Products

SOLID ROTARY DIES

Our solid dies types cover any product challenge you’re facing by providing solutions for food and medical grade products, and those are dealing with very abrasive materials. Our high precision tooling, made for tight tolerances, is long lasting and beneficial to your bottom line.​

MRD1000: CORROSIVE RESISTANT TOOL STEEL
Food Grade
Medical

MRD2000: VERSATILE TOOL STEEL
Most Commonly Used
Average Yield Jobs

MRD3000: SUPERIOR TOOL STEEL
Medium-High Yield Jobs

MRD4000: ABRASIVE RESISTANT TOOL STEEL
Cryogenically Treated
Used for Abrasive Materials

MRD5000: PREMIUM PROPRIETARY TOOL STEEL
High Yield Jobs
Used for Challenging Abrasive Materials

SLUG REMOVAL

There are several different methods for removing slugs and other waste from converted parts or the web. They range from low tech to high complexity; cost-effective to expensive; and have pros and cons to each method. Finding the perfect combination for customers is the goal, and IMPACT has the most comprehensive solutions in the industry for removing web waste.

Special Die Coatings

Non-stick coatings are available from IMPACT for applications such as cutting exposed adhesive. This coating does not affect the blade quality or cutting performance. The coating is applied with base coat at our facility and the tool is ready-to-go upon arrival. Additional applications of the non-stick coating may be purchased from IMPACT and applied at your facility if desired. Other coatings offering corrosion protection, extra durability, or special release properties are also available.

WHITE NON-STICK

           Our standard non-stick is a white silicone release coating that is applied on the die evenly in house prior to shipment. This coating can be removed easily prior to retooling and re-applied as needed.

CLEAR NON-STICK

           The clear non-stick is a treatment coating on the die that actually impregnates into the steel and provides a non-stick surface to the die that won’t flake off. Though this coating has a longer cure time than our standard non-stick, retooling does not require removal of this coating but rather a quick re-application with a quicker cure time.

CORROSIVE RESISTANT COATING

           Many converters using material with high moisture content seek this option for coating their dies to prevent corrosion of the steel.

PERFORATIONS

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.

   STANDARD PERFORATIONS

3/32″ cut, 1/32 tie is industry standard, fold perforation for folding carton is typically 0.125″ cut & 0.125″ tie. Customers can request custom perforation specs as needed.

 

   MICRO PERFORATIONS

.030″ or less tie is considered a micro perforation. IMPACT has precise machining capable of creating micro perforations as small as .010 tie with a .020″ cut.

 

MULTI-LEVEL CUTTING

IMPACT’s multi-level cutting tools enable the converter to manufacture complex parts with a single rotary die. Tools have been successfully created with up to five different cutting levels in the same tool.The production advantages are obvious:

  • Lower cost due to reduced number of tools required to accomplish all needed cuts
  • Less waste due to elimination of registration between stations
  • Reduced press setup by combining several tools into one
  • Higher press speeds leading to shorter converting runs to achieve the same volume.

CRUSH CUT DIES

We invented the solid hardened rotary die in the late 1960s by creating a wedge-type cutting edge on a solid cylinder through the use of EDM (electric discharge machining). Our proprietary process allows us to precisely manufacture dies, thereby achieving high-quality cuts at high speeds for countless materials and products. We make our crush cut rotary dies from solid tool steel, assuring an exceptional level of hardness and longevity. We manufacture these dies to exacting tolerances in order to ensure a precise cut, smooth die rotation, and consistently accurate results.

REASONS TO USE CRUSH CUT DIES:
  • Capable of extremely high-speed operation
  • Machine sharpening
  • Fully-hardened, solid steel construction for strength and longevity
  • Dies can be partially or fully segmented
  • Capable of quick-changing
  • Precise cutting shape tolerances
  • Scrap stripping

SHARPENING CRUSH CUT DIES

                     Each crush cut die produced at IMPACT is durable enough to withstand multiple sharpenings throughout its die life. Each time we sharpen an IMPACT crush cut die we bring it back to the same flawless quality it had when it left our facility, keeping it as precise and consistent as the day you installed it.

PARTIALLY OR SEGMENTED ROTARY DIES

                   Our crush cut dies can feature specially designed segments and removable rings to accommodate a wide variety of applications and enable selective repair of high wear areas. In addition to cutting, these partial or fully segmented dies are also perfectly suited to embossing and laminating. The removable segments turn a generic carton die into a fully customizable solution for several end-users simply by changing customer specific segments in the die, spreading the cost justification of a single die set over multiple customers and applications.

