A large folding carton manufacturer was consistently experiencing blade breakage during production runs. Frustratingly, their vendor offered no solution. 

The firm had recently attended Pack Expo, and had connected with experts at IMPACT who had demonstrated their knowledge of troubleshooting folding carton design. In need of a real solution, the folding carton manufacturer decided to reach out and forwarded a picture of the broken die. 


After a free, in-depth consultation to gain understanding of the nature of the job, the IMPACT engineering team got to work evaluating the die layout, and recommended the following design modifications: 

  1. Revising the standard reverse tuck with a radius to aid material separation and relieve a known pressure-point on folding carton dies.


  2. Revising from 4-across layout to 3-across, because the 4-across width created difficult scrap removal areas that slowed production speed. IMPACT indicated the press speed could be increased from 350 ft/minute to 500 ft/minute—more than making up for the loss in width because of the better-running radius tuck design.


  3. Recommending the die be made with the firm’s Max-Life D2 Tool Steel with its exclusive deep-cryogenic treatment based on the high-volume, long-running nature of the job.

IMPACT’s sales guys were mindful that the deep-cryo treatment would raise the price about 15% over a die without it, and that the folding carton manufacturer had no experience with Cryo dies or IMPACT. They quoted the job and described the rationale for the layout and material changes versus the specifications provided. 

And because the folding carton manufacturer recorded all tool performance statistics, IMPACT offered the deep cryo treatment with the promise that if they did not experience exceptional performance gains, the cost of the cryo treatment would be refunded.


The customer purchased a replacement die from their original die supplier because getting the line up and running quickly with a new die was mission critical. But, with IMPACT’s guarantee, they also purchased the IMPACT die to conduct a side-by-side comparison. Here’s what the Plant Manager had to say about their comparative analysis: 

“We found the IMPACT die ran about twice as long as the die we had been using. We were very pleased with it’s performance statistics,” which we was happy to share:

  • 65% faster line speed than before, close to 600 ft/minute, with no hang-ups or downtime
  • 30% more finished product per shift
  • 15% lower tooling cost over a year (dies, retools, shipping)
  • 23% lower cost per thousand cartons 


Often it’s a crisis that drives us into action, forcing us to change the way things get done. But IMPACT guarantees your satisfaction or we will repair, replace, or refund. Period. So you don’t have to wait for a failure or breakdown in your process to optimize your press and realize savings. IMPACT is here for you. And our experts would love to help you with your next challenge.