THE

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CUTTINGEDGE
Vol. 32, No. 11 – December 2014

SM
“Your Definitive Industry Resource”

Cover Story:

Matrix:
The Science of Creasing
Fiber Board for
Folding Cartons

INSIDE TechTeam™ Digest: PETG; fluctuating radial

dimensions; rule bending over, excessive dust; magnetic
material w Why Your Business is Stuck in Neutral: Five

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common excuses w Corrugated vs. Paperboard:
Advantages and limitations of each substrate (part 2) w
Safety Corner: Compressed air; OSHA's lockout stardard;
forklift maintenance …
IADD
INTERNATIONAL ASSOCIATION
of DIECUTTING and DIEMAKING
 SAMPLE
“OVER THE COURSE OF A YEAR, SAVING A FEW MINUTES
ON EACH SET-UP ADDS UP TO THE EQUIVALENT OF AN
EXTRA WEEK OF PRODUCTION.”

The Quick Set NS Grid John Lackner

provides automated, push-button set-up so no tools are needed Director of Manufacturing for Walter G. Anderson, Inc.
and repeat set-ups are easily recalled from the diecutter’s computer.. Hamel, Minnesota and Newton, Iowa

Walter G. Anderson’s John Lackner constantly measures
all aspects of the productivity of his two facilities. By
finding ways to shave minutes off downtime he has
raised production rates and gained greater overall
throughput. That was the thinking behind upgrading the
non-stop feed system on the company’s three BOBST
MASTERCUT 145 diecutters in their Newton, Iowa facility.
“We feel that we have a great deal of equity in our rela-
tionships be they suppliers of board, ink, pre-press and,
of course the manufacturers of our machinery. So when
BOBST provided the opportunity to be the first in North
America to install the Quick Set NS Grid we jumped at it.”
Installed and tested first on one MASTERCUT, soon
thereafter the Quick Set system was added to two
additional diecutters. “The Quick Set fully integrates with
the machine and its electronics so set-ups at the push of
a button are much faster than older systems where each
‘sword’ had to be set and locked in with a tool,” according
to John.
With an average of 11 daily set-ups across the machines
in the Newton plant John sees the growing trend of more,
shorter runs, hence even more frequent set-ups. “So
what I’m always looking for are ways to reduce downtime
and increase our true throughput. A few minutes of
savings, when it’s several times a day, adds up quickly.”
Quick Set NS Grid is available now as a retrofit for many
BOBST diecutters and as a standard feature on our new
diecutters. It is fully compatible with the Angle Lock®
Blanking system, facilitating better tool design and
further optimization of the press.
Single button, automated set-up of the grid is one more
of the ways that BOBST helps ensure higher production
rates, greater efficiency and increased profitability.

Bobst North America Inc.

146 Harrison Avenue
Roseland, NJ 07068-1294

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Tel: 888 226 8800 Fax: 973 226 8625

www.bobst.com
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INSIDE THIS ISSUE

4 From the President

Giving thanks
26 Corrugated vs. Paperboard (Part 2)
Advantages and limitations of each substrate

6 Matrix
The Science of Creasing Fiber Board for Folding
32 IsTenEmployee Cynicism Killing Your Culture?
ways to reconfigure around trust
Cartons

36 Rethink Employee Retention

14 Why Your Business is Stuck in Neutral
Five common excuses
7 guidelines for engaging older staff

38 Safety Corner
16 TechTeam™ Digest
PETG; fluctuating radial dimensions; rule bending
Compressed air; OSHA’s lockout stardard; forklift
maintenance
over; excessive dust; magnetic material

