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.
We had the pleasure of contributing to the March 2019 issue of FLEXO Magazine, on helping open the communication for printers when specifying dies for a folding carton project. The variability of modern converting technologies has significantly increased the...read more
Since 1972, Bernal Rotary Dies has been producing Rotary Dies and Systems for the folding carton industry and have conquered many challenges conversion projects. Throughout the years, we have helped create some of most iconic and recognizable packages from french fry containers to mega-size beverage cartons.read more
Vacuum Transfer Techniques for Rotary Die Cutting — An Overview The use of the vacuum transfer technique allows non-stop transfer of die cut parts onto another part or web while maintaining accurate relative positions. As the material is...read more