Products

MODULES & SYSTEMS

A WIDE VARIETY OF CUSTOM MODULES, SYSTEMS, AND DIE & PRESS ACCESSORIES TO COMPLETE YOUR CONVERTING SYSTEM

IMPACT offers portable, or permanently mountable press stations, narrow web systems, and custom purpose-built systems to meet your converting requirements.

PROTOTYPE
PRESS STATIONS

Many customers are using these manually-driven presses for short runs, prototyping, or testing applications. The module is portable, or permanently mountable. They can be operated as stand-alone units, or integrated into your processing line.

IMPACT offers these manually-driven presses for short runs, prototyping, or testing applications. Many customers are using these manually-driven presses for short runs, prototyping, or testing applications. The module is portable, or permanently mountable. They can be operated as stand-alone units, or integrated into your processing line. They are used in multiple industries, including Medical, Automotive, Specialty, and many others.

KEY FEATURES

          Simple to use fixed or infinite-adjust material guides

  • Customizable out-feed guides, with or without material stripping
  • Crystal clear safety guarding
  • Durable double-truck hold down units
  • Multiple lubrication ports for easy maintenance
  • Manual operation (easy hand wheel), or integrate into your drive system
  • Hydraulic or digital pressure gauges can be added for more precise pressure application
  • Press stations are available in standard press widths of 7, 10, 16, and 24-inch, or customizable per your specifications to fit your current die blank on press for easy prototype to production progression.

DIE CUTTING MODULES

IMPACT Modules are designed to maximize die performance. As premier die manufacturer, we know the qualities required in every module design to assure precision die cutting with trouble-free operation. Modules come in many standard sizes and are designed to suit a wide variety of applications, including folding cartons, medical supplies, consumer products, batteries, foods, and many others.

SINGLE-SLOT MODULE

         Single slot modules carry four bearing housings in which the upper and lower tools are mounted. We offer this type of module with and without in-module stripping capability.

DUAL-SLOT MODULE

          We recommended dual-slot modules when extreme precision between first and second station tooling is an absolute must. This arrangement allows two tool sets to be removed and kept in register with each other. The majority of our dual-slot modules are configured in a base-mounted or roll-in style, so the module can roll or lift onto a set-up platform.

MODLE BEARINGS

          Our family of bearing housing designs can support our largest dies or cylinders up to 110” (2800mm) in product processing width and up to a maximum diameter of 35 inches (890mm). Available bearing designs are manufactured to extremely low-tolerance specifications, and available with either oil or grease lubrication. The bearings used are of the highest quality and precision, and capable of the RPMs needed to reach die cutting speeds of up to 1,500fpm (500 mpm).

 

SCRAP REMOVAL SOLUTIONS

          We offer a variety of stripping methods to remove both continuous scrap and island scrap without sacrificing speed or precision. In-tool stripping features a pin mounted in the lower tool to skewer the scrap, and a stripping comb mounted to a rigid assembly to lift the scrap off the pin, which is then vacuumed away. We also provide outboard stripping, in which the stripping pins (which may be fixed or retractable) are housed in a separate cylinder and in a separate station.

 

The precision modules we make allow our dies to operate at their highest speed and achieve the longest life possible. The rigid construction of our dies eliminates the flex that causes premature die wear and poor cut quality, resulting in a die that will outlast and outperform its competition.

We excel in creating and manufacturing 100% custom die cutting modules. Our knowledge and expertise allow us to design modules that fit seamlessly into our customer’s existing rotary cutting or processing systems — even those designed by other manufacturers.

FEATURES & BENEFITS

Our side, bottom, and top plates are stress-relieved, precision-machined and assembled in highly rigid box sections. All Bernal modules include bearing housings of our own design and manufacture, with print class, precision-matched bearings.

 

  • In-module pin stripping
  • Rapid changeovers
  • Maximized die life
  • Compatible with all types of rotary dies
  • In-stock parts
  • Single-source die and module responsibility
  • Highly rigid box construction
  • Precision bearing housings
  • Rigid stripping comb assemblies
  • Temperature-controlled oil lubrication
  • Grease lubrication
  • Side, rotational and skew bearing adjustments
  • Available in journaled and journal-less versions

ROTARY
SYSTEMS

IMPACT was the first to incorporate “invisible” perforation into engraved cutting tools. Once only achieved using steel rule dies, now irregular and complex shapes can have all the aspects of an invisible perforation in fully-hardened rotary dies. Clean edge perforations up to 50 TPI are available.


NARROW WEB SYSTEMS

PURPOSE BUILT SYSTEMS

our development process

The Moment of IMPACT

IMPACT’s industry knowledge is deep and vast, with experience and solutions for the growing demands of its customers’ converting needs. The experts at IMPACT look several steps downstream at its customer’s customers. The company can create a “moment of impact” when the consumer sees its product. IMPACT gives them the resources of experience, knowledge, and solutions to create – their moment of impact.

Customers benefiting from IMPACT’s one-stop-shop offerings include large national integrators with 200-300 facilities producing a wide range of items. They gain efficiencies by having one company service them. Converting is more than just cutting a box – it’s also folding, creasing, scoring it, making an opening feature that will tear when it’s supposed to but not before. IMPACT has found that most converters will use a combination of means to convert, cut, crease, and fold material. IMPACT is incentivized to offer the best solutions that meet all its customers’ requirements.

Products

From Start to Solution

We help create brilliantly designed, engineered dies, and systems.