Folding Carton Manufacturing
In order to produce truly exceptional cartons, you need truly exceptional equipment. While the nuts and bolts of folding carton die cutting involves the use of specific die cylinders and rotary machines that fold, crease, cut, stamp and label cartons, the key to increased performance, efficiency, and thereby cost-savings are making sure the various parts are all working together. That’s where our Folding Carton Systems truly shine.
We offer state-of-the-art designs for unwinds, prefeeds, decurls, cutter infeeds, rotary modules, skew belts, shingle deliveries, fan-wheel stackers, and receding pile stackers. We’re in the business of supplying total converting systems, beginning with our world-class and highly regarded rotary dies and modules. We take full responsibility for your entire project, from design, R&D, and manufacture through service and ongoing customer support. This includes working with you and your team on designing new applications for the ever-evolving folding carton industry. The folding carton systems we make here at Bernal achieve highest speeds and efficiencies possible today, and we’re constantly building upon our tradition of excellence to gain even more speed and efficiency in the systems we’ll create tomorrow.
Why Choose Bernal Folding Carton Systems?
- We achieve speeds of up to 1500 FPM (500 mpm)
- Can accommodate widths from 15” to 60” (38 to 152 cm)
- Carton repeats from 3 to 80 inches (76.2 to 2032 mm)
- Registration accuracy within .005” (.013 cm)
- Industry-leading 10 minute cutting module changeovers between products
- > 90% efficiencies
- Our module designs maximize die life while reducing scrap rates and increasing press capacity, which directly results in an extraordinarily low cost-per-thousand
- We offer expert die maintenance, repair, and service
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 Die Modules Offer Unmatched Precision Bernal Die Modules are designed to maximize die performance. As a premier die manufacturer, we know the qualities required in every module design to assure precision die cutting with trouble-free operation....read more
Modified comb blocks add a blast of air directly at the problem area to help keep the combs clear of scrap. Pin Seal added to keep paper from building up around stripping pins. CHALLENGE Bernal has a customer that supplies folding cartons to a fortune 50 company and...read more
CHALLENGE A large international customer’s project had two separate parts they wanted to produce for an application, however, one product had different interior features. Upping the scale was that these products were going to be in time sensitive production that...read more