Design Process


We begin all of our projects with a basic, solution-oriented concept. Whether you give us a drawing on a napkin or a fully fleshed-out machine spec, we take your idea and convert it into a structurally sound and cost-effective reality. At this important beginning stage of the design process, our project engineers will help you in the following key areas:

  • Evaluate the feasibility of your project
  • Provide detailed feedback analysis of your basic concept
  • Suggest improvements to your concept to make sure our project goes above and beyond your expectations

Once we’ve finalized the goals and objectives of your unique concept, we enter the crucial stage of engineering — this is where we make sure everything is going to work precisely as intended in the real world. Our engineers carefully complete all due-diligence up front to:

  • Identify how the machine will work
  • Provide fully detailed conceptual solutions with all the diagrams and drawings required to do so
  • Ascertain how long it will take to finish building your project
  • Determine a projected delivery to your facility based on current assumptions and requirements
  • Ascertain the total cost of the project.

We provide a ballpark number up front to make sure we’re all on the same page and that the project is going to be as good for your bottom line as it is for the items you want it to produce. We update budget numbers as requested before completing a final, firm, detailed quotation for all of the work required to make your vision a reality.

We build upon the Concept and Quotation stages of the project to inform the detail of the machine design, integrating standard designs, unique designs, commercial components, electrical systems, and overall system design. During this phase, we’ll provide you with 3-D modeling, force calculations, and detailed component selection options to arrive at a finalized machine design, and then all we need is your sign-off to proceed.

We integrate your electrical specifications, applicable safety standards and regulations, and approved components into our unique Electrical Automation Package. Our engineering team will work with you throughout this phase of the design process to make sure the finished project meets or exceeds your needs and requirements by doing the following:

  • Determining the overall automation design and strategy
  • Completing the electrical design for the project
  • Determining best operating platform for the project
  • Finalizing all computer programming and operator interfaces
  • Collecting all relevant data

Here’s where we put it all together, fabricating your machine to precisely meet all of the exacting specifications we set in the first 4 phases of the design process. The key milestones in this phase of the project include:

  • Structural fabrication
  • Mechanical fabrication
  • Electrical wiring installation
  • Piping/Tubing installation
  • Instrumentation
  • Component assembly
  • Finishing
  • Guarding

Since we’ve handled every step of the process in house, the machines that leave Bernal are fully tested as they operate in exactly the same manner you plan to operate them in your facility. We welcome you to our shop during this process so you can see exactly how we put your machine through its paces. Our start-up and commissioning process includes:

  • FAT testing
  • Operator training
  • Punch list resolution
  • Maintenance training
  • Shipping
  • Continuous Improvement

After your machine has passed our battery of tests, it’s time to bring it home, and we’ll provide you with the following support during this final stage of the process:

  • Supervise the installation of your machine
  • Provide you with clear and exhaustive Operation & Maintenance Manuals
  • Perform rigorous factory testing and commissioning (FAT)
  • Monitor your Site Acceptance Testing (SAT)
  • Monitor continuous improvement
  • Provide comprehensive operator training

Bernal Dies can do some amazing things.



Customer Testimonials


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.

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Bernal Rotary Dies

2960 Technology Drive
Rochester Hills, MI 48309


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