Solid Rotary Die for Label Die Cutting

Solid dies are made to order for the machine, shape and repeat. RK needs the following for a quotation:

• Machine make and model (RK machine name, or the maker, model and gear pitch of another rotary die cutting machine)
• Label artwork or die drawing with dimensions, corner radius, gap and number across and around
• Repeat length or teeth count of the die station
• Web width and the material to be cut – face stock, adhesive and liner
• Kiss cut (leaving the liner whole) or full cut through

A solid die, or solid rotary die, is a one-piece steel cylinder with the label shape engraved as raised cutting edges on its surface. The edges are hardened so they keep their sharpness through long runs. Like other rotary dies, it is geared to the machine drive and rotates against a hardened anvil roller with the web in between, cutting the label shape once per revolution.

The solid die is the older and heavier of the two rotary die types. Its strengths are edge life, cutting depth stability and the ability to cut heavier or tougher stock than a thin flexible die can. Its limits are cost per shape and the fact that one die cuts one shape only, which is why it is chosen for long-running, repeating jobs rather than for a plant with many short jobs.

One-Piece Hardened Construction

The cutting edges and the cylinder body are one piece of hardened steel. There is no die plate to lift or slip, so cutting depth does not drift over a long run.

Long Edge Life for High-Volume Jobs

Hardened edges keep cutting cleanly through very long runs, which is what makes the solid die economical for labels that are produced continuously.

Made to Your Label Shape and Repeat

Each die is engraved to the customer's artwork – label size, corner radius, number of labels across and around – on a cylinder cut to the repeat and teeth of the machine.

Suitable for Heavier and Tougher Materials

The rigid edge and stable depth let a solid die kiss cut thick or abrasive label stocks, and full cut unsupported materials, where a flexible die would wear or deflect.

Fits RK Rotary Die Cutting Units

RK makes the die stations the die runs in – on rotary die cutting machines, slitters with die cutting and flexo presses – so the die is made to the correct gear pitch and shaft arrangement.

Re-sharpening Where the Edge Allows

Depending on the shape and the wear, a solid die can be re-sharpened and returned to service, extending its life further.

The solid die is mounted in the rotary die cutting station and geared to the machine, so it turns in step with the web. The die's raised edges are set against a hardened anvil roller with a fixed gap. As the printed web passes between them, each cutting edge presses through the label face stock and adhesive down to the surface of the release liner but not through it – a kiss cut that leaves the labels on the liner ready for the next stage.

Because the die and the anvil are both hardened steel and the die is one piece, the cutting depth is set once and stays the same across the whole run. The waste matrix between the labels is lifted away and rewound, and the finished labels continue to slitting, inspection or rewinding. On a full-cut job – unsupported paper, tags or card – the edges cut right through and the pieces are collected or the web is sheeted.

• High-volume self-adhesive labels – pharma, FMCG, lube, agrochemical and other labels run continuously in one shape.
• Rotary die cutting machines – RK's rotary die cutting and slitting machines with turret or up-and-down rewinding.
• Die cutting stations on flexo presses – inline die cutting behind the print units.
• Heavier and abrasive stocks – thick paper, board and film labels where edge life matters.
• Full cutting of tags and cards – unsupported materials cut right through on machines built for it.
• Replacement of a worn solid die – re-making an existing shape to the original machine.

With the right edge profile and depth setting, a solid die kiss cuts the standard self-adhesive label stocks – paper, chromo, thermal, PP, PE, PET and similar film labels on a release liner – and full cuts unsupported paper, tag board and film on machines designed for full cutting. Its rigid one-piece edge suits thicker and more abrasive materials better than a flexible die. Tell RK the exact face stock, adhesive and liner so the die is engraved and set for it.

• Flexible Diethe thin steel die for short and medium runs, carried on a magnetic cylinder.
• Magnetic Cylinderthe base cylinder that holds flexible dies in the die station.
• Printing Cylinderaluminium plate cylinders for RK flexo printing units.
• Rubber Rollnip and pressure rolls for printing and converting machines.
• Powder Brake and Clutchunwind and rewind tension control.

RK Label Printing Machinery Pvt. Ltd. has built label printing and converting machines in Ahmedabad, Gujarat since 1995, works from three manufacturing units and supplies customers in 23+ countries. RK designs the rotary die cutting units the die runs in, so the die is matched to the machine's gear pitch, anvil and shaft from the drawing, not measured from a worn part. The company supplies both solid and flexible dies, and will tell a customer plainly which one suits the job rather than sell the more expensive tool.

• Run length: a shape that runs continuously in large quantities justifies a solid die; a plant with many short jobs is better served by flexible dies on one magnetic cylinder.
• Material: thick, abrasive or tough stocks and full-cut work favour the solid die's rigid edge.
• Cost per shape: the solid die costs more per shape but lasts far longer; the flexible die costs less and is quick to replace.
• Machine: confirm the die station's gear pitch, teeth and shaft arrangement so the die meshes correctly.
• Artwork accuracy: send the final label artwork; the die is engraved to it and cannot be changed afterwards.

The price of a solid die depends on the cylinder size and repeat, the complexity of the label shape, the number of labels across and around and the machine it is made for. Prices are quoted ex-works Ahmedabad with GST at 18% applicable. If an RK engineer fits and sets the die at your plant, the engineer's transport and stay are borne by the customer. Send RK your label artwork, material and machine details for a quotation.