Die Cutting Modules
Bernal Die Cutting Modules
Bernal Modules are designed to maximize die performance. As premier die manufacturer, we know the qualities required in every module design to assure precision die cutting with trouble-free operation. Modules come in many standard sizes and are designed to suit a wide variety of applications, including folding cartons, medical supplies, consumer products, batteries, foods, and many others…
Features and Benefits
Our side, bottom, and top plates are stress-relieved, precision-machined and assembled in highly rigid box sections. All Bernal modules include bearing housings of our own design and manufacture, with print class, precision-matched bearings.
- In-module pin stripping
- Rapid changeovers
- Maximized die life
- Compatible with all types of rotary dies
- In-stock parts
- Single-source die and module responsibility
- Highly rigid box construction
- Precision bearing housings
- Rigid stripping comb assemblies
- Temperature-controlled oil lubrication
- Grease lubrication
- Side, rotational and skew bearing adjustments
- Available in journaled and journal-less versions
Modules for Every Die Cutting Operation
The precision modules we make allow our dies to operate at their highest speed and achieve the longest life possible. The rigid construction of our dies eliminates the flex that causes premature die wear and poor cut quality, resulting in a die that will outlast and outperform its competition.
Single slot modules carry four bearing housings in which the upper and lower tools are mounted. We offer this type of module with and without in-module stripping capability.
We recommended dual-slot modules when extreme precision between first and second station tooling is an absolute must. This arrangement allows two tool sets to be removed and kept in register with each other. The majority of our dual-slot modules are configured in a base-mounted or roll-in style, so the module can roll or lift onto a set-up platform.
Bernal Custom Designed Modules
We excel in creating and manufacturing 100% custom die cutting modules. Our knowledge and expertise allow us to design modules that fit seamlessly into our customer’s existing rotary cutting or processing systems — even those designed by other manufacturers.
Scrap Removal Solutions
We offer a variety of stripping methods to remove both continuous scrap and island scrap without sacrificing speed or precision. In-tool stripping features a pin mounted in the lower tool to skewer the scrap, and a stripping comb mounted to a rigid assembly to lift the scrap off the pin, which is then vacuumed away. We also provide outboard stripping, in which the stripping pins (which may be fixed or retractable) are housed in a separate cylinder and in a separate station.
Our family of bearing housing designs can support our largest dies or cylinders up to 110” (2800mm) in product processing width and up to a maximum diameter of 35 inches (890mm). Available bearing designs are manufactured to extremely low-tolerance specifications, and available with either oil or grease lubrication. The bearings used are of the highest quality and precision, and capable of the RPMs needed to reach die cutting speeds of up to 1,500fpm (500 mpm).
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.
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
Rotary Die Cutting is a precise process that uses a die to cut rolled or sheeted material such as plastic, rubber, foil, cloth, paper, foam, and many others. This is a manufacturing process that cuts uniform shapes out of materials to create both component...read more
Bernal Rotary Die Cutting is essentially a process that can cut or form materials into virtually any shape. Technological developments have expanded the processes that a rotary die configuration can perform. Die cutting is a primary go-to process in the material...read more