42 Member News
24 Blame Makes You Weak
How to avoid it
New members; press releases

48 Chapter Update
25 IADD & Industry Calendar
Upcoming events
Chapter news and upcoming activities

VOLUME 32, NUMBER 11 Q DECEMBER, 2014 EDITOR & CHIEF EXECUTIVE OFFICER
Cindy C. Crouse, CAE
THE CUTTING EDGE (FIDN 23-74-55048) Established 1972
Published monthly by the PRESIDENT
International Association of Diecutting and Diemaking Darrel Griffin, Stafford Cutting Dies, Inc.
651 Terra Cotta Ave., Suite 132, Crystal Lake, IL 60014. PRESIDENT-ELECT
© 2014 International Association of Diecutting and Diemaking Jeremy Guest, Diansuply, Inc.
Phone: 1-815-455-7519 Fax: 1-815-455-7510 SECRETARY/TREASURER
Email: cuttingedge@iadd.org
Natalie Taylor, Pace Punches, Inc.
Information on new products, personnel, industry activities, and product research and VICE PRESIDENTS
development, as well as comments and opinions, are obtained from sources believed to Eric B. Anderson, Anderson International Trading
be reliable, but THE CUTTING EDGE assumes no responsibility for inaccurate state- Reg Cunningham
ments or omissions of fact, except in articles written by members of our staff. John Dickison, Bobst North America Inc.
If you are interested in writing for THE CUTTING EDGE, please contact the Editor at 1- Robert R. Pettijohn, Mark-Maker Company, Inc.
815-455-7519. All press releases and product announcements should be mailed to THE Samuel Vial, Karl Marbach GmbH & Co. KG
CUTTING EDGE at the address below, faxed to 1-815-455-7510 or emailed to Ian Young, Radiant Lasercut, Inc.
cuttingedge@iadd.org. DIRECTORS
Advertising inquiries should be directed to Cindy Crouse, IADD, 651 Terra Cotta Ave., Connie Adams, Adams Technologies, Inc.
Suite 132, Crystal Lake, IL 60014; phone 1-815-455-7519; fax 1-815-455-7510; email Joseph B. Adkison, Adko, Inc.
advertising@iadd.org. David Bialoglow, National Steel Rule Co.
Gino Gualtieri, Central Die Supplies Inc.
Standard (A) postage paid at Crystal Lake, IL 60014 and additional mailing offices. Dan Harvey, PGC
ISSN 08995923. Shaun Larson, Jonco Die Co. Inc.
POSTMASTER: Please send address changes to THE CUTTING EDGE, 651 Terra Cotta JC Marovich, Triangle Dies and Supplies, Inc.
Ave., Suite 132, Crystal Lake, IL 60014, USA Mark Pierce, Davis & Pierce Die Service, Inc.
Rick Putch, Dicar Inc
© 2014 International Association of Diecutting and Diemaking Jennifer Thoroe, AmeriKen Die Supplies, Inc.
Cover Photo: IADD, Crystal Lake, IL, USA Mauro Tomelleri, Serviform SRL

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Bob Wax, Associated Pacific Machine Corp.
IADD Website - http://www.iadd.org IMMEDIATE PAST PRESIDENT
Special username & password emailed monthly to all members Andrew Carey, Cimex Corp.

December 2014 The Cutting Edge 3

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FROM THE PRESIDENT
Dear Colleagues and Friends,
I hope this month’s edition finds you and
yours doing well. Here in North Carolina, the
air is cooler and crisp and the days are be-
coming shorter as night fall comes earlier with
each passing evening. The leaves on most
trees have changed to an array of red, yellow
I’m thankful for our and orange hues before releasing their grasp
and descending to the ground—time to pull
Association that has out the rakes. Here it seems all of nature is
given me the preparing for the winter months soon to ar-
rive, while we are preparing for the holiday
opportunity...to season beginning with Thanksgiving.
serve and work with
some of the best Thanksgiving is a traditional holiday in
the US with its origins most commonly said
and brightest folks to root from a well-known harvest celebra-
our industry has to tion in 1621 among the Pilgrims of New En-
gland and their Native American neighbors.
offer. Although that’s the most popular story for the
US, harvest celebrations have been going on
for many centuries and among many cultures
throughout the world to give thanks for plen-
tiful bounties. The Ancient Greeks held an
autumn festival for three days known as
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Savannah and Jacob
4 The Cutting Edge
Thesmosphoria; in Rome the Cerelia; in China
the Chung Ch’ui; the Erntedankfest in Ger-
many; Ladainha in India and so on and so
forth. There are many festivals dedicated to
giving thanks for abundance and prosperity.
For many of us here in the US, Thanks-
giving is a time of gathering with friends and
families, eating way too much and watching
football (the kind of football where you mostly
use your hands), followed by the most insane
retail shopping day of the year. The latter is
great for our industry, but you will not catch
me out there in that chaos! I know it’s very
exciting for many folks, so have at it and en-
joy if that’s your cup of tea. I’ll wait and pay a
little more just to stay out of that mess, or
perhaps I’ll shop online.
Thanksgiving is also a time where we give
thanks for the important things in our lives. I
am very thankful for my family, especially my
wife Misty and our two blessings, Savannah
and Jacob. I am thankful for the friends I
have: the ones who have been there for me
since grade school, my comrades from my
military days, college pals, neighbors, new
friends I’ve made along the way, friends here
at work and the many I’ve made here in the
Association and throughout the industry.
I am thankful for my health. It’s not
where I would like for it to be, but fortunately,
much of that can be modified by my actions.
All in all, it’s all good so far. I’m thankful for
my employer for giving me an opportunity to
build and grow with a company that puts its
people first. I’m thankful for our customers
who give us the opportunity to provide our
services to meet their needs so that we can
provide for our greatest asset, our people.
I’m thankful for our Association that has
given me the opportunity to not only meet
and learn about so many other companies
and people in our industry, but also the op-
portunity to serve and work with some of the
best and brightest folks our industry has to
offer.
December 2014
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I sincerely hope that the year has been kind
to you and yours so far and that you have much
to celebrate and be thankful for this holiday
season. Sometimes it’s hard to see the good
within the many challenges and obstacles that
life throws our way at times, but the good is
there… you just may need to rake a few “leaves”
that have fallen to expose it.

