioning, here are the reasons why International Cutting Die should be your provider.

 

Full Die Rebuilding Service

International Cutting Die has in-house mechanics and engineers trained to provide a spectrum of service to build and rebuild your die cutting machines. Since our founding in 2002, we have helped numerous businesses redesign their cutting die stations. It enabled them to save tons of their investments on equipment as we repurpose their machines into powerful beasts customized to their business needs. Our engineers are also equally capable of reconditioning your cutting dies from any supplier. Depending on your needs and specifications, we upgrade them to tailor-fit any production requirements. It includes disassembling, parts inspection and replacement to reassembling.

 

Quick turnaround

In every business, time is always essential. Short delays can mean a significant loss to the firm. Hence, we practice a quick turnaround time with all our projects. Save from exceptional cases, our normal turnaround time for rebuilding services is five business days. Our experts will exert every possible effort to ensure the least amount of disruption on operations as we work on your machine. You also have the option to have your machinery or its components repaired, built or reconditioned on your site or on our facility. We think of your convenience and satisfaction every step of the way.  

 

Maximized benefits

We provide a triad of vital benefits for you. First, we extend the life of your dies that saves up on maintenance expenses. You make use of your surplus on other important units of the operations. It also cuts down the number of issues to address in the production process. Second, it ensures proper functionality. You should not put up with a weak functioning machine and make-up for it by compromising your human capital or other production aspects. Third, our results and practices meet original equipment manufacturer (OEM) specifications, which assures that we only use the best parts for your machine.

When you want quality and speed, set up a consultation with us and know more of the services we can do for you.

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What is a Customized Rotary Die Cutting Stations and Why You Need it?

What is a rotary die cutting?

Die cutting is a precise and versatile cutting and forming solution to produce forms, shapes, and cuts according to product specifications. Most die cutters can work on different materials from plastics, metal, fabric, and foil. Rotary die cutting (and other die cutting processes) made it a salient part of a business’ product and service production.

 

What is rotary die cutting station?

A rotary cutting die station or machine is one of the basic types of die cutting stations. The machine has a cylindrical die that is attached to the rotary press. The rotary die contains the cutters specifically designed to produce the desired shape or cut on the material. Against it is a cylindrical anvil serving as the flat surface that counters the rotary die’s pressure on the material. In between these two rollers, the material such as cardboard, plastic or metal is fed.

 

Why customize your rotary die station?

 

  • High-volume production

One of the benefits of rotary die cutting is its capacity for high-volume production in contrast to other cutting dies. Customizing your rotary die not only provides you with the required cut or shape for your product, but also ensure that you produce the right amount to suit your inventory and distribution requirements.

 

  • Tailored to product specification

Some businesses have complicated cutting demands or have unique designs that are exclusive to their brand. Customizing your rotary die cutting stations allows you to fit the machine with the demands of exclusive designs, helping you create iconic products. It enhances both its functionality as well as your product identity.

 

  • Reconfiguration instead of purchasing

Die cutting service provider such as the International Cutting Die offers reconfiguration services on existing rotary die machines. Instead of getting a new station, service providers can help you retrofit existing ones. It’ll help you save on equipment investment by your working rotary cutting dies that are already in place.  

 

  • Easier operation mechanism

A customized rotary cutting die further enables you to a simplified operation. In fact, some machines need less human intervention once its program is set. This automated process gives you more opportunity to maximize your manpower, while still ensuring quality outputs from the station.

 

To know more about how customized rotary die stations can help your brand, talk to die cutting station experts for consultation. International Cutting Die is a trusted partner of hundreds of businesses that can provide you guidance on tailor-fitted rotary dies.

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Cutting Die Maintenance Essentials and Its Importance in Business

Machine maintenance is necessary for continuous functioning, especially where production is always a critical part of the business. For rotary die cutting system, lack of station care can spell not only loss of equipment investment. It can also disrupt production and profit. We came with a discussion of the essentials of cutting die maintenance and its importance.

