Ro t a r y t o o l i n g a n d co nve r t i n g s o l u t i o n s

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RiRo 1250Re-start Sleeve Concept

Rotary Tools

REVO / RiRo

Creasing / Punching

In-feed Unit

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Madern your global partner in rotary tooling and converting solutions

Evers International LLC845 Bethel AvenuePennsauken, NJ 08110, USAPhone +1 856 910-0002Fax.: +1 856 910-0003Email : sales@evers-int.com

AJB Instrument B.V.Postbus 11733180 AD RozenburgThe NetherlandsP: +31 (0)181 21 33 77F: +31 (0)181 21 55 42E: info@ajb.nlW: www.ajb.nl

Madern International BVVikingbank 1NL-3133 KX VlaardingenP.O.BOX 326NL-3130 AH VlaardingenThe NetherlandsPhone: +31 10 248 54 60Fax: +31 10 248 99 20Email: sales@madern.com

Madern USA Inc. 1010 Burma DriveApex, NC 27539, USA Phone: +1 919 355 1600Fax.: +1 919 355 1602Email: sales@madernusa.com

Madern Asia Ltd. Unit 3, 11/F., Westin Centre26 Hung To Road,Kwun Tong, Kowloon, Hong KongP: +852 2186 6706F: +852 3151 7958E: info@madernasia.com

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madernJOURNAL

This is already the seventh time that Madern is participating at the Drupa show. During our first Drupa in 1990, Madern had just started to design and manufacture rotary dies for the folding carton industry. Almost three decades later, we have established a leading supplier position of rotary dies to the folding carton industry. Madern rotary dies are not only producing -day in day out- millions of tobacco and liquid cartons, but also general folding cartons such as beverage carriers, fast, dry and frozen food cartons, paper cups as well as personal care, pharmaceutical and display cartons.

Besides our dedication to rotary tools, we are also focusing more on the supply of total rotary converting solutions. For a number of years, Madern has integrated rotary die-cutters in new or existing gravure, flexographic or litho web-fed presses.

More recently, we started to offer total solutions such as; single or multiple station rotary die-cutters. Combined with our rotary tool technology, we can supply you a total custom made rotary converting solution with single source responsibility or partnership.

Our latest innovation on rotary die-cutting technology is demonstrated at our Drupa booth. It is a rotary set with shafts that can be separated from the bodies and are a part of the bearing blocks. Furthermore, the bearing blocks will be less dependent on diameter and more universal. This innovation reduces the costs of rotary cutting and is making rotary cutting more accessible for smaller production quantities / runs.

Besides this, we believe that instead of segmented dies for cutting or combined cutting and creasing dies; occasionally a die can be made out of one piece to reduce costs. As a result, the total cost of ownership will drop between 20 - 50%. Due to these cost savings, rotary cutting will come within reach faster as an alternative to flatbed. The final solution depends amongst others on productionvolume, production speed, carton design, product configuration and board.

A few years ago, the Madern group purchased AJB which is a precision mechanical machine shop that produces small parts for various industries and also manufactures punching, stripping parts and other essential pieces for rotary dies.

In view of Drupa 2016, we hope you enjoy the exhibition and we would like to invite you to visit us at our booth C61, Hall 11 to meet us and discuss your rotary converting needs.

Jean Madern CEO of the Madern Group

Cutting Edge Technology and Improving Performances

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On Drupa 2008 we presented the concept of the sleeve system. The main targets were:

- No bearing blocks- No couple gears- Lower investment in tooling- Depth adjustment on the run.

Rotary converting now also within your reach!

to the latest developments of the Madern delivery system. The system can be easily interfaced with existing or new printing presses and will be a perfect match with the new short run gravure, flexo or litho sleeve technology printing presses available in the market.

With this new rotary die-cutter innovation, the variable cost of rotary tooling can be reduced significantly. Due to the individual driven upper and lower tool, the use of gears, bearing blocks or other diameter depending parts are no longer necessary. With the elimination of the diameter de-pending adaptation parts and the use of more simple dies, cost savings on rotary tools of 30-40% are achievable.

MST machine specifications:

Web width: up to 850 mm

Tool diameter: min. 200 mm; max. 320 mm

Maximum web speed: 300 m/min

Sleeve change: max. 10 min with sleeve change-over device

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A perfect match with the new short run on gravure, flexo or litho sleeve technology printing presses.

