For the custom paper boxes, die-cutting is a manufacturing process, using die to cut various custom shapes out of the paperboard and to crease various custom folding lines on the paperboard. The E flute corrugated mailer box is a typical die-cut paper box, easily assembled without any glue flaps.
The die consists of the cutting and creasing rules. When performing the die-cutting operation, the die reciprocates up and down towards the paperboard, which is placed on the make-ready. After one cycle the cut paperboard sheet is removed and a new one is fed into the machine.
Laser cutting is by far the most elaborate and exclusive cutting method. It allows very small details and very complex designs. With the right paperboard, almost any paper box structures can be achieved. The operating principle is rather simple. The original design is etched through a copper template, which is positioned over the paperboard sheet. A sharply focused laser beam runs back and forth over the template and wherever there are etched areas, the laser beam vaporises the paperboard.
The task of the ejection rubber is to hold the sheet in a ﬁxed position during cutting and to eject the paperboard blanks from the cutting die. The rubbering of the cutting die plays a very important role for the quality of the ﬁnal result. Correctly done the rubbering also supports productivity by allowing higher speeds and minimising the risk of stops due to waste coming loose in the machine or sheets not ejecting properly from the die.
A good cut for the custom paper box should be clean and free from loose ﬁbres and particles. This will give accurate and clean edges and avoid contamination problems during further processing of the paperboard or in the packaging operation.
To achieve clean, debris-free edges, it is important to have the correct cutting conditions. Due to its strength, toughness, and density, paperboard requires sharp, well-adjusted knives and good control of the die-cutting machine. The high force required to cut through has to be well controlled to minimise what is called the “overshoot” of the moving die. Otherwise the knives will hit the counter plate too hard which will quickly damage the knives and degrade the quality of the cut edges.
Creasing is an operation which facilitates the folding operation of the custom paper box. During creasing, the paperboard is weakened along well deﬁned folding lines, which then act as hinges for folding packaging boxes. It is very difficult to fold paperboard with a good result without creasing.
The creasing rules are ﬁtted into the die. When performing the creasing operation, the die reciprocates up and down towards the paperboard, which is placed on the make-ready. After one cycle the creased paperboard sheet is removed and a new one is fed into the machine.
The paperboard is creased by being pressed into a channel or groove in the make-ready. The forces created deform the paperboard in a predetermined way and the deformation is permanent. The result is a reduction in the bending resistance of the crease. The paperboard is therefore weaker along the crease than elsewhere.
Die-cut paper box mainly refers to the folding cartons which can be easily setup without the help of the glue flaps. They are widely used in the making of the book folders and corrugated mailer boxes. The Custom E flute corrugated box is one of our most featured products.
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