High-precision machining techniques are essential to producing dies with exceptionally long life-spans. Our Advanced Machining Lab with a climate controlled environment ensures that your die is manufactured to the highest standards, using CAD/CAM, CNC and CMM inspection.

SPECIFICATIONS

  • Cutting edge accurate to .001″(.025mm)
  • Web widths from 1″ to 110″ (50mm to 2794mm)
  • Die diameters from 3″ to 40″ (76.2mm to 762.0mm)
  • Run-out accurate to .0001″(.0025mm)
  • Hardness: 60-62 RC
  • Sharpenings: up to 5

CRUSH CUT DIE LIFE COMPARISONS

 
SBS Board – 40 Million Revolutions
Poly Board – 80 Million Revolutions
Lead – 8 Million Revolutions
PVC – 5 Million Revolutions
Sandpaper – 2 Million Revolutions

TYPICAL MATERIALS

  • Poly Board
  • Cloth
  • Lead
  • Sandpaper
  • Polypropylene
  • Paper
  • Recycled Board
  • Dough
  • Non-woven
  • Laminates
  • Fiberglass
  • Copper

MATCHED SET TOOLING

Many applications require ‘matched’ tooling for enhanced production performance on press. IMPACT’s specialized tooling sets address a wide variety of manufacturing challenges. 

Single-station folding carton tooling combines cutting and creasing in one die station, eliminating the need for cut to crease registration between multiple stations while also lowering tooling cost, set up time, and material waste.

Dual function die sets allow cutting from the top and bottom of the web in a single die station. Often called “stack dies,” this setup can either consist of two cutting dies with an anvil in between or two stacked cutting dies with anvil pads on surface opposite of cutting blade on each die. This eliminates registration requirements between stations, as well as the common problem of “wander” of the unseen undercutting tool.

Vacuum anvils matched to a cutting die enable precise island placement capability, holding a part to the anvil until a specified location is reached.

Stripping pin anvils matched to a cutting die enable extremely effective slug removal in folding carton tooling and can also be used to remove other scrap and matrix waste at high speeds.

Phase adjustable gearing enables precise registration of upper and lower tools. Simple on-press adjustment is possible without removing tools.

HEATED TOOLING

Many specialty converting applications require the addition of heat to the die to assist in cutting exotic materials (fabric, poly, non-wovens), or to seal material as it cuts for improved edge quality. Heated dies can also be used to seal two or more layers of material. The rotary tool is designed to accept an internal heat cartridge which heats the tool to a preset temperature. Heated tooling finds wide usage in the packaging industry. In-line sealing offers wide versatility for “single pass” production using rotary dies. Heated tooling requires an external heat controller to regulate temperature. IMPACT’s tooling can be made to work with your controller, or with IMPACT’s ThermoDie™ Heat Controller. This controller uses a non-contact, infrared heat sensor to read tool surface temperature for precise control within ± 5°F.

SPecial tool machining

If you’re facing a product challenge that requires a unique blade application, IMPACT’s design team will collaborate with you to ensure proper fit, and effectiveness are implemented. Often your rotary converting project calls for a die with unique features. Would your application benefit from hollow-body tooling for reduced weight? Deep routing for part relief or thick stock? Special blade angles to improve cutting an exotic or abrasive material? IMPACT will collaborate with you to assure you are getting all you can from your rotary tooling. Best of all, we’ll ask the right questions to assure you get exactly what you need from your cutting tool.

RP® DIES

Our RP® rotary dies represent a breakthrough technology in the folding carton industry for solid rotary tooling since the mid-1980’s. These dies provide significantly longer die life than conventional rotary dies while maintaining like-new cutting quality and minimizing waste by using shearing blades on both the upper and lower dies.

The unique shearing action of our RP® dies assures the best cut quality and the longest die life when cutting materials suitable for this cutting process. We offer a wide variety of RP® die options, with various steel alloys and hardening techniques, in designs with and without journals. High wear areas can be fully segmented for quick and easy maintenance in between full servicing intervals. Whatever your needs, we have a die priced to generate the lowest cost-per-thousand for the most carton volumes across the industry.

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

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