Mike Davison of Intech reports on the development of Laser die cutting for labels cartons and sleeves.

The ability to digitally die cut labels, cartons and sleeves has been available for some time, but until recently there was no place for the technology in the narrow web printing and converting market. However, the industry has moved on and we are increasingly seeing short-run, JIT orders becoming common-place and the growing presence of digital printing machines providing the opportunity for incorporation of digital converting systems.

Now that the digital world is growing in all sectors of packaging production, the benefits of fast job turnaround coupled with the elimination of high cost mechanical dies are now being realised by the labels and packaging sectors. Working in cooperation with A B Graphic International Ltd with its long experience in providing converting solutions, we have been able to develop the Sabre Extreme CO2 laser digital die cutting concept based on market demands.

The features of the Sabre Extreme begin at the origination stage and go straight through to the finished packaging product. Up front of the system is the Softplot™ software that is in effect a digital die shop. With this software the operator can either import or create the die line pattern, edit the die line pattern and then test the die line on a virtual machine before going to actual production of the finished product.

The actual die cutting module employees twin CO2 lasers that provide very fast cutting speeds with resultant high quality. We have actually run a printed web using this technology at speeds in excess of 400 fpm (120 m/min) with acceptable quality. The system includes a ‘Position Domain Controller” that provides true real time web tracking thus ensuring accurate registration with each image. It offers pulse-by-pulse laser energy control giving precise cut depth for any substrate combinations. The controller gives variable speed cutting to compensate for product pattern to allow for corners, windows, etc.

An important aspect of the Sabre Extreme is the laminar flow smoke control. Using laser energy for die cutting naturally creates varying degrees of smoke and particulate waste. Efficient removal and collection of these by-products is ensured by the laminar flow smoke control to minimise deposition of debris on the laser lens and contamination of the work environment.

The new Mark II Sabre Extreme launched at Labelexpo Americas incorporates a very small spot resulting in faster cutting and superior cut quality. The totally modular design allows for simple maintenance functions of cleaning filters, checking of the optics and cooling water that enables the lasers to operate for over 20,000 hours of actual working time.
Peak laser cutting speeds are dependent on a number of variables: material thickness, amount of cutting required, amount of small radius curves and the amount of jumping between features/images.

The Sabre Extreme can easily be used in-line with other printing and converting operations or used off-line to allow high-speed printing. Often, the off-line laser die cutting will be incorporated with slitting, inspection and rewind systems such as those systems manufactured by A B Graphic International Ltd.  Used off-line, re-registration is simplified and is synchronised at every repeat and can align to allow random image spacing.

During trials the Sabre Extreme demonstrated the proven ability to both kiss cut and through cut most all paper and filmic substrates with especially good results having also been achieved on carton board.

Optimised for digitally printed webs Sabre Extreme offers many benefits over conventional die cutting without tooling. The die line is simply downloaded from the pre-press department, the image stepped across the web, the material cut type and cut path selected and Sabre Extreme is ready to start producing. States Mike Burton, Managing Director of A B Graphic International Ltd. “The new laser die cutting technology offers on-demand converting without the expense and wear and tear of handling and storing conventional tooling. Other benefits include job changes in seconds with minimal material waste, real time tracking to ensure perfect register of print to cut, storing of up to 16 jobs on press, ability to kiss cut / through cut and perforate and long life lasers.

Sabre Extreme can be supplied with the Omega Digicon from A B Graphic International Ltd, a versatile converting machine for digitally printed webs. Servo driven web tension control permits a wide range of substrates to be converted from self-adhesive labels to folding cartons.