RP® Rotary Dies
Our Bernal RP® rotary dies represent a breakthrough technology in the folding carton industry for solid rotary tooling since the mid-1980’s. These dies provide significantly longer die life than conventional rotary dies while maintaining like-new cutting quality and minimizing waste by using shearing blades on both the upper and lower dies.
The unique shearing action of our RP® dies assures the best cut quality and the longest die life when cutting materials suitable for this cutting process. We offer a wide variety of RP® die options, with various steel alloys and hardening techniques, in designs with and without journals. High wear areas can be fully segmented for quick and easy maintenance in between full servicing intervals. Whatever your needs, we have a die priced to generate the lowest cost-per-thousand for the most carton volumes across the industry.
RP®: Allowing You to Focus on What Matters
All of our RP® dies feature consistently strong blade design and long-life, meaning your technicians can focus on the important work of maintaining an entire rotary cutting machine, instead of worrying about when the die is going to need sharpening again.
RP® DIES DELIVER
Bernal’s RP® dies provide consistently excellent results because we guarantee:
- Cleanliness of cut
- Burr-free cutting
- Low operator maintenance
- High-speed operation
- In-die scrap stripping
- Perfect creasing, scoring, and embossing
Crossover Technology — How We Ensure the Cleanest Cut
Our unique and proprietary technology allows us to place all of the upper cutting edges of a rotary die on one side of the cut, across and around the die unit. Doing this allows us to move the upper and lower cutting edges closer together, ensuring a cleaner cut. We gain extraordinary precision by engineering a side position adjustment for blades running around the die, and rotational position adjustments for blades running across the die. Ultimately, this results in a vastly increased die life while also giving you more control over the most precise die adjustments.
Cleanliness of Cut
By using shearing blades, we eliminate the need for metal-to-metal contact between the upper and lower dies, preserving the sharpness and integrity of the blades while eliminating chaff, slivers, and ragged cuts. By making simple side and rotational adjustments, Bernal can maintain the consistency and precision of the die throughout its lifecycle, avoiding the steady degradation of crush-cut type dies.
Ideal materials for this type of die cutting include a wide variety of high-density materials, including highly abrasive media. The ability to change RP® dies in their modules in a matter of minutes maximizes productivity by minimizing downtime during changeover, increasing line capacity and resulting in the lowest possible cost-per-thousand in the industry.
Typical Products Suitable for RP® Rotary Dies
- Gable top packaging
- Aseptic packaging & pouches
- Beverage carriers
- Frozen food cartons
- Paper cups
- Cereal cartons
- Overnight mailer envelopes
- Cigarette cartons
- Liquor cartons
- Fast food cartons
- General folding cartons
- and many more…
Our RP® Rotary Die Specifications
- 10 to 500 million revolutions before sharpening
- Solid, Partially or Fully Segmented Construction
- Cuts material thickness up to .125″ (3.175mm)
- Die diameter range: 3″ to 30″ (76.2mm to 762.0mm)
- Lowest cost-per-thousand in most volumes
- Web width of 1″ to 110″ (25mm to 2794mm)
- Able to withstand multiple sharpenings over the course of the die life
- Suitable materials: paperboard, high-density plastics, masonite, corrugated, recycled board, coated boards
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 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
Rotary die cutting is a versatile fabrication process employed in a wide array of manufacturing sectors to precisely and efficiently cut, form, and shape a wide variety of materials ranging from paper to plastic, and from metal to edible food products. Rotary dies...read more
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