New die-cutting method for special labels

In recent years, due to the economic development and the need for market competition, various new types of labels have emerged. These include pure aluminum foil beer bottle seals (hats) and aluminized paper beer bottle labels; all kinds of cover materials made of aluminum foil, PE coated paper, PP or other materials (such as yogurt caps, fast-faced bowl lids, civil aviation The lid of the lunch box, etc.) is molded in plastic containers made of PP, PE, PS or other materials. These labels are often difficult to produce using conventional die-cutting machines (including on-line die-cutting machines) because of the high degree of registration and special materials. Let's take a look at the problems existing in the die cutting of these special labels and their solutions.
First, the cap marked here refers to the use of very thin pure aluminum foil (thickness is generally between 0.010 to 0.012mm) after rotary printing, embossing patterns, injection holes and die-cut bottles made after the closure. At present, most of the processes for the post-press die-cutting of such labels are (1) wind-up after printing, (2) post-cutting of convex and embossed patterns, and (3) flattening and re-injection of a stack of leaflets; (4) ) Flat pressure die cutting.
Due to the length error caused by the cut sheet and the difficulty of aligning the thin aluminum foil with the difficulty of aligning with the color code, the cap labels produced in this way have a considerable portion of positioning errors, even large errors are achieved. Unilateral above 1mm. Now, more and more caps are lengthening and replacing the original neck mark (ie, the label attached to the neck of the beer) with a symmetrical pattern. The inaccurate die position will also affect the appearance of the beer bottle. Also, due to the metal characteristics of the aluminum foil, it is easy to cause a plurality of stickings at the time of the injection hole and the die cutting, thus causing troubles for the labeling of the brewery. Posting double sheets (or multiple sheets) causes waste, and the bottom caps that are stuck sometimes fall off during the transfer process. As a result, the flying is everywhere. In severe cases, mechanical failures of the labeler and the beer production line are also caused. At present, the speed of most brewery production lines has increased from the past 20,000 bottles per hour to the current 40,000 bottles. The problem of sticking labels can cause more serious consequences, and from now on, it should attract the attention of manufacturers.
Second, the wine label here refers to the use of low-weight vacuum aluminum paper (usually between 66-70 grams) after printing and die-cutting after the bottle label made. Because aluminum-plated paper is non-absorbent material, its surface is smooth and its stiffness is poor, so it is more suitable for rotary printing. At present, the conditional label production factories have changed to use more efficient flexographic or gravure printing machines. The cutting process is mainly (1) winding after the printing; (2) cutting the pattern after the embossing and embossing pattern (the wine label without the pattern is directly cut after the printing); (3) the plastic head (ie the label The glue is glued on the top of the head to prevent slipping of the underlying material during the entire stack of blanks, or scraping into small pieces; (4) Die-cutting on stamping or extrusion type die cutting.
Due to the positional errors and full stacking caused by cutting single sheets, cutting small sheets and plastic heads, the following materials are difficult to slip (even after the plastic head), and the color scale registration cannot be used when die-cutting. A considerable portion of the wine labels came out of position and the unilateral errors were more than 1mm. And more and more label designs are printed with border lines around them. The distance from the border line to the edge of the paper is only 2mm (such as Suntory Bid). Once the unilateral error exceeds 0.4mm, it is obvious enough to affect the beer. The appearance of the image. In addition, due to a large number of subsequent processes, there will be an inverted mark (two cases: one is upside down and the other is reversed). When the label is touched, it must be reworked. This caused a lot of trouble for the brewery.
In short, the use of the above process to produce caps and wine labels has a high rate of rejects, quality is difficult to guarantee, and it takes a lot of manpower, and it also brings a lot of problems to users - the brewery. So what is the solution?
For production plants that use web printers for printing caps and labels, special die-cutting machines, such as the Deckel series of high-precision web-fed die-cutting machines manufactured by Remele, can be considered. Its characteristics are advanced photoelectric register technology, horizontal and vertical registration accuracy is within ±0.15mm, Capkel material suitable for Deckel Boy SL, its feed width is 200mm, speed is 240 punches per minute. , You can complete a variety of subsequent processes at once, including embossing patterns, injection holes and die cutting. For example, the double caps can produce 28,800 tags per hour, 600,000 tags per day (three shifts), and 180 million caps per year (with 300 working days).
The models suitable for wine labels are Deckel Master 320 and Deckel Master 500. The paper feed widths are 320mm and 500mm respectively. The speeds are 240 punches and 170 punches per minute respectively. It is also possible to complete various subsequent processes at one time, with Deckel For example, the Master 500 can produce 40,800 labels per hour for four-seat triple-drink labels. It can produce 850,000 labels per day (three shifts) and 255 million labels each year (with 300 working days).
Since there is no need to cut a single sheet, the distance and position between the trademarks when typesetting can be carried out in the most material-saving way. The use of high-precision web-brand die-cutting machines produces caps and wines with high registration accuracy, low reject rate, and material savings, without the inversions and sticking caused by a wide range of downstream processes such as cutting of leaflets. Problems such as the quality of headaches encountered by various breweries, and the large amount of labor that can be saved.
The aforementioned lidding materials, such as yogurt lids and quick-faced bowl lids, are actually special labels because they are printed with fine designs and logos. In addition, in recent years, in Europe and the United States and other developed countries increasingly popular plastic containers molded in-mold labels, but also a special label. Due to the special material and high precision of registration, these two products can use high-precision web-brand die-cutting machines for register and die cutting.
Then, how can a factory that adopts sheet-fed printing and cuts Zhang Xiaozhang's die-cutting process? Consider a multi-layered trademark cutting machine such as Lombardi's Master series. The feature of the machine is that it can perform multi-layer cutting and cutting on various shapes of labels without cutting the sheet. It does not need to be scrapped and the speed can reach 65 times per minute, and the output is about 250,000 marks per hour. In order to improve the accuracy of registration, it is necessary to do as much as possible at the time of printing, constant temperature, constant humidity, printing and timely die cutting (to prevent paper deformation), before the die cut paper stack. Because the machine mold can rotate 360 ​​degrees, the typesetting can be done in the most provincial way. The machine adopts cast steel molds and can be produced in China. (Tian Jun, president of the United States Cheung Fung Young Line) (From "Print Today")

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