 

Maintenance practices

  • Problem identification
    The most obvious indicator that a rotary die cutting station requires maintenance is the occurrence of a problem. While it is not advisable to wait for problems to arise, part of station care is to immediately determine operation or functionality issues. With the machine’s complex components, it is vital to address station problems through proper and speedy problem identification.
  • Downtime measurement
    Preventive measures for rotary die cutting care involves downtime monitoring. Station operator should ensure that there is limited to zero downtime to prevent affecting product distribution flow. This enables the business to hit inventory and the sales targets period after period.
  • Regular lubrication
    Working with different materials against the steel parts of the rotary die station exposes the machine to friction problems. Friction often leads to heat that complicates the whole die cutting process. The key to counter this hazardous heat is lubrication. Station operators should perform lubrication on vital components to prevent heat build-up.
  • Pressure adjustment
    Aside from the heat, rotary die cutting station is regularly subjected to pressure, which is another source of friction. The station operator is responsible for controlling the pressure used and applied by and to the machine. It requires a proper balance to apply enough pressure for cutting while preventing heat to ensue.

 

Benefits of Conducting Die Cutting Maintenance

  • Extends the life of your dies
    Proper and regular care of your die cutting stations helps you extend its life and function. What separates a good operator from a bad one is not just the capacity to buy top-of-the-line die brands, but as well as the ability to take good care of it.
  • Ensures proper functionality
    Your business relies on the proper functioning of the die cutter. Conducting thorough proper care on a regular basis keeps its operations as effective as your production needs require. Downtime, whether short or long, can mean bad costs you can’t profit.
  • Meets OEM Specifications
    It’s not enough to have your cutting stations working. It should be working according to the standards of OEM specifications. This will support your distribution strategies while creating a reputation for high-quality manufacturing processes.

 

To keep you rotary die cutting stations in good working conditions, have only an experienced professional conduct regular maintenance and repair.

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Die Cutting, its Importance in the Industry

New Developments are made to improve production speeds, quality and customer satisfaction. Increasing demand comes to a rapidly growing need for better and faster technology in all trade sectors. Die Cutting, a constantly evolving finishing technique that relied heavily on its field relevance.

Die Cutting Machines are used to cut/emboss different materials from paper, vinyl, vellum, and cardstock to fabric, plastics, thin metals, and leather in order to give a definite shape. These machines that use dies to help cut, shape, and design materials help save time and cost compared to traditional cutting methods.

It has greatly increased the efficiency of a number of industries, including packaging, automotive manufacturing and mobile phone assembly in particular. It allows workers to cut crisp, clear shapes directly from substrates, it is a fantastic option to create sleek and impactful packaging.

Integrating die cutting in production strategy benefits both single and multi-piece packaging designs.

Why do manufacturers adopt processes die cutting?

  • Technology advances in both the manufacturing process and the commodities created by die cutting have made it a more and more efficient way to incorporate oddly shaped or delicate parts into product designs. For this reason, die cutting especially benefits applications in the electronics and medical industries, improving products from headphones to hearing aids.
  • Growing populations mean growing markets for all kinds of products. It enables factories to achieve high-volume production runs for sensitive components that used to take longer or cost more to assemble using other techniques.
  • Growing disposable incomes have driven the growth of specialty item manufacturers of specialty seeking to cater for those wishing to associate with unique brands. It enables even small businesses to achieve high-volume production runs as required without sacrificing each item’s quality.

Die cutting continues to grow as an essential method of manufacturing products that consumers use every day. It is capable of operating any type of metals, allowing manufacturers to produce sleek, stylish products without sacrificing efficiency or affordability.

There are many Cutting Dies Industry, but who will help keep your business thriving and make sure provide excellent service to all? The answer is International Cutting Die (ICD). Skilled Professional Staff and Industry Experts, hosts Leading-edge Machinery and Equipment and guarantees high quality of products and services locally and internationally.

Contact us at 708-343-3333 or email your queries to info@icd-inc.com.
Our Services: www.icd-inc.com/services/

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Understanding Rotary Die Cutting

Die cutting is often used to make unique shapes from plastic, foam and rubber materials.

It’s important to consider all specific project requirements before starting a die cutting project since there are several different types of services. Whether it’s Flatbed, Digital and Rotary Die Cutting, look for the best fit for the project because each service has its own distinct advantages based on production output, material capabilities, costs, etc.

What is Rotary Die Cutting?

Rotary Die Cutting is die cutting that uses cylindrical dies attached to a rotary press to convert flexible material for example web. A highly accurate and precise cutting method, very cost effective on high volume orders and less waste produced compared to other methods.

