How integrating Omron Automation extends die-cutter performance.

Developing an integrated drives and machine control solution from Omron Automation has allowed UK producer of label die-cutting and finishing equipment Daco Solutions, to meet converting industry needs for fast and precise changeover between die-cutting options for high output and lower-output digital print.

As Daco Managing Director Dave Beynon explains, while low-output digital print was the norm, converters would match presses with dedicated semi-rotary die-cutters, typically running at speeds of up to 40m a minute. But with demand growing for digitally printed labels in food and drink, and other consumer sectors, digital inkjet technology is now printing labels at much higher speeds. In Daco’s case, full rotary die-cutting will run at up to 175m a minute. “With our new DF350SR system, label converters handling short and long runs can switch between semi-rotary and full rotary mode, with a changeover time of only 10 minutes,” says Dave. “By using Omron’s NJ controller, we have produced a powerful and flexible piece of kit, which effectively works as several machines in one.”

Change of operating principle

A change of operating principle is necessary because full rotary and semi-rotary die-cutting use completely different types of tooling. Cylinders for full rotary operation are expensive to produce, but the cost is justified by the high volumes of labels being printed. Semi-rotary tooling consists of a magnetic foil, which is cheaper to produce and therefore suitable for shorter run lengths.

The foil wraps around the die-cutting cylinder, but unlike the standard cylinder, it is not in register with the label web. Because the semi-rotary foil only covers a proportion of the cylinder’s surface, the movement of the label web has to adjust. In fact, the web moves forward and then reverses slightly with each turn of the die-cutting cylinder, creating an oscillating movement. The challenge in motion-control terms is to ensure precision in these movements so that each label is accurately cut in register.

Trend towards shorter runs

Daco Sales Manager Mark Laurence discusses the new trend: “There is greater demand around the European food and drink industry for digitally-printed shorter runs, as manufacturers produce more line extensions. The new EU labelling regulations require labels which specifically match the product in question (for example, regarding allergens) rather than generic labels.”

As a small company founded 15 years ago, Daco competes most effectively in the niche and bespoke converting machinery segment. This latest semi-rotary die-cutter allows it to take on some of the largest equipment companies in the important – and growing – high-output digital niche.

The machine is controlled using an NJ controller, G5 servo drives and Omron’s NB human-machine interface (HMI) making it easy to programme and operate. Says Dave. “A lot of our machines go to far-flung countries, and it’s always the electrics that customers worry about, so working with Omron Automation has been a really good selling point for us.”

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