An Exploration of the Factors Affecting the Cutting of Label Rotary Die Cutting Machines

The label rotary die cutting machine plays a crucial role in the label printing and processing industry. Its cutting effect is directly related to the quality of labels and production efficiency. Numerous factors can have an impact on its cutting process. A deep understanding of these factors is of great significance for optimizing the die cutting process, improving product quality, and reducing production costs.

Blade-related Factors
Blade Material and Hardness
The material of the blade determines its key properties such as wear resistance, toughness, and sharpness. For example, blades made of high-quality high-speed steel have high hardness and good wear resistance, enabling them to maintain a sharp cutting edge during the long die cutting process, thus ensuring the neatness and smoothness of the cutting edges. Blades with insufficient hardness are prone to edge wear and dulling when cutting relatively hard label materials, resulting in rough cutting surfaces and even the inability to complete the cutting task smoothly.
Blade Edge Shape and Angle
Different edge shapes and angles are suitable for different types of label materials and die cutting requirements. For thin paper labels, a sharp edge with a small angle can achieve precise and rapid cutting and reduce the pulling of paper fibers. For some plastic labels with a certain thickness or toughness, special-shaped edges, such as wavy edges, may be required to distribute the cutting pressure and prevent the materials from deforming or tearing during the cutting process. Incorrect selection of the edge shape or angle will lead to uneven distribution of cutting force and cause problems with the quality of label cutting.

Die Cutting Pressure Factors
Precise Setting of Pressure Magnitude
Appropriate die cutting pressure is one of the core factors to ensure a good cutting effect. If the pressure is too low, the blade cannot completely cut through the label materials, resulting in phenomena such as incomplete cutting and continuous cutting, which will affect the separation and use of the labels. For example, when cutting multi-layer composite label materials, if the pressure is insufficient, the layers of materials may not be completely separated. On the contrary, excessive pressure will cause excessive wear on the blades and equipment and may also lead to the crushing and deformation of the label materials. Especially for some labels with soft textures or special coatings on the surface, such as thermal labels, excessive pressure will damage their thermal coatings and affect the functional characteristics of the labels.
Uniformity of Pressure
The uniform distribution of die cutting pressure across the entire die cutting area is also of vital importance. If the pressure is uneven, the edges of the labels after cutting will show different degrees of quality differences, such as some edges being smooth and some having burrs or serrations. This may be caused by factors such as poor surface flatness of the die cutting rollers, failure of the pressure adjustment device, or uneven thickness of the label materials. For example, when the die cutting rollers have local wear after long-term use, the pressure in this area will be inconsistent with that in other areas, thus affecting the cutting effect.

Label Material Property Factors
Material Thickness and Hardness
The thickness and hardness of label materials have a significant impact on the die cutting process. Thicker or harder materials require greater die cutting force to complete the cutting. For example, thick cardboard labels require higher pressure and sharper blades compared to thin paper labels. Moreover, the uneven hardness of materials, such as some label materials containing fiber impurities or local hardening, will increase the difficulty of die cutting, easily lead to increased blade wear, or unstable cutting quality, and may result in local incomplete cutting or uneven cutting surfaces.
Material Flexibility and Elasticity
Label materials with high flexibility and elasticity, such as some rubber or stretchable plastic labels, are prone to rebound during die cutting. This requires that the blade and pressure settings of the  Label Rotary die cutting machine can adapt to this characteristic. Otherwise, the edges of the cut labels may not remain flat and may curl or deform. For example, when cutting elastic rubber labels, if the cutting speed and pressure cannot be reasonably controlled, the labels will rebound quickly after the blade leaves, resulting in uneven cutting edges and affecting the appearance and pasting effect of the labels.

Equipment Mechanical Precision Factors
Concentricity and Cylindricity of Die Cutting Rollers
The concentricity and cylindricity of die cutting rollers are directly related to the uniformity and stability of die cutting pressure. If the concentricity of the die cutting rollers is poor, radial runout will occur during the rotation process, causing the die cutting pressure to change periodically, resulting in regularly uneven cutting edges of the labels. The cylindricity error will make the contact area between the die cutting rollers and the label materials uneven, causing local excessive or insufficient pressure and affecting the cutting quality. For example, when the die cutting rollers have a large concentricity deviation due to manufacturing or installation precision problems, the edges of the cut labels will have obvious wavy undulations.
Precision and Stability of the Transmission System
The precision and stability of the equipment's transmission system also have an important impact on the die cutting effect. The transmission system includes components such as motors, gears, and chains. If the transmission precision is insufficient, such as excessive gear meshing clearance and chain slack, it will lead to unstable rotation speed of the die cutting rollers or instantaneous pauses, making the relative movement between the blades and the label materials discontinuous, thus producing scratches, faults, and other defects on the cutting surfaces of the labels. Moreover, unstable transmission will also exacerbate the wear of blades and other components of the equipment, reducing the service life and reliability of the equipment.