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

 

Bernal Dies can do some amazing things.

SEE WHAT BERNAL DIES CAN DO

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Customer Testimonials

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.

Specifying Folding Carton Dies with FLEXO Magazine

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...

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Why Bernal Is The Industry Leader In Rotary Dies and Packaging

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.

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Vacuum Transfer

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...

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Bernal Rotary Dies

2960 Technology Drive
Rochester Hills, MI 48309
1-800-BERNAL-1



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