Laser Hardened Dies Stay Sharper For Longer!

When running at high speeds especially on a rotary press cutting out envelopes or labels, the pressman needs to feel confident that the flexible die he is using will last the course allowing production to meet the deadline.

To minimise any risk of die failure Kocher+Beck use the very latest technology when manufacturing its products but sometimes difficult materials will put extreme pressure on any die. We always recommend laser hardening dies used in high pressure situations and on long runs. Why? Because it works! Dies can last up to three times longer in production. Some materials such as “tyvek” or recycled carton board can be very abrasive and could quickly dull the cutting profile. Where the material has to be cut through, such as a carton, it’s imperative to laser harden the tip of the cutting profile.

Die Production with Laser Hardening

During December 2009 a new generation of laser hardening machines has been installed at Kocher+Beck’s Coalville factory. Not only is it faster, bigger and therefore more productive, but it will ensure dies that need hardening will be produced with super precision. Laser hardening is extremely controllable both in intensity as well as depth of hardening to meet the demands of the material to be cut. Even the new Inline Offset Cutting system: IOC for short, which is used on offset litho presses benefits when converting things like light-weight cartons or document folders.

Earlier this autumn the Coalville production facility increased its CNC tooling capacity with the installation of a specially built three axis cutting machine. This new camera recognition machine supports other generations of CNC machines to ensure the companymaintains its strategy of offering a same day despatch as printers respond to the demands of the industry, labels in particular.

Kocher+Beck’s same day despatch has virtually trebled over the last year, with each request individually prioritised based on the days production scheduling. With the plant in 24 hour production, despatching dies in the middle of the night is not unusual. Kocher+Beck take pride in maintaining relationships with all of its customers and will always stand firm on the strategy of quality and service first.

Laser hardening is an extra process in the careful production of a die which has to remain flexible to allow it to curl around a cylinder. It is important therefore to harden only the tip of the cutting edge. Any deeper and the plate could crack under the strain. Unlike the CNC sharpening of the cutting edge where the precision tool finely shaves each side of the profile, the laser actually follows the very centre, or the summit of the tip. Precision is everything.

The new laser hardening machine, like the CNC machine, has been specifically designed and built by our parent company in Germany. It offers a much faster cycle time and a larger bed size capable of processing bigger dies or several small ones sequentially. In line with Kocher+Becks’s environmental policy it also has friendly power consumption which brings major benefits.

So to my final point: As printers, do you run presses with magnetic cylinders in them?

If so, when did you last have their settings checked? Did you realise that standard web-fed cylinders (for instance) should have an air gap of 480 microns? If not it will severely effect die life and cut quality.

Kocher+Beck offers a FREE magnetic cylinder health check which takes place at your premises and our experts leave you with a full report highlighting any attention needed.
If you would like to know more about this offer you can contact my colleague, Jason Carter, for further information on 01530 275688 or by email at: technical@kocher-beck.co.uk

After all, the cylinders you use and the dies you install on them are your life blood. Do not leave anything to chance.