All the best,

Darrel Griffin

If you wish to reach Darrel directly, please contact him by

phone at 1-704-821-6330, email at darrelg@gostafford.com
or fax at 1-704-821-6270.

December 2014 SAMPLE The Cutting Edge 5

Matrix:SAMPLE
The Science of Creasing Fiber Board for Folding Cartons
Joe McDowell, Channel Creasing Matrix, Inc./CCM Die Supply, Martinsburg, WV, USA
In life we are often negative or antago-
nistic towards things we do not fully under-
stand or things that present us with
challenges. I think we can all agree there are
few things more frustrating than trouble-
shooting an issue when you don’t grasp the
full picture of what’s happening (or is sup-
posed to be happening). About a year ago I
wrote an article for The Cutting Edge regard-
ing “how versus why.” We may understand
how something works (the process), but we
also need to understand why it works—what
the goal of the process is and why the pro-
cess is designed exactly as it is. By under-
standing this we will then understand what
is wrong when something does not work.
On that note, I would like to talk about
this subject as it relates to something we see
daily: a better understanding of creasing and
how and why creases form in various sub-
strates. Every day we not only help people
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Diagram 1
6 The Cutting Edge
solve specific creasing issues, but we also
teach them why things work the way they
do, which often gives them a more positive
outlook on their challenging situation and en-
ables them to better approach future chal-
lenges. Although results will vary based on
conditions and other factors, most people can
achieve a consistent result if they simply fol-
low proven formulas and communicate with
each other.
While substrates in today’s market are
always changing, we find there are still three
basic ways to crease materials during the
diecutting process: matrix, phenolic counter
or steel counter plate. Which of these is the
best way to crease your product? The an-
swer is all of them—when you use the ap-
propriate method for your substrate’s
qualities and characteristics. Please note I
am discussing this process only in flat
diecutting; rotary diecutting is completely dif-
ferent. To simplify, we’ll address
substrates as three categories,
which are as follows:
1. Fibrous material: This en-
compasses any material
made up of paper fibers
that are compressed and
bonded together to form a
sheeted material. These
are generally known as
SBS, CCNB, chip, Kraft
back and recycled board,
as well as some names I
cannot write here. These
are the materials you see
every day in cartons, fold-
ers, mailers, etc.
December 2014
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2. Fluted materials: Generally known to
us as corrugated or, as people in the
Stone Age used to call it, cardboard.
This is usually a Kraft material, ei-
ther found in brown box form or, as
you will see more and more, in shelf-
ready or POP displays. Many times
you will find these fluted materials
either printed on directly or lami-
nated with a label or fiber board ma-
terial. This can cause many problems
depending on the material lami-
nated. (There is another article to
come on creasing this specific sub-
strate; we have been doing research
to find ways to accommodate these
laminations and to address them
with a formula, as we do non-lami-
nated materials.)
3. Plastic: People are looking at this
style of carton for a variety of rea-
sons, one being the visualization of
the contents, which are readily seen
with the simplicity of the print. An-
other advantage is the virtual lack
of moisture degradation that occurs
if it gets wet. Creasing plastic is usu-
ally not done with a counter mate-
rial, although it can be. Instead it is
normally achieved by slitting or per-
forating the plastic.
Fibrous material is generally used in the
folding carton and printing industry (see Dia-
gram 1). These materials are usually diecut
using flat steel rule dies on either a platen or
cylinder-style press. Roller presses are not
set up to use matrix or any other type of
counter material. Let’s talk about deciding
what to use to crease any of these fibrous
products.
There are many factors that need to be
determined and discussed when creasing fi-
ber board:
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• The design of the finished product.
