How the Use of Servo Electric Die Cutting Presses Can Improve Productivity, Profitability &
Add Sustainability to the Converting Industry
By Greg DeFisher, Owner/CEO, Freeman Schwabe Machinery
Hydraulic die cutting, laminating, and molding presses have been the standard types of presses used in the converting industry for years. Developments in servo electric actuator technology have created sustainable and ‘cleaner’ solutions for material converting.
This advanced technology uses a servo electric actuator system which is ideal for Clean Room™ manufacturing. While ideal for medical device manufacturing, a servo electric die cutting press can also be used in other manufacturing facilities that must avoid material or part contamination.
The servo electric technology can enhance the productivity, safety, and profitability of material converters.
Considerations in Choosing a Servo Electric Die Cutting Press vs. a Hydraulic Die Cutting Press
Using servo electric presses for your die cutting and converting applications has multiple benefits.
Cost Effective
A servo electric die cutting press has a smaller footprint and cuts costly parts (vs. a hydraulic powered system), such as filters, pumps, and valves. Maintenance on servo electric die cut machines is minimal – no refilling or worrying about proper disposal of the hydraulic oil. A servo electric system results in a lower cost of ownership over the life of the press.
Faster Production
The shorter reaction time of a servo electric die cutting machine equals higher cycle rates! A servo electric system has superior precision and control that increases flexibility, part quality, and tool life.
Safe & Environmentally Friendly
Low noise levels – there is only audible noise you will hear from a servo electric die cutting press is when the platen is moving. Comparing this to a hydraulic die cutting system where there is the constant noise of an electric motor.
No use of hazardous fluids – a servo electric die cutting solution can be an environmentally friendly and safer option for manufacturing facilities.
Flexibility
Another major benefit of using a servo electric die cutting system is that you can do many of the same things that a hydraulic die cutting system does – which includes using multiple types of tooling (cutting against steel & kiss-cutting, steel rule, match metal, forged, etc.) and the tooling can be mounted in multiple ways. The feed systems vary and can be designed and tailored to specific applications including cutting on a medical grade PET belt, powered tables, and even robot integration.
Energy Efficiency
Servo electric die cutting presses save you money and help the environment, the benefits add up! Servo electric die cutting machines use 80% less energy used than a hydraulic powered die cutting system. The servo electric die cutting presses provide faster cycle times with superior precision and control that increases flexibility, part quality and tool life.
Servo Electric Die Cutting Press Applications
Servo electric presses can be used to die cut, mold/trim, laminate and emboss all types of materials that are converted for consumer, agricultural and industrial applications.
A servo electric die cutting system is perfect for converting materials such as:
Get Started With a Servo Electric Die Cutting Press from Freeman Schwabe®
Servo electric presses are a technologically advanced and flexible option for die cutting processes. Freeman Schwabe® Servo Electric Presses offer increased programmability, precision, flexibility and reliability you can trust.
Need a die cutting machine FAST? Freeman Schwabe has a complete line of in stock machinery ready to ship! Including this 150 Ton belt press with a clamp feed system – ready to cut your roll or sheet non-metallic material.
CGR Products has continued to grow its capabilities by adding several new pieces of die-cutting and converting machinery over the last couple of years. This new state-of-the-art machinery has added new die-cutting capabilities and will bring several benefits to our customers. Benefits include improved efficiency, enhanced quality, expanded product range, increased capacity, and competitive advantages. This new machinery incorporates energy-efficient features, reducing power consumption and lowering operational costs in the long run. Additionally, improved efficiency and quality control can minimize material waste and rework, leading to cost savings for all our customers.
Waterjets
CGR Products has added 4 new state-of-the-art waterjet cutters. These use a high-pressure stream of water to cut, offering excellent material yield and the ability to cut materials that are more difficult to cut with a die. Utilizing a CAD operating system, CGR Products’ waterjet equipment has a rapid change over time and allows for easy dimensional changes to parts.
Slitters
CGR Products has added 2 new Cevenini material slitters and a core cutter. These machines offer slitting of a variety of materials utilizing the technology of displacement slitting (more commonly known as baloney slitting), a process whereby rolled materials are automatically slit without unwinding/rewinding. The high-speed core cutter quickly cuts cores on demand, which increases production speeds.
Belt Driven Die Cut Presses
CGR Products added 2 new belt-driven die-cutting presses featuring auto cad to improve the placement of the cutting die on the material to be cut. These give greater control over die-cutting operations and offer the largest saving in materials. The speed and feeding accuracy are double compared to the traditional systems. The die-cutting capabilities of these machines offer improved reliability and cycle repeatability.
Rotary Die Cut Machine
CGR Products has moved its latest high-volume Delta Modtech rotary die-cutting machine to its Inver Grove Heights, MN location. The MN location is ideal for tape converting and rotary cut applications. This new rotary system is ideal for high-speed, cost-effective, and precision cut parts on high-volume orders. It is ideal for “kiss cut” or “peel and stick” applications. Kiss cutting is performed by cutting through the part down to, but not through, the release liner. The parts are supplied on a roll or pad for easy “peel and stick” application.
