Improved Productivity in Creasing

In order to improve diecutting productivity we need to look closely at  creasing make-ready. With today’s shorter press runs and more frequent make-readies, reducing make-ready times is often more important than increasing press speeds. After all, the goal is to get the job on and off the press as quickly as possible.

There are four methods of creasing make-ready commonly used: 

• cut pressboard

• creasing matrix

• phenolic counterplates

• solid steel counterplates

Pressboard:

Hand cut pressboard is now obsolete for the following reasons. Its cost in press time is higher than either creasing matrix or phenolic counterplates. Even when a machine is used to cut straight channels, the accuracy of pressboard is by far the worst of the systems under discussion. Its life expectancy is also potentially the lowest of all. Some of the people still using this method claim it is better because it can be adjusted on press.   The only reason it needs adjustment on press is because it is so inaccurate in the first place. It cannot be reused, and is not self-adhesive, so slippage and movement on press is possible.

Steel:

Solid steel counterplates have some applications despite their very high cost. They can be amortized over their lifespan in very long run jobs or jobs that repeat often. Because they are one piece, they are the quickest to load on press, they are highly accurate and they can be reused easily.

The Winners:

This brings us to what is best to use on the typical jobs run in most  converting plants, creasing matrix or phenolic counterplates. And the winner is ....BOTH!!

Look at the advantages both offer. Both creasing matrix and phenolic counterplates can be set up off press and take only minimal press time to install. Both offer excellent accuracy. Both are self-adhesive to the cutting plate to ensure instant usability and strong holding power.

Creasing matrix offers low cost, relatively easy installation and of course, off press set up.

Phenolic counterplates offer reasonable cost, very easy installation, long life and again, off press set up. They are even re-useable, if care is taken when removing them.

The potential drawbacks of creasing matrix are that one piece has to be prepared for each and every creasing rule in the die. This can be tedious for intricate creasing and impossible for curved scores. The lifespan is medium and the matrix is not removable for re-use.

The potential drawbacks of phenolic counterplates are that they are more expensive. If they are to be removed  for re-use, care must be taken not to break them.

Summary:

In conclusion, use matrix for short to medium run jobs, one and two-up dies, and your "easy" jobs - it is a rapid and affordable solution for creasing make-ready. Use phenolic for your medium to longest run jobs, multiple-up jobs, intricate and difficult jobs, such as curved scores, reverse cut scores and combination cut-and-crease. These products are both excellent tools to utilize in maximizing quality and productivity in diecutting creasing.

In choosing the right way to crease a given job, the diecutter must look at:

• economy

• accuracy

• ease of use

• rapid OFF-PRESS make-ready.