Find the proximity of the creases to
each other and the cutting rule. This
December 2014
information can lead to variations in
the die manufacture and counter
used.
• The substrate to be used. Different
substrates have different character-
istics and they will all have unique
attributes that need to be handled
accordingly.
• The type of press to be used. Is it a
platen or cylinder-style press? Many
people ask if it really makes a differ-
ence, and the answer is absolutely.
We have found many ways around the
differences, and they all entail a little
work, but if not done correctly can
cause many more problems on press
that may not seem to be related to
creasing, yet are. The preeminent
problem is the lack of communica-
tion between a diemaker and
diecutter in reference to what type
of press is being used. People who run
cylinder presses have
• The length of the run. Some counter
materials are made for short run told me that dust is
(15,000 or less), while others can run the nature of the
hundreds of thousands of impres-
sions.
beast, but after we
make a few changes
If the above items are not discussed in to the die they’ve
more than a passing conversation, you are
guaranteed to experience a problem during not just tamed the
the diecutting process. Sometimes that prob-
beast—it has
lem is taken as status quo. For example, a
long makeready may seem like standard prac- disappeared.
tice, but the truth is it doesn’t have to be.
People who run cylinder presses have told me
that dust is the nature of the beast, but after
we make a few changes to the die they’ve not
just tamed the beast—it has disappeared.
I am not suggesting the problems are the
fault of the diemaker; rather, I am saying the
problem lies in the communication, or lack
thereof, between the diemaker and the
diecutter. If a diecutter will tell his diemaker
some of the problems that are occurring, the
diemaker may make some suggestions or
The Cutting Edge 7
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changes. On the other side of that coin, the
diemaker needs to ask some of these ques-
tions to make sure they are making the best
tooling possible.
So let’s look more closely at why fiber
material folds the way it does. First we need
to look at the makeup of the material. A typi-
cal SBS board looks like Diagram 2.
As you can see, the fibers are bonded to-
gether and run in the same direction, thus
the reason you can crease with grain (creas-
ing in the same direction as the grain) or cross
grain (where the crease runs perpendicular
to the grain direction). The proper way to get
a good crease is to break or delaminate these
fibers while stretching the upper and lower
liners of the material. To do this, we have stud-
ied how fibrous paper reacts under pressure
and what causes the material to delaminate.
Diagram 2
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Diagram 3
8 The Cutting Edge
To be clear, the pressure I am speaking
about is not only the vertical pressure of the
crease rule, but also the lateral pressure.
This lateral pressure comes from the mate-
rial being forced into a channel that is nar-
rower than you would think at first.
In the old days, we used to use the fol-
lowing formula: 2 x paper thickness + crease
rule width. If you think about it rationally, it
makes sense; this formula would put a line
in a piece of paper, allowing you to fold it.
The problem came as the quality of print in-
creased, the ways in which we printed and
the drying of the inks evolved and the qual-
ity of the material changed with much of it
being recycled. The newer methods of dry-
ing have also added some difficulty to the
diecutting and creasing problems we have
today.
Getting back to the use of the 2 x paper
thickness formula…this theory sounded good
and seemed logical. However, the physics in-
volved in the proper folding of paper blows
the logic out of the water. If you try to fold or
bend this paper over without changing the
dynamics of the paper (displacing materials),
you will stretch the face or front liner over a
greater surface area, which is created by the
mass of material meeting at the crease area.
When this happens you will find cracking all
throughout the crease. This will come up later
in this article as well, when we discuss the
three basic cracks that occur, the reasons they
happen and what to look for.
