Die Cutting Three Times Better

As is fitting for a high performance die cutter, we are constantly improving the Dymatrix 106. Already, it features three technological innovations that allow folding boxes to be produced faster, more reliably and at lower costs.
 
Producing high quality packaging, such as those for cigarettes, cosmetics or candy, is the strength of the Dymatrix 106. The die cutter has full mastery of an extensive repertoire of various folding box types and materials, from thin paper to corrugated board and plastic. It can do all this and still be profitable. "Especially in the case of industrial production, packaging must look perfect and needs to be produced quickly, reliably and flexibly. That is why we have fine-tuned three important points: we have further improved the alignment and separation of the sheets and also made it easier to implement tools from other brands," explains Hakim Arbaou, Production Manager Postpress at Heidelberg.

Faster: Sheet Alignment
During die cutting it is particularly important to transport the sheets straight-edged and in a stabile horizontal position to the individual stations. Only then can an absolutely accurate register and maximum production speed be achieved in die cutting. But usually things look quite different: hardly any piles of sheets make it from the printing press to the die cutter's feeder with completely straight edges. A lot of operators simply do not have the time to align the pile of sheets exactly. This is no problem for the Dymatrix 106.

Now sheet alignment does not just take place mechanically with front and side guides, but with a uniquely developed automatic feed system called DySet. At its core is an optical sheet sensor. After a pile has reached the feeder and the sheets have been separated on the belt table, the front guides in the feeder register their alignment. The optical sensor then surveys the side edges of the sheets. In case of a false position, the side position of the sheets is corrected before they are handed over to the gripper bars. These then transport the sheets to the next stations on the machine.  "Thanks to DySet, the number of waste sheets in the feeder, the so-called stoppers, can be reduced by up to 70 percent," reports Arbaou. In addition to the higher productivity, manufacturers of folding boxes and die cutters profit from increased register accuracy. This enables them to cut even difficult layouts reliably.

More Reliable: Sheet Separation
Not only the alignment, but also the separation and transport of the sheets, is now more reliable and simpler. This is due to the new belt table and feeder of Dymatrix 106. "We modified all components with the goal of making the separation and guidance of the sheets in the feeder absolutely reliable," says Arbaou. Fewer but therefore wider belts, a newly designed suction head as well as an optimized inclination angle of the sheet ramp are just a few of the improvements.

Thanks to these innovations, the Dymatrix 106 processes a wide range of materials reliably and without the need to convert parts of the machine - from very thin paper (80 grams per square meter) up to solid board (up to 2,000 grams per square meter).  "Businesses don't have to add any additional equipment like rolls or brushes for changes in material, for example from paper to solid board and vice versa. The sheets are also separated reliably at high production speeds," emphasizes Arbaou.

Flexible and More Cost-Effective: Using Tools from Other Brands
Businesses which use die cutters from various manufacturers can assign orders more flexibly in the future. This is because cutting tools from other brands specific to a particular order can be used on the Dymatrix 106. "Particularly for businesses with high cutting workloads, this is an enormous advantage. It gives them the necessary leeway to process short-notice jobs on time. First-time orders and recurring orders no longer have to be carried out on the same die cutter," explains Arbaou. In addition, Dymatrix businesses do not have to acquire new cutting tools. A variety of order-specific cutting tools can be used for various orders because they can be used regardless of the printed design. This is true for packaging for hair dye, for example. Here it does not matter if hair is blond, brown or black - the folding box is the same.