We find it essential for CGR Products to effectively communicate these advancements to our existing customers, suppliers, and potential new customers. Highlighting these benefits and increased capabilities will help new business opportunities and reinforce existing partnerships. Die Cut Gaskets, Seals, and custom-fabricated parts are our specialty. Contact us today for your next project.
Used Gapped Plate Laminator System purchased new in 2015. This equipment is located in Rockledge, FL. A video is available. Contact Daniel Martel for more information 819-448-0863 dmartel@protac.ca
Maximum working width of complete system 65″ (1650mm)
Maximum outside roll diameter 65″ (1650mm) both unwind and rewind
All unwinds/rewinds set up for 3″ cores
Allowable material thickness of 2mm-110mm
PSA maximum roll diameter 25″ (635mm)
Maximum roll weight not to exceed 600 pounds
Speed of machine 1-40 feet per minute
Power 240V/3Phases/60Hz
Unwind with two PSA Unwinds
Unwind with web guide system; 5″ correction from center (10″ total); up to 5″ thick
PSA unwinds: 1 unwind to deliver PSA to the underside of the material; 1 unwind to deliver on the top ply of PSA; Each unwind with pneumatic clutch/brake to control tension
Portable table 62″ wide and 100″ long to be used for material in sheets
Laminator Practix Model OK-300
Teflon coated fiberglass belt to carry the product through the laminating process
This belt is 0.018″ (0.36mm) thick
1 lower heating platen
2 upper heating platens
Each heater platen with three-zone heat control
The bottom heater assembly is fixed
The upper platens are gappable from 2 mm up to 110 mm
The front and back of each of the heater platens can be adjusted independently of each other
The movement of the upper heating plates is achieved with a gear motor and an Acme thread The movement is controlled by the HMI
The heating platens is constructed from 20 mm aluminum 6061 plate
The bottom plate measures 55″ long x 74″ wide
The upper heaters platens measure 40″ x 74″
Silicone coated calendar rollers that travels with the upper heater platens
The lower pressure roller is fixed
The upper pressure roller can be adjusted
In-between the two upper heating platens are 2 unwinds and 1 rewind with pneumatic clutches/brakes
This allows for addition of another substrate e.g., aluminum foil
Stop, jog and run button in the area in front of each laminating section
This allows the operator to manage the set up on start-ups by themselves
E stops located at convenient locations
Loading areas with trip wire and safety gate that stop the machine in the event something trips it
Rewind system
2 rewinds
Each with web guide system; 5″ correction from center (10″ total); up to 5″ thick
Human Machine Interface Control (HMI)
15-inch touch screen control with Mitsubishi controls.
Can store up to 1000 recipes
CW800HD Duplex Slitter Rewinder – it’s less than 2 years old and was only really used for 6 months from December 2020 – May 2021
The final cost per machine when purchased $320,000. We are looking to sell one of our two machines $208,000 (35% below our cost)
Purchased brand-new in 2020, this high-speed Elite Cameron CW800HD Duplex Slitter Rewinder can handle slitting many different nonwovens, papers, and films up to 94” wide.
Score Slitting – 33 Off Knives (min slit width 2.75”)
Variable Bowed Roll
REWIND:
2 Off 3” Cantilevered Rewind Air Shafts
Automatic Rewind Tension Control
Slit Tail Web Clamp
Laser Core and Knife Positioning
Unload Cart
Layon Roll
GFA Members, the GFA technical webinar: Rotary Die Cutting vs. Waterjet Cutting is now available in the member’s resource center. Jeff Stetler with DCS USA and Richard Ward with WARDJet present a webinar with a difference! They compare rotary die cutting and waterjet cutting in an interactive manner that is intriguing, full of action, and fun.
Want to know when one machine process would be better than another? This 60-minute webinar will be the place to be.
So, get set to relax and enjoy a brief explanation of these totally different processes that are so important to our industry. Watch the webinar now in the resource center.
CGR Products has added 4 new state-of-the-art waterjet cutters. These use a high-pressure stream of water to cut, offering excellent material yield and the ability to cut materials that are more difficult to cut with a die. Utilizing a CAD operating system, CGR Products’ waterjet equipment has a rapid change over time and allows for easy dimensional changes to parts.
CGR Products has added 2 new Cevenini material slitters and a core cutter. These machines offer slitting of a variety of materials utilizing the technology of displacement slitting (more commonly known as baloney slitting), a process whereby rolled materials are automatically slit without unwinding/rewinding. The high-speed core cutter quickly cuts cores on demand, which increases production speeds.
CGR Products added 2 new belt-driven die-cutting presses featuring auto cad to improve the placement of the cutting die on the material to be cut. These give greater control over die-cutting operations and offer the largest saving in materials. The speed and feeding accuracy are double compared to the traditional systems. The die-cutting capabilities of these machines offer improved reliability and cycle repeatability.
CGR Products has moved its latest high-volume Delta Modtech rotary die-cutting machine to its Inver Grove Heights, MN location. The MN location is ideal for tape converting and rotary cut applications. This new rotary system is ideal for high-speed, cost-effective, and precision cut parts on high-volume orders. It is ideal for “kiss cut” or “peel and stick” applications. Kiss cutting is performed by cutting through the part down to, but not through, the release liner. The parts are supplied on a roll or pad for easy “peel and stick” application.