The formula we use today is: 1.75 x ma-
terial thickness + crease rule width
This formula is based on the principle
that proper creasing is created by delami-
nating the fibers. This is achieved when the
channel you force the paper into is nar-
rower than the original formula. That
causes the material to pinch at the top of
the channel, stretching the upper and lower
liners slightly and breaking the bond be-
tween the fibers. Then, when the item is
folded, the lower liner and the fibers that
were delaminated move out of the way and
the top liner stretches around a smaller sur-
face area (see Diagram 3).
Notice that as the fibers move out of
the way the face or top liner is able to wrap
See MATRIX page 10
December 2014
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 SAMPLE
MATRIX
Continued from page 8
around the material without cracking. This
is how a crease in fiber material should
work—and most times does. However, there
are times when the coating was dried at a
greater temperature to dry it faster, causing
some really dry stock or dry print. This in
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10 The Cutting Edge
turn may crack and will look like the board
is cracking when in fact it is the ink.
I am often asked what is the best way to
run the crease. I would say from my experi-
ence that across grain will give you a more
stable crease than with grain. The reason for
this can be found when you look at the way
in which delamination occurs. As you can see
in Diagram 4, the material will delaminate
in long lines when creasing across
grain. However, when you crease in
grain direction a different kind of
delamination occurs. Imagine the fi-
bers as a bunch of straws in a glass.
Now put something in that glass and
the straws will separate but remain
in clusters. This is what happens
when you crease in grain direction:
the fibers have a tendency to cluster
(see Diagram 5).
Do you see how the delamination
is a series of holes or pockets? If these
pockets or clusters move too close in
the same direction, you may get some
cracking, even if the channel width is
the same in both directions (with and
cross grain). To eliminate this, you
would narrow the channel to the next
lower matrix size. Doing so will break
the clusters down even more. This al-
lows the material to move evenly
when folded and not to cluster in the
same place.
Another thing I am often asked
about is making the crease wider. You
can do that using this formula—just
plug the thickness of the crease rule
into the formula. However, I do cau-
tion people about doing this. Although
it will give you a better-looking crease
as far as delamination, it will also give
you a ropy, wide crease which will not
fold squarely. You will find that one
side of the crease will become domi-
nant over the other and this domi-
nance will switch from side to side,
not remaining constant.
A good rule to follow is the chan-
nel width you use should be no greater
than three to four times the thickness
of the material being diecut. There
may be times where four and half
times the thickness is acceptable, but
December 2014
 SAMPLE
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the general rule is three to four times. If you cess. The tolerance for cutting rule and
have to do a capacity fold or one that goes crease rule is ± 0.001" (0.0254 mm); this is
back onto itself, there are ways to do it be- potentially a 0.002" (0.0508 mm) difference.
sides just using a double crease, e.g. making For cutting plate, it is ± .0002" (0.0508 mm),
two distinct creases. To explain would take potentially another 0.004" (0.1016 mm) dif-
too much time here, but I may write a sepa- ference from end to end. In essence, there
rate article on how to achieve some of the could be a 0.003" (0.0762 mm) difference be-
folds people say you cannot produce. tween the rule and the plate when you add
the tolerances together in any given area.
Over the length of the plate there can be a
Crease rule height difference of 0.006" (0.1524 mm). Now the
We have talked about channel
width, which is imperative to get-
ting the delamination correct, but it
is not the only factor in obtaining
the proper crease. We must also
look at the height of the crease rule.
The height is calculated by using the
following formula: (cutting rule –
material being diecut) – membrane
thickness.

