Rotometrics/Maxcess

Rotary Converting Takes More Than Any Die 

Have you ever stopped and thought about how our industry of converting roll fed material into product has changed? Over the last decade, substrates have changed and evolved to include thin films and multiple layered webs. With these changes, tighter registration demands have continued to challenge converters. These changes have tasked the equipment available to be well maintained and the cutting die needs to be specifically manufactured to meet the requirements of completing the job.

Production is the key. Maxcess/RotoMetrics is a part of the largest one stop resource to assist in the maintenance and inspection of current rotary production. We are here to partner with you with a full line of innovative new products. Not only does this include solid and flexible cutting dies but also the newest web control technology updates available. Visit Maxcess.com to shop for new ideas or find the blade or roll that you need. With over 4,000 parts listed online, we can fully support your process and equipment with quality replacement parts. The quality expectations of converted product require not only a well-maintained machine, but a quality cutting die as well.    

Maxcess is dedicated to helping you run,  BETTER, FASTER, SMARTER! 

The die cutting challenges of today demand cleaner cutting along with cut depth control, or liner impression quality after material burst, more than ever before. Solid engraved cutting dies are still playing a vital role in rotary die cut converting. Our full line of quality machined dies offers consistent, reliable results. Our recent acquisition of International Cutting Die (ICD), a leader in high-speed nonwovens die cutting, offers customers a supplier that can cut virtually any material from a single vendor.  With nearly 70 years of developing proprietary manufacturing, heat treating, sharpening, and coating processes, the Maxcess/RotoMetrics team continue to innovate and offer solutions and products to help increase throughput. Solid dies also offer deep blades for thicker substrates and offer long life for both controlled depth and metal to metal die cutting.

Flexible cutting dies have become a specialized product as well. Not only have we opened a new manufacturing plant in Asia, but we have also expanded production into the Midwest. Our new Eureka, MO facility will better allow us to continue to serve our customers with quick and reliable product. Our capacity continues to grow worldwide.

RotoMetrics’ continue to lead the industry in offering the right die for the job. By incorporating and investing in state of art manufacturing equipment and to continue to support our team members throughout the world, the Maxcess Brand continues to grow. Our goals are the same as our customers, to be efficient, productive, on time and to deliver product that meets or exceeds the need. The quality of the flexible die needs to match expectations in cut, life, and inspection. It is important to share these expectations with your customer service contact. We can help you make the right choice for the job.

With rotary converting machine automation and the rise in the developments of digital semi rotary presses hiring and training new operators is a challenge that the entire industry is struggling with. The new quick die change features and adjustable anvil offerings such as the new Maxcess/RotoMetrics AccuAdjust Anvil. It is a revolutionary new product that will allow for die strike adjustment on the fly. Plus, upgrading to Industry 4.0 automation with RotoAdjust and RotoScan  is simple for a fully automated solution to reduce operator error and enhance performance tracking.  It is easy to use and train on. With all the things going on press side, the die should be the easy part.

Flexible dies are easy to change (with proper training to minimize damage), and mount and storage is as easy as a coat rack. Pressure control can be controlled with the fine-tuned control feature on the adjustable anvil. Changes are immediate and will reduce setup time and training trying to acquire the “perfect touch” on a pressure screw on top. Again, our goal is to have the operator up and producing better product smarter and faster, with reduced waste.

 All our flexible dies are coated, each coating fills a specific need. From simple rust prevention, to extended life, we can offer the best product for the job. Our unique and Industry leading nonstick coating, RotoRepel continues to lead the industry in positive results. With less adhesive buildup, reduced stripping issues and unparallel ability to minimize adhesive whip, RotoRepel is now expanding into idler rolls and shear slitting blades as customers have noted the advantages of RotoRepel. 

The current Maxcess/RotoMetrics product line of flexible dies is the result of years of experience. With OEM and converter relationships for nearly 70 years, we have worked closely with customers in the development of our products. Based on these partnerships of onsite beta testing and data collection we have honed our products to be industry leading and of highest quality. Our dedication to the growth of our industry with innovation and constant improvement continues. Technology and the voice and feedback of our customers will drive us to offer the best solutions to drive up production, reduce waste and ease the shortage of operators.

Purchasing a die is simple, purchasing the right die may be a little more detailed: 

1. What are you cutting? 
2. What is length of run or possibility of repeat total? 
3. What is liner strike expectation? 

The answer to these questions will help lead you to the right die for the job. It is simple – do not buy more or less than what you need. Our simple price quote calculator on our website MyRoto.com will ask you guiding questions to lead you to the best die for the job. It is easy and worth the time. Receive simple quotes in only minutes from your estimator’s desk. Time is money, right?

While these questions seem simple, they are important. What you are cutting leads to blade angle and profile. All our flexible cutting dies are machine-finished to exact standards of controlling blade angle on both sides of the cavity. All materials have slightly different burst strengths required to cut. By intentionally manufacturing a cutting die to force this burst to happen cleanly while controlling depth of liner impression, we can ensure faster speeds and reduced waste. As face stocks change the carrier liner plays a larger role in the process. Blade profile plays a significant role in the burst quality of each combination. This combination of specifications built for the application ensures the best quality.

One die does not fit all, so be sure to communicate what you are cutting. If a cutting die is not specific to the material, any changes or variances will affect cut quality and die life. At times an adjustable anvil may get you through the job – they are an effective tool in controlling variables in material thickness.

Flexible cutting dies require a magnetic cylinder to mount. Care and maintenance on your cylinder inventory are particularly important. Dies are made to an exact blade height to ensure clean cuts of face stocks and adhesives. Our magnetic cylinders are made to the same high standards. It is important to know and understand how the TPH (total blade height) of the built into the flexible die and the “diff” or “drop” in your cylinder work together to create clearance for the die cut depth. Monitor your inventory for wear and surface condition. Each should be measured and inspected yearly. By being able to plan and identify which cylinder you will be running die on ensures the best results. All specs were included in manufacturing specifications.

Maxcess/RotoMetrics offers a full line of magnetic cylinders, each with a purpose, from budget minded to best tool for investment. Our cylinder line also offers a lightweight option to reduce weight, increase safety, lower inertia requirements and lower freight costs. Be sure to visit our website or ask your RotoMetrics contact for information.

Based on our experience and the feedback provided by our partners over the years we believe that we can make a difference. Maxcess is a worldwide end to end solutions provider. A one-stop resource for press upgrades. From replacement parts to new and innovative vision inspection systems, Maxcess connects the latest technology developed for controlling or guiding web path and tension, both manual and automated slitting options, idler rolls, and of course Rotary cutting dies, solid and flexible.

Please reach out to your Maxcess Representative or visit our web site Maxcess.com for more information and detail.