Gaskets - A large gasket converter approached us with a way to cut his material but remove the holes in one stroke. In addition, they wanted us to accurately knock out and stack the finished product and then rewind the waste. We designed a machine with a hollowed castle so when the part was cut the holes were fed through the cutting die and then fell out the castle out to a conveyor. We went with this design because vacuuming out the part is not 100% guaranteed. After the cut was made our K3/2 pneumatic expeller knocked out the finished part and then stacked them onto a tray. The matrix was rewound onto our KR rewind unit. This machine saved this company a considerable amount of time because now they no longer had to remove the holes by hand.

Wood - An existing customer of our was cutting 1/8" thick wood with sheet dimensions of 24" x 48". They wanted a system to automatically load the sheets, foil emboss their company logo, die cut the part and then automatically stack the finished product into a box. MSC built an automatic sheet loader with an extra heave duty vacuum system to load the pallet of sheets. Once the sheet entered the nip rolls the first head came down and foil embossed the logo. After embossing, the material traveled to the second head for cutting. Once total cut, the second set of nip rolls pulled the sheet through and the finished part was expelled and loaded into a box, automatically. Once the box was filled with the desired amount of parts, it was off loaded onto a conveyor system to proceeded to the packaging division. This system increased productivity by 50% because we were able to combine three steps into one.

Flexible Circuits - We were approached by a company that had three major concerns about converting their product: laminating, registered mark reading, and the ability of kisscutting the part and removing the matrix. Our first solution was to have a dual roll holder; one to hold the adhesive the second to hold the product. We used heated nip rolls to laminate the product together; first concern solved. The second was the accuracy of the cutting. With our optical marked reading registration to the die we were able to hold tolerances of +/- 0.01MM; second problem solved. The final obstacle was kisscutting the parts and removing the matrix. Since this material was extremely flexible, precision was critical in removing the waste without tearing the finished part. We built a special blade system (TL) to hold the material in place while the scrap was being removed (K2) and the final product was being rewound. Problems solved.

Graphic Overlays - Printed materials can be tricky to accurately cut and convert. Registration, diversity of cutting dies, and the ability to process rolls and sheets. However, we were able to formulate a solution to all of these hurtley. Thanks to our optical die registration and tolerances of +/-0.01MM cutting printed materials accurately is no longer a concern. With this registration system we were able to eliminate the need for pilot holes and minimize rejects. Our unique single cylinder allows companies to use a wide variety of cutting dies such as steel rule, forged, bent rule, male/female, progressive, etched etc. In addition, our mechanical positive stop decreases die wear considerably. Finally, we were able to develop a an in-line lamination unit to turn sheet stock into a continuous roll of material as well as the capability of laminating rolled goods.

Abrasives - A large abrasive company was interested in a high speed press to cut large abrasive discs (18" Diameter) but at the same time remove the five holes. We took our largest press (GD654D) which can accommodate material up to 24" in width and designed a special head so when the part was cut the holes were forced through the die down a chute into their scrap box. In addition, abrasive cutting is very abusive to cutting dies but with our simple die holder dies could be replaced in seconds. Production was increased by nearly 35% due to the fact that there was no need for manual intervention in removing the bullet holes.

Foam - One of our customers was considering an application to bring in house. They were wanting to laminate a 3/16" foam on both sides, total cut and kiss cut their part, knockout the center hole, remove the matrix and finally rewind the finished product. We designed a unwind stand to accommodate three rolls and laminate these together with heat in one step. The nip rolls were heated to apply the adhesive and were used as a material conveyor. Due to the accuracy of our systems (+/- 0.01MM) we were able to total cut the center and kiss cut the finished product. Once the part was cut, we needed to remove the matrix and then knockout the center scrap. With our K2 system we were able to accurately rewind the scrap. Our K3/1 system was used to accurately knock out the center hole and finally rewind the completed roll with our rewind stand. Now this company no longer needs to rely on someone else to do this for them so delivery time was considerably increased to meet their customer's demands.

Shoe Insoles - An existing customer approached us with a new application they were trying to pursue. The company was making comfort shoe insoles. They wanted to take a roll of this material and then silk screen their pattern on the product, register the product with the die and then cut, stack and finally rewind the scrap. We designed an in-line silk screening machine equipped with a heating unit. After the material passed through the dryer, the machine had to register the material, then cut the part. Following through the nip rolls we were able to expel the part onto a conveyor system and then rewind the scrap. With this system we were able to combine three machines in one system saving our customer a substantial amount of labor and material waste.

Rubber - Rubber is normally a simple material to convert. However, an existing customer wanted a system to laminate, kisscut and then cut-to-length the finished product. We used our dual roll holder (KK) to laminate the rubber material together. From there we took the laminated product and kiss cut 1" circles. After the kisscutting, we rewound the scrap on our K2 scrap removal system. Finally we were able to sheet the finished product with our CTT system for the transversal cutting of material to the desired lengths using a knife counterknife design. This company was able to produce 60 finished sheets with 8 1" circles in one minute. "Amazing".

Filters - Filter material can be difficult to convert due to the "angelhair" fibers. We were contacted to design a system to accommodate up to four rolls of materials and heat seal them together with one trip. We designed a four roll holder to accommodate their rolls and special powered nip rolls to feed the material through. From there our heated platen and pad rotating device we were able to seal and eliminate any fibers in one trip. Increasing the depth of the cut eliminated the fibers and with our orbiting pad system we could provide more efficient cleaner cuts.

Send us your special application now. Not only can we help improve your current process but support you 100% with our service and the next obstacle you need to overcome in the future.