The membrane is the material

used to hold the matrix together and
it is present in between the chan-
nels. If the material is metal, it is
approximately 0.010" (0.254 mm)
thick; if it is Mylar or plastic, it is
usually 0.005" (0.127 mm) thick.
Some people will say you do not
need to subtract the height of the
membrane, but I can tell you both
from the physics Diagram 4
of what we are
doing when
diecutting and
from my experi-
ence, you must
subtract the
membrane!

Before we go
much further,
let’s look at our
industry’s accept-
able tolerances

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for the materials
that go into the
diecutting pro-
Diagram 5

December 2014 The Cutting Edge 11

 SAMPLE
Diagram 6
Diagram 7
argument will be made that we use
makeready for the low areas. This is true,
but only for the cutting rules!
If you do not take the membrane out
when figuring the crease rule height, you can
actually bottom out on the crease (see Dia-
gram 6), leaving what we call “stand-off” in
the cut areas near a crease.
If you look at the sandwich you make,
even without taking into consideration the
tolerances, you will notice that with the cut
rule minus just the material thickness (let’s
say it is Mylar-based), how do you account
for the 0.005" (0.127 mm)? The membrane
is still in the channel, so the crease rule would
push the paper and the membrane still be-
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ing intact would then act as a barrier, stop-
ping the cutting rule from making a full cycle
12 The Cutting Edge
and leaving it a couple of thousandths of
an inch (0.0508mm) short of full penetra-
tion (see Diagram 7).
In this case, the diecutter might say
the die is not right or the cutting rule is
bad or stop the press and do makeready.
Worse yet, they may add pressure and
force the cut while the crease cracks. All
of these could be avoided if the formula
had been followed.
When using a phenolic counter you
must know how much material is left in
the membrane of the channel. I have
heard people say “It’s either 0.005" or
0.007" (0.127 or 0.1778 mm)—it’s only
a 0.002" (0.0508 mm) difference.” Yes,
that is only a 0.002" (0.0508 mm) differ-
ence, but if the material is 0.016" (0.4064
mm), the difference is actually 12.5% and
that can make a difference in the crease
and the cut, as well as cause the prob-
lem of stand-off. It is my understanding
that many of the diemakers today have
settled at 0.006" (0.1524 mm).
If the membrane is not taken into con-
sideration, different problems can occur.
First, you don’t cut all the way through and
the product doesn’t strip at all. Second, the
product cuts, but only in certain areas and
you end up with a checking problem (where
the bottom ink seems to strip off in pieces).
Nicks can become stronger, making blank-
ing or stripping a tougher task, and a major
makeready delay. And, of course, the crease
will be cracked either on the surface or un-
der the ink, but will surface on the folder
gluer, if not on delivery.
Types of cracks
Let’s talk about the different types of
cracks we see when we try to crease papers,
and the results and causes.
December 2014
 • SAMPLE
Cracking on the sides of the crease:
Usually noticed on delivery before
folding. Caused by the channel be-
ing too narrow.
• Cracking on the bottom of the crease:
Usually noticed on delivery before
folding. Caused by the crease rule be-
ing too high.
• Cracking on the folder gluer: Where
the crease looks nice on delivery, but
cracks when folded. Proper delami-
nation has not occurred and too
much material is in the way of the
top liner, generally caused by a
crease rule that is too low (see Dia-
gram 8). Notice how much material
is near the area that the top or face
liner has to bend around. It is too
great and the material ruptures.
EXPLORE Innovation with advancements
in diemaking/diecutting, foil stamping/
embossing and specialty effects processes
SAMPLE
Booths over 80% Sold Out!
December 2014
These problems can be avoided simply
by following the formulas and with commu-
nication between the diemaker and diecutter.
These problems can
be avoided simply by
following the
There are many other problems that oc-
cur because people do not follow formulas formulas and with
or take into account the collateral damage communication
that can happen when the focus is on only
the problem at hand. When it comes to creas- between the
ing, some subtle changes can make major diemaker and
impacts on your profitability in your
diecutting job. These changes and problems
diecutter.
will be discussed in the next article. Thank
you—both of you—for reading this.
Joe McDowell is the Vice President of Channel
Creasing Matrix, Inc./CCM Die Supply. He can be
reached at 1-800-451-7373 or by email at
jmcdowell@ccmdie.com. For more information,
visit www.ccmdie.com.
Innovation and Tradition Converge
May 13-15, 2015 • Schaumburg, IL, USA
www.OdysseyExpo.org
The Cutting Edge 13
 SAMPLE
The Five Most Common Excuses for
Why Your Business Is Stuck In Neutral
Jack Dennison, J2Development Services LLC, Pueblo, CO, USA
Growing your business is a lot of hard work! I know
this better than most. Over nearly a decade of work, my
company grew by an average of 46% every year, and it was
a lot of hard work! Whatever gross revenue high mark we
achieved the year before, we grew an astonishing 50% the
next year, and the next, and the next.
For owners who have a knack for business develop-
ment like me, making plans, executing strategies and living
with constant change is invigorating. Each new insurance
carrier or third-party administrator that we added, every