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We have continued our developments based upon the feedback we received on the prototype. These develop-ments were split up into smaller separate R&D projects.Based upon the positive results of these developments, we are now ready for the next step and change the con-cept into an operational unit.

The fixed sleeve cylinders are mounted in heavy duty bea-ring blocks, which are mounted on high precision linear guides on the main frame. All the horizontal and vertical movements of the bearing blocks and cylinders are done by servo driven linear ball screws. This guarantees precise positioning for the sleeve change-over, as well as for the correct position of the upper and lower cylinder during production.The main frame is made of a special material composite, which absorbs vibrations and shocks, which may occur du-ring production.

The modular design of the MST 850 die-cutter is based on the proven Madern die-cutter technology and fits perfectly

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Madern introduces unique rubber pins for its rotary dies. Although the new rubber pins are only tiny parts in our rotary dies, it offers big advantages for our clients. The rubber pins enable proper release of potential sticky parts in the product area. Placing these special rubber pins in the receiving holes prevents the accumulation of dust or waste. The new design increases the visibility of the rubber pins which are designed for ease-of-use. The pins do not require the use of any glue, because they are self-tightening and based on friction. In case of replacement of a rubber pin, the old one can be taken out and quickly replaced with a new one. In addition, each size of rubber pins have a unique color, which increases visibility and enables clear distinction of the pin size. The rubber pins have been successfully tested in practice as waste ejector pins and as filling for stripping pin receiving holes. For insertion and removal of the pins, we can supply a special tool.

New colored rubber pins for rotary cutting dies

Insertion tool

Removal tool

Rotary tools, still our core business

With our sophisticated CNC machine park we are able to supply a wide range of rotary tooling. From a web width of approximately 500 mm up to 1750 mm and a diameter from approximately 180 mm up to 650 mm with a maximum weight of 5.000 kg. (cylinder dimensions outside this range upon request)Due to higher web speeds and different board grades, we are continuously looking to improve the performance of our rotary tools.We can manufacture our rotary tooling suitable for any rota-ry die cutter including of course our own Rotary Die Cutters.In this magazine you can read about our latest models, the ReVo line and the RiRo line.

Our cutting, creasing, embossing and punching tools are used in many different applications for the packaging indus-trie such as: tobacco and liquid packaging, as well as for gen-eral folding cartons. Also for other applications, such as non-woven-, plastic- or sanitary products Madern tools are used.

The applied cutting technology, crush cut or MP dual knife (scissor cut), depends on the type of material to be cut, the shape of the product and the required performances, such as speed and life time of the tool. Madern can offer either technologies or a combination of both in one and the same tool.

With the different in-house manufacturing technologies we can offer a wide range of cutting, creasing and embossing tools, such as:

• Mechanically machined solid dies• Fully or partially segmented dies

Madern dies are available in different type of tool- or PM steels. Depending on the specifications of the dies, special hardening treatments (laser or traditional hardening) or sur-face treatments (PVD or chrome-plate coatings) can be ap-plied.

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Main benefits Madern rotary tooling• Madern has more then 35 years of experience in rotary tooling

for folding cartons

• Highest production speeds for maximum productivity

• Low waste levels and less jam-ups, thanks to efficient and accu-rate stripping technology (inboard, outboard, matrix, air eject, etc.)

• High quality cartons, thanks to consistent cutting, creasing and embossing performances

• Longer die life as a result of the use of high quality PM steels and additional surface treatments

• Rotary tooling solutions for low to high volume production

• Excellent support during installation, start- up and commission-ing of the tooling

• World wide service organisation

• Dedicated training programs for tool engineers and machine operators

• Single source supplier for all your rotary tool requirements, in-cluding stripping-, outfeed and adaptation parts for any die-cutter

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REVO – LINENew competitive rotary die-cutterThe Madern Revo-Line rotary die-cutter is a very versatile, opera-tor-friendly die-cutting concept. It is one of the most recent de-velopments and last year the first set has been successfully instal-led. The Revo-Line derives from the previous series of successful Madern rotary die-cutters and customers input. Therefore we are convinced this die-cutter will become ‘the one all converters are talking about’

The modular design of the Revo-Line allows the converter to choo-se from a wide range of options to customize the unit to its own needs, specifications and budget. The Revo-Line is available as a single converting station using combined rotary cutting and cre-asing converting tools and can be extended up to 4 stations for separate cutting, creasing, embossing, punching and perforating operations.

