Trends in Large Format Die Cutters

As shown in Larson Worldwide Article–October 2011
(Re-printed here with permission from My Press Needs LLC)
(http://www.mypressneeds.com)

Trends in Large Format Die Cutters
Over the last several years, the large format market exploded in packaging, P.O.P and digital print.  Today’s digital printers run sheet sizes as large as 62” x 102” at speeds up to 175 an hour, and industry insiders only expect this number to increase over the next several years. However, the average digital die cutter runs only 15‐30 sheets1 an hour, creating a bottleneck in this high‐speed, large‐format production environment.  Initially, companies installed lasers and plotters hoping to increase the production times with newer technology.  However, many found that lasers and plotters, often marketed as digital die cutters, slowed production because the machines typically can only cut one coordinate at a time.

In many instances, die cutting teams returned to traditional technologies that allowed them to cut an entire image in a single pass.  Die cutting departments realized significant production gains when they installed a clamshell or flatbed die cutter, which cuts with a single impression.  To accommodate the growing demand for large format clamshells, My Press Needs introduced a larger format clamshell in both its Crest and Jack Rabbit series.

“In 2007, our most popular press size was a 40 x 56 inch press, but in the last two years, the majority of inquiries were for 80 and 125 inch presses,” said Rob Weidhaas, President of My Press Needs LLC.  “While the requests for larger die cutters increased, few companies offered larger clamshells, which is why we decided to introduce larger sizes in both our Crest and Jack Rabbit series.”

The Crest offers users the “No More Make‐Ready”™ fast setup, precision die cutting for large format displays, boxes, etc.  The Crest Clamshell provides users with the fastest setup and most precise cut.  While the Jack Rabbit, offers users a flat platen, but is a more price‐sensitive alternative to the Crest Clamshell.  Both the Crest and Jack Rabbit are available in sizes up to 66” x 125.”

My Press Needs recently installed a 62” x 96” Jack Rabbit at CoolSeal USA; a joint venture between Hinkle Manufacturing and Tri Pack Plastics located in Perrysburg, Ohio; to meet the needs of its large format die cutting division.  The Jack Rabbit, with its fast set‐up times and large platen, will allow CoolSeal USA to die cut large jobs in less time than a laser or plotter to serve the company’s short to medium run needs.

To satisfy CoolSeal USA’s medium to long‐runs, the team selected another single pass die cutter, the Redline, a semi‐automatic flatbed die cutter with fast job set up times.  Tab Hinkle, President and General Manager of CoolSeal USA, recognized the similarities between his two die cutters and introduced Steve Waterhouse from Diecut UK to Rob Weidhaas from My Press Needs.  When Waterhouse and Weidhaas met, they realized the synergy between their companies and products.  The clamshell press meets the needs of a short to medium‐run production environment in a single pass; while the Redline offers a solution for die cutters that need to run higher volumes.
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1 Die cutting speeds vary widely.

The introduction by Tab Hinkle, their mutual customer, led to today’s partnership between Diecut UK Limited and My Press Needs LLC. My Press Needs represents the Redline and Whiteline semi‐automatic and automatic die cutters in North America; while Diecut UK now represents the Crest Clamshell and Jack Rabbit clamshell series throughout Europe.

“The Redline and Whiteline automatic and semi‐automatic die cutters expand our ability to meet the evolving needs of large format die cutters, “said Weidhaas, President of My Press Needs. “By adding flatbed die cutters to our clamshell product line, My Press Needs can offer solutions to today’s large format die cutters, P.O.P. and packaging companies that need to improve their short, medium or long run production.”

“While many companies manufacture clamshells, we felt either the quality of the product was poor or the individuals were quantity focused, not quality focused. We wanted a partner who was ambitious and committed to the industry, which is why we chose to work with My Press Needs,” said Waterhouse. “We can now offer our UK and European customers a clamshell manufactured from highest grade raw materials.”

Key Features of the Crest Clamshell:
Today, the Crest is known as the “No More Make‐Ready” Clamshell and provides the fastest set‐up and make‐ready times in the industry. Crest users set up most jobs within 8‐10 minutes based on the press’ advanced engineering and proprietary anti‐deflection platen design.
Crest Sizes: 25”x35”, 30”x43”, 33”x46”, 40”x56”, (2M) 60”x82”, (2.5M) 60”x105”

Key Features of the Jack Rabbit Clamshell:
The Jack Rabbit, an introductory clamshell, features steel construction, quality raw materials and is designed to service the general die cutting markets. The Jack Rabbit shares one design element of the Crest; the press’ split‐frame design offers users the capability to run heated applications and custom configurations, such as bolster die cutting.
Jack Rabbit Sizes: 20”x26”, 28”x41”, 38”x54”, 44”x66”, 58”x80”, 62”x96”, 65”x97”, 68”x107”, 66”x125”

Key Features of the Redline:
The Redline, a semi‐automatic press, will kiss cut or die cut a variety of substrates either in a hand‐fed mode or fully automatic. This allows users to select hand feeding for short runs or difficult substrates and fully automate the press for longer runs.
Redline Sizes: 43.3”x59.8,” 47.2”x67.7,” 55.1”x75.6,” 59.1”x83.5,” 66.9”x87.4,” 66.9”x99.2”

Key Features of the Whiteline:
The Whiteline, a fully automatic flatbed, provides users with a cost‐effective solution for high‐volume, large‐format corrugated die cutting.
Whiteline Sizes: 39.4”x51.2,” 43.3”x59.1,”47.2”x67,” 51.2”x74.8,” 59.1”x82.7,” 66.9”x98.4”

For more information on any of the products mentioned in this article, please contact My Press Needs Toll Free
866‐347‐1200 ext. 804 or e‐mail sales@mypressneeds.com
My Press Needs LLC
National Sales Office
3001 North Rocky Point Drive East, Suite 200
Tampa, FL 33607