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.
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Our solid die types cover any product challenge you’re facing by providing solutions for food and medical grade products, and those converting 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
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.
IMPACT’s Pulse Air™ system offers an improvement over standard air eject tools. This system utilizes a special air manifold to control and direct the burst of air to each cavity as the tool rotates. This means you achieve the most effective slug removal while reducing the amount of air pressure required. Pulse Air™ dies require no press modification.
Advantages of the Pulse Air™ System include reduced air consumption, higher air velocity, and highly directional air delivery. This method is user-friendly with superior slug removal and high press feed efficiency.
Sometimes due to press constraints it is not convenient to eject a slug immediately after cutting. The Vacuum-Transfer method allows slugs to be held in the die cavity under vacuum and transferred around the die to a preferred point of ejection into your collections system.
This method also allows you to separate an inner slug from a finished (OD) part without using separate die stations. This eliminates the need for die-to-die registration between die stations.
This System uses a matched die and anvil configuration. This scrap removal system has been run at press speeds over 800 feet per minute with 100% scrap removal. Matched set tooling uses a “pin” to stab the scrap and pull it down through a removal comb. Some minor modification is required to the support/drive rolls for pin clearance, and the addition of the comb for stripping the pins. All modifications can be performed by IMPACT and are adapted for each specific application.
Advantages of the Stripping Pin Removal System: Highest press speeds 100% removal rate No interference with normal press operation Minimal operator involvement Pins are removable/replaceable
Vacuum dies offer an effective means for removing small die cut waste from the web. A vacuum die uses suction to pull waste through the center of the die, and out the end of the journal using a vacuum assist block. Removable inserts are used to provide increased clearance for the waste slugs that must pass into the die’s core, reducing the chance of buildup that could cause blockage of the air passage.
Vacuum dies are most effective on small cavities, thin materials, tag stock, polyesters, and materials without adhesive.
Screw-in spring plungers offer positive slug removal from die cavities when cutting stiffer materials. The spring-loaded plunger “pushes” out the scrap, freeing it from the die to be collected with a vacuum collection system. The plunger extends beyond the blade of the die, but retracts as the die rotates in the press. This method is highly effective for ejecting stiff materials such as metal, thick tag, rigid vinyl, and polycarbonate. Screw-in design allows for easy replacement on-site.
Advantages of Spring Plunger Ejection include low cost, no press modification requirements, easy replacements, quiet, and very strong ejection capabilities.
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.
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.
.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.
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:
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.
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.
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.
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.
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.
If you are looking for the best tooling to handle high speed cutting of abrasive materials, IMPACT has the answer that will not only lower your manufacturing costs, but also increase your productivity. We use a unique self-sharpening blade angle and bearer-less tool design. The self-sharpening blades eliminate reconditioning costs, while the bearer-less design allows the tool to continue to cut as the blades begin to wear.
Whether you need “control depth cutting” to a liner for pressure sensitive applications or “metal to metal cutting” for individual part manufacturing; Whether you are converting sandpaper from a low 120 grit silicon oxide to the most sophisticated glass polishing pads for the eyeglass industry.
We offer Insertable Blade Sheeting tools, providing a low cost method of sheeting using replaceable steel rule blades. Because individual and multiple slots may be used as required at any given time, a single tool can do the job of many more expensive dies.
Our CamLoc™ blade holding system allows fast blade removal requiring only ½-turn of each screw. This unique design also eliminates thread stripping so common with conventional set screw blade holding. ‘On-press’ blade replacement increases press efficiency and reduces run time. The CamLoc™ system enables IMPACT’s lightweight sheeter design, incorporating an aluminum body coupled with fully-hardened tool steel bearers and journals.
Advantages of Insertable Blade tooling:
Three-piece tool design dramatically reduces the weight of large repeat and wide web tooling. Manufactured using high-chrome tool steel, hollow tooling sacrifices nothing in performance, at a fraction of the weight of solid dies. Reduced weight means lower shipping costs, when new and when shipped for future reconditioning.
Hollow tooling also offers the ability to pump heat or cold through the die to apply different temperatures to the web as required. Used as a “chill” roll with cooling systems, these tools can be used to help “set” adhesives on hot melt coating lines.
Segmented dies require a mandrel that serves as a base surface for the segments to attach to. Once segments wear out or are damaged you replace individual segments, providing a cost-effective alternative to an entire die retool.
To accommodate thick materials such as PVC foam or even finished pouched products, die cavities can be deepened to minimize cutting distortion. Added cavity clearance also minimizes web retarding and “bagging” due to web compression. Extra depth routing is recommended anytime thicker materials are to be converted.
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.
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.
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