by Lara Copeland, assistant editor, PostPress

The Insignia 7 Diecutter from Rollem International, headquartered in Anaheim, California, is a sheet-fed, rotary, flexo-magnetic machine designed to meet the shorter to long run, on-demand needs of the packaging and label market segments of the printing industry. Susan Corwin, marketing manager for Rollem International, noted that the setup and changeover processes are simple and quick. “The processes do not require a high degree of skill, as called for by the larger flatbed style diecutting machines seen previously,” she said. This ease of setup fills a niche for customized, craft packaging, prototyping, limited-run products and more.

The Insignia functions on purely mechanical timing and movement throughout the machine, which ensures greater reliability than dependence on servo motor and electric timing. Sheet after sheet, the guide and gripper registration system ensures 100-percent cutting accuracy. This finishing solution is suitable for both commercial offset and digital printers. “The Insignia provides a tremendous amount of flexibility to owners of the system,” Corwin commented. The addition of the rotary diecutter allows for more avenues of income, such as short-run folded cartons, customized labels and pocket folders, door hangers, POP displays, shaped invitations and more. Corwin added, “The flexibility in setup and changeover translates into the ability to offer and fulfill many different SKUs and shapes for products.”

Built to meet the specific requirements of its customers, the Insignia system is semi-customizable; it is offered with single or dual magnetic cylinders. “The single magnetic system is recommended for pressure-sensitive label work or straight diecutting,” Corwin stated. These systems are commonly used for applications that do not involve folding, such as kisscutting and straight “crush cut” diecutting. The dual magnetic system utilizes a paired set of male/female dies used for turning packaging products, carton work or presentation folders. This paired male/female set of dies translates into no makeready, only requiring switching the sets of dies between jobs.

Single magnetic machines have the option of being a bearer system or a non-bearer system, whereas dual magnetic machines always will come as a bearer system. With a non-bearer machine, the operator has the flexibility to use a die tool to kisscut varying thickness of adhesive liner as the operator physically adjusts the gap between the cylinders. On the other hand, a bearer configuration – available for thicker substrates – provides a floor for the cylinders to run against, creating a fixed gap between the cylinders. Corwin explained that this prevents an operator from accidentally crushing or damaging a die tool, while also providing stability in the cutting station. Bearer cylinders are at a fixed gap and cannot be adjusted. One die can be used to diecut across all thicknesses of material; however, different die tools are required for stock thickness changes and channel scoring.

Two optional delivery systems are available for the Insignia. A waste stripping unit removes the cut pieces from the matrix or skeleton of the cut sheet. “The ability to remove a hanger hole, or sombrero hole, from finished, cut pieces means eliminating a manual labor choke point in production lines,” Corwin said. She further explained that being able to batch count finished, stripped product on the back end of the system allows for a more streamlined collection and fulfillment of orders. The Insignia also can run inline with Rollem’s folding/gluing unit for any box or packaging work. The Insignia will cut product, strip the waste material and feed cut products directly into a folder/gluer unit for “printed sheet to folded/glued box” production utilizing a single operator.

“The Insignia7 has been well received by both existing packaging companies seeking quick changeovers and traditional printers and marketers seeking entry into the expanding consumer packaging market,” reported Corwin.

Technical Details:

The Insignia7 weighs 4,800lb and has a footprint of 79x58x55″ (200x147x140cm), not including delivery. It is offered in either a single upper magnetic cylinder configuration, lower hardened anvil cylinder configuration or a dual upper and lower magnetic configuration.

The Insignia7 has a feed capacity up to 40″ (101cm). It offers the largest sheet size available in the rotary diecutting class, featuring the B2 sheet capacity of 30×24″ and run speeds of up to 5,000 sheets per hour.

Sheet sizes range from a minimum of 8×8″ (20x20cm) to a maximum of 30×24″ (76x61cm). Material thickness ranges from a minimum 2pt (40-60gsm) to a maximum 24pt (430-450gsm) cardstock.