MATERIAL USEThe Revo-Line distinguishes itself in the choice of material. The base frame is manufactured from a special stone cast material, which is less sensitive to temperature changes, compared to cast steel or iron. The special stone cast material will reduce vibrations drastically, because of its damping and absorbing characteristics. The base frame can be mounted on special high precision linear guide rails allowing motorized lateral settings of each individual converting station. The base plate of the top frame is also made from the same stone cast material. The removal of the top frame from the base frame can be fully manually or optionally automati-cally locked by means of heavy duty magnets which are incorpora-ted in the base frame.

Each converting station of the Revo-Line rotary die-cutter is pro-vided with the latest servo drive technology. The converting tools are directly driven by means of a fixed position motor gear and are engaged with the drive toolfree.

The Revo-Line rotary die-cutter is fully enclosed, reducing noise and dust coming into the pressroom and optimizing safety for the operators. The wide doors on operator and drive side allow con-venient and easy access for change-overs and maintenance. The sliding roof doors can be fully opened to load the converting tools from the top.

GENERAL SPECIFICATIONS

Tool diameter Up to 430 MMWeb width 650 – 750 – 850 – 950 or 1050 MMWeb speed Up to 400 M/MIN

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We have developed a universal modular in-feed unit for web width between 750 and 1750 mm.Speed up to 600 meters per minute.The in-feed unit is the interface between either unwinder or printing press and the Madern RDC.

In addition, the in-feed will ensure a proper preparation of the board before going into the RDC.The in-feed station is a multi-functional unit, which receives a web (printed or unprinted) and guides it into the first sta-tion of the rotary die-cutter by means of a servo driven pull roller with a pneumatically controlled nip roller.

Basic execution of the in-feed unit, consisting of:• Rigid frame structure• Servo driven pull roller with a pneumatically controlled

nip roller• Manual web feeding system through the complete in-

feed unit• Electrical equipment & integrated operator console

(HMI)• Maximum cable length 40 meters.

Optional equipment for in-feed unit:• Dancer roller • Control of constant web tension, especially during start

up and stopping of the line • Automatic post press de-curl• Adjustment based upon reel diameter unwinder, signal

to be supplied by unwinder supplier (In addition to a pre-press de-curler)

• Lateral web guide system• Walk-over frame with in-feed roller (interface with prin-

ting press or unwinder)

The Madern universal In-feed unit

• Web guide mounted under walk-over frame• Standard with “Fife” web guide with single web edge

sensor (manual positioning). Other web guide brands and types upon request

• Web cutting and clamping unit• Cuts and clamps the web in case it is activated• Activated in case of an emergency stop, web break or

board jam• Including necessary detector sensors• Protects the tools in the die-station (avoiding board

wrap around the tool)• Cross bar with brackets for positioning the register sen-

sor. Type of in-setter system similar to the printing press.

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RiRo rotary die cutter, next generation wide-web converting solution

The essence of the Madern RiRo “Roll in Roll out” wide web rotary converting concept is set-up reduction and quick change-over. The system is equipped with several ad-vanced quick changeover features and techniques, such as:

• Tool change can be done by one operator. No addition-al support required during loading, transportation and positioning of the tools;

• Automatic and accurate positioning of the tools in ma-chine and cross direction;

• No manual connections between the die module and rotary die-cutter;

• Tool-less, simple driven connection by means of a tim-ing belt;

• Automatic coupling of the gear lubrication system;• On-the-fly tool adjustments possible in cross direction;• Motorized settings and job memorization;• Multifunctional in-feed unit, equipped with an easy web

feed system.

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General specification:Available for high speed reel to reel production and rotary die-cutting applications.Single or multiple rotary die-station for cutting, creasing, embossing, punching and perforating.Simple and easy handling of the tool carrier and tools by means of an electrical transport truck.

Web width: 1350 mm, 1550 mm or 1750 mm Web speed: mechanical up to 600 M/MIN

The RiRo rotary die-cutter is fully enclosed, reducing noise and dust coming into the pressroom and optimizing safety for the operators. The wide doors on operator and drive side allow convenient and easy access for change-overs and maintenance.

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