Bernal performance has become the benchmark for high-speed rotary die cutting and has established a new standard for inline web printing and converting. Born as Bernal Rotary Systems, we pioneered the development of web converting for the folding carton and consumer products markets.
We hold over 50 patents on rotary dies and related equipment, and our line of rotary dies in conjunction with advanced product and packaging automation equipment offer a complete solution for a wide variety of applications across multiple industries.
Bernal’s vision for the future and engineering excellence continue to provide innovative solutions for web converting that reduce costs while improving product quality.
- Rotary Converting Systems
- RP® Rotary Dies
- Alcohol Swab Machines
- Crush Cut Rotary Dies
- Die Cutting Modules/Cassettes
- Food Processing Machinery
- Folding Carton System Manufacturing
- Finger Bandage Systems
- R & D Proof of Principle
- System-Wide Design & Build
Flexible vs. Solid Rotary Dies. What’s the Difference?
There are two types of rotary dies: flexible and solid. Rotary die cutting involves either a flexible or solid rotary die. These dies are both cylindrical dies. A flexible die is made of a thin sheet of steel, and wraps around a magnetic cylinder. A solid die is a solid steel cylinder, and is traditionally used in more long run applications for extended die life. Bernal develops solid rotary dies for converting and product manufacturing applications throughout many industry sectors.
Creasing is an operation which facilitates the folding operation. During this process, the paperboard is weakened along well defined folding lines, which then act as hinges for folding packaging and graphical products. Without creasing the surface, plies...read more
Bernal RP® rotary dies represent a breakthrough technology in the folding carton industry for solid rotary tooling. These dies provide significantly longer die life over conventional rotary dies while maintaining cutting quality and minimizing waste by...read more
Bernal 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...read more