If you deal with die-cutting machines, you would know how common it is to generate scrap during the process. If you don’t find ways to control, then reduce. You can timely remove scrap generated during the die-cutting processes. which can affect your post-production costs. The build-up of scrap can also lead to severe damage caused to die-cutting machines. Some try to remove the scrap using their hands, but it eventually increases the labor costs. Not only that it also increases the possibility of losing more money if the finished product gets rejected by a client.
Even if you don’t remove scraps by hand, removing them from final product parts or removing them mid-way by stopping the machine can also increase your post-production costs. If you want to make the best use of die-making supplies and ensure the scrap gets removed during the die-cutting process, this article will help you achieve it.
Scrap Removal: The Fundamental Details
Irrespective of the die-making supplies you’re using, there will always be sections from the materials that emerge as waste or scrap. It can be an odd-shaped piece or something else. Regardless of its shape, the scrap won’t stay with the web. It is where following some effective scrap removal processes can help. For the uninitiated, scrap removal refers to the process of disposing of the slugs/scraps that get automatically generated during every die-cutting process. You can remove the scrap manually or implement an automated process that keeps removing scrap on autopilot.
Scrap removal can appear as a menial task, but it significantly impacts your overall production costs. Not removing scraps using the correct method or at the right time can cost you money in the long run. You can experience problems like increased press clean-up time, tooling & press damage, increased labor cost, build-up of scrapped parts, increased part-sorting, and more. If you want to minimize the costs or potential losses due to scrap build-up, following our scrap removal techniques can visibly help.
7 Ways to Remove Scrap during Die-cutting
There are numerous ways to remove scrap during die-cutting. But here we recommend proceeding with the technique that best aligns with your machine type. To make things easier, we have listed below the seven best scrap removal methods you can review and apply to your die-cutting machine.
Using Spring Plungers
If you are looking for fairly inexpensive scrap removal methods, then spring plungers would work the best. You need to insert a good-quality spring plunger into the rotary die to ensure scrap/slug doesn’t get stuck in the die’s cavity. You can use spring plungers without making any modifications in the press. To get the best results, you should use spring plungers with rigid materials. It can be considered an effective mechanical method that is easy to replace on-site and relatively inexpensive. The only negative aspect of using a spring plunger is you may have to use an additional under-web vacuum.
Implementing Pulse Air
One of the best and reasonably affordable methods of removing scrap during die-cutting is using pulse air. This device ejects scrap at specific time points in the die-cutting rotation process through a well-timed burst of air. When you use pulse air, the air consumption by the machine is minimized since an air blast is enabled only when needed. It makes it the best air ejection system on the market. Although it is slightly more expensive than the standard air ejects systems, it is much more effective.
Place a Rubber/Foam/Neoprene Inserts
An inexpensive way to effectively remove scrap during die-cutting is by inserting materials like foams, neoprene inserts, into the die’s cavity. It prevents any scrap/slug build-up in the machine. If you are looking for more options, silicone products can also be installed. These materials don’t exert much pressure to remove slugs/scraps, so their effectiveness can be slightly limited compared to other scrap removal options.
Standard Air Eject
Another effective way of making the most from die-making supplies is using standard air eject to remove any accumulated or generated scrap timely. In this method, forced air helps blow the scrap out from the machine. The air probe installed inside the die helps direct the airflowpushing strong air blows through all die cavities. As the tool continues rotating at its normal pace. This air probe’s best part is that it helps reduce noise and air consumption. This easy-to-use method is inexpensive and effective, so you must try it.
Vacuum Thru (Inserts)
A vacuum thru helps pull all the scrap/slug inside the machine and expels it out at once through the journal. The best part about using vacuum thru is it eliminates the requirement for having a multi-die setup and the need for registration between two die stations. This method may not be ideal if the part has adhesive.
Often installed under the anvil, the sacrificial liner uses its strong adhesive to carry away the generated slugs/scrap. Once the liner is placed, the scrap generated during the process gets adhered to the low-tack stripping tape. This is the best way to remove it from the machine if minimal scrap is generated during die-cutting. It doesn’t require additional equipment modification and tooling costs.
If you want the slug/scrap to get removed at high speed, stripping pins can do a great job. All stripping pins have sharp pins firmly mounted in the anvil. It does an excellent job of piercing the scrape. Which eventually carrying it to a well-designed comb system for removing scrap from the machine. These are incredibly effective, and the scrap removal process does not affect the press speed.
Get Your Die-cutting Machine Functioning at Optimum Levels
From picking the right die-making supplies to timely removing scrap from the machine- a lot goes into controlling the production costs. Irrespective of the materials you use, products you’re trying to make, etc., there will always be some amount of scrap/slug generated during the process. The good news, on the other hand, is that you can easily remove scrap from the machine by following any of the methods discussed above. All the techniques are cost-effective, easy to implement and give excellent results.