Types of Rotary Cutting Dies

Flexible cylindrical rotary dies are composed of a thin sheet of engraved metal that is usually tool steel affixed to a separate magnetic cylinder while solid cylindrical rotary dies are composed solely of an engraved solid metal cylinder. Both are flexible and solid dies are capable of cutting most types of materials, each carries its advantages and disadvantages in regard to manufacturing applications.

A comprehensive approach is required in choosing the right type of die for a rotary die cutting operation. Aside from the material being cut and the required specifications you also need to consider the initial and overall investment costs, and the optimal lead and turnaround time.

Flexible vs. Solid Dies

Flexible dies are suitable for easier, less abrasive materials and shorter runs, while solid dies are more for harder, abrasive materials and long-term and large production run. Flexible die machine’s initial investment is more expensive than solid dies due to costly magnetic cylinders, re-purchasing the cheaply manufactured flexible die component can prove to be more economical in the long-term. Solid dies may be more expensive to manufacture, but when cutting consistent designs in large quantities, the cost of it may be justified as the dies are less likely to need replacement mid-production. And it does not require a large investment in supplementary components as with the magnetic cylinders necessary for flexible dies. Flexible dies may be simpler and faster to obtain, but they are more prone to experiencing fatigue and need replacement. Solid dies may take longer turnaround times, but it’s more durable and likely to last through more production cycles.

These are just some things to consider when choosing between flexible or solid rotary dies for a rotary die cutting application.

rotary die

Benefits of Rotary Die Cutting

It offers several advantages including consistent and uniform precision cuts, reduction of material waste, decreased lead times, rapid turnaround times and high volume production.

Rotary Die cutting consists primarily of heavy cylindrical anvils and customized rotary die sets, geared towards high a volume of tight tolerance applications. International Cutting Die (ICD) employs state-of-the-art-servo-driven press solutions. The versatile nature of rotary solutions proves to be a core competency for ICD with different modules and operations.

ICD, a world leader in rotary die making. Contact us at (708) 343 3333 or email your queries to info@icd-inc.com.

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How to Maintain a Functional and Profitable Rotary Die?

A rotary die cutter is a serious investment that is an essential part of the production process. Its malfunction can mean loss not only of your investment, but also of your possible profit. While a piece of equipment is susceptible to wearing and tearing, there are a few things that you can do as an owner or operator to decelerate the lifespan of the equipment. Here are four ways you can maintain a functional and profitable rotary die:

  • Put Safety on Top of Everything

Operating and maintaining a rotary die has inherent risks heightened with improper personal safety practices. A rotary die can be challenging to handle and a small oversight can lead to serious consequences. Operators should understand that any accident equates to additional liability to the company or business, which may result in financial losses. Thus, you should follow safety procedures at all times no matter how small or trivial it may seem. You should first be trained regardless of previous experiences because each die supplier may incorporate slight differences in function and anatomy.

  • Ensure There’s Enough Lubrication

Among the mechanical factors that can affect the function and therefore the profitability of the rotary die is the friction and heat that occurs in the process. Steel and heat is not always a good combination in rotary die cutting. It may result in equipment damage, inefficient product and bad produce. Hence, leaving the company yet another unprofitable products. What rotary die operators can do is to ensure that there is enough lubrication to regulate friction and heat. This means that part of the daily monitoring and maintenance is to check and determine if lubrication is needed from time to time for safe and efficient operations.

  • Be Aware of the Condition of the Anvil

Like all other parts of the equipment, the anvil also wears and tears from usage, especially that pressure is constantly applied to it. However, most operators focus on the die itself and often forgets that the anvil is also an important component of the equation. A positive feature of an anvil is that it is replaceable when it does not work as sharp it used to. To protect your possible profits, you should also consider the condition of the anvil as you operate day by day. You need to have a spare anvil in place at all times to prevent stoppage of production.

  • Handle Equipment With Proper Care

Alongside personal safety, you should also exercise proper care with the equipment and all its accessories and components. What sets apart a profitable operator from an unprofitable one is the ability to extend the life of the equipment while still producing quality results. There are suppliers and installers that provide durable equipment, but that is subject to the usage and abuses of the users.

For professional care and servicing, International Cutting Die provides expert maintenance services you to extend the life of your dies, ensure proper functionality and meet OEM specifications.

Contact Us to discuss your cutting die requirements:

(708) 343 3333
info@icd-inc.com

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