Folding Cartons
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
Customer Testimonials
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“For more than 10 years GMV Tool and Die has delivered more than 150 die sets from Bernal to Scandinavian customers. Most of the dies have been manufactured with Bernal’s unique laser cladding technology. Our customers have experienced outstanding results. We have had the best response possible from our customers. They come back for more.”
GMV Tool and Die
"Cavanagh Company and Bernal have been great partners for over 35 years. We at Cavanagh have enjoyed the high level of manufacturing and service that Bernal continues to deliver on. Our critical specifications and geometry are unique and have evolved over the years that Bernal has mastered in complete confidence."
Cavanagh Company
"Bernal's expertise and skill are evident in their design and workmanship. The high level of knowledge and friendly service makes Bernal an easy choice for OEM equipment."
Cascade Designs
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Blog
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.
7 Reasons To Use Crush Cut Dies
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...
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Diverse Uses & Applications for Rotary Die Cutting
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...
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What Can Rotary Dies Create?
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...
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Rochester Hills, MI 48309
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