new large loss we received, each time a new insurance agent
sent us work, thrilled and energized me. Every day was a
sunshine day filled with new opportunity.
But what if your days are not filled with sunshine and
instead you feel mired down and stuck in the mud? Your
hopes and dreams for your company’s development have
gone unfulfilled. The joy of starting your own business and
growing it into a “going concern” has been replaced with
the darkness of disappointment over your fading hopes for
greatness.
SAMPLE
14 The Cutting Edge
When growth eludes us, disappointed owners each seem
to speak a common language of excuses. They voice the
same issues and share similar concerns as others who have
become unhappy with business. “I never thought running a
business would be so hard and growing it would seem so
impossible,” many conclude.
When asked why they don’t do something about the is-
sues that produce disappointment, you hear the same ex-
cuses time and time again. The real problem with lack of
growth is not out there, but it is in here, in the heart and
mind of the owner. Have you ever heard someone else, or
perhaps yourself, say the following?
1. “I’m confused and I don’t know what to do.”
The truth is many owners genuinely don’t know what
to do to turn the corner, to generate more work, to improve
fading profits. They get stuck, caught up in the daily grind
and all they can see are the problems and challenges of
owning a small business. Their creativity has been shat-
tered by circumstances and the daily stress of being a small
business owner. While I too sometimes felt confused while I
was walking on unfamiliar ground, I always found help in
my network of relationships who I reached out to often.
Drawing on the experience and counsel of others often shed
the light I needed to make my path clearer and my deci-
sions more certain. Whatever issue I faced, I was always
certain I could find the answer and I searched the counsel
of others until I found it.
2. “I just don’t have the time to do more than I am
already doing.”
This is perhaps the #1 reason given by restoration own-
ers for why they don’t grow beyond where they currently
are. “I just don’t have the time to invest in growth,” they
say. I know first-hand how demanding and all-consuming
small business management can be. My company grew from
December 2014
 SAMPLE
a startup to a successful hyper-growth company over nearly
a decade of work. I lost entire summers to hail and wind
catastrophes and worked 24/7 during these times. BUT, there
is always time to do the right thing, the needed thing. When
plans, you must get help from someone who does. I meet
many business owners who have a limited number of skills.
The successful ones go strong on what they do well and
they turn to others to supplement and compliment their
I became convinced that I had to spend more time working weaknesses with strength. As the owner you are respon-
on, not in, my business, my perspective changed, and I be- sible to insure stability and growth, but you don’t have to
came even more intentional about doing the right things that do it all yourself.
would undergird my growth plans and reach the success I
so desperately wanted. You can grow. I am confident you can! Which will it be?
Do you see the opportunity? Will you reach out and seize it?
3. “I am overwhelmed by the daily demands of Sure you can! If you need help, there is help available. I sought
running my business, and I feel like I am drowning.” help from others and found it. You can ask for help from
others and get it.
Yes, you may feel psychologically and physically over-
whelmed by the constant stress of ownership, but there are Jack Dennison is an entrepreneurial business leader who has suc-
still those moments that can be devoted to future planning. cessfully fueled six prior business startups before entering the res-
My wife and I would regularly go to our favorite restaurant, toration industry. Dennison shared his restoration industry
sit at the bar over margaritas and talk about our life and experience and success with his highly skilled wife and partner
business. The owner once bought us a free round of drinks Jackie Dennison. The Dennisons currently serve as business coaches
because he said he saw us so frequently and wanted to show helping other businesses grow in the restoration industry. For more
his appreciation. I told him that we came to his restaurant information, visit www.growmyrestorationbusiness.com.
whenever we had a hard day and needed to decompress or
had a good day and wanted to celebrate. “We are here four
or five nights a week,” I joked. We all laughed. But it was
true. Some of our best business decisions were made at that
restaurant where we would sit, tired but unhurried, and could
think, talk, plan and make decisions about the future of our
lives and our business. Where do you go or what do you do
that gives you the space to think and dream, to plan and
prepare for tomorrow? You know what it is. Do it more often
and spend some of that time planning for the future of your
business and not simply dealing with its current operation
and problems.

4. “I am afraid growth will cost me money I don’t

have.”
I know conventional wisdom tells us that you pay upfront
in order to grow by buying more equipment, adding new
staff, etc. I never found that very helpful or doable. I always
found that I just needed to stretch a little more until the rev-
enue was produced by our growth efforts and then I could
spend the money to add a new layer of management, a new $20,000 US
estimator or new specialty equipment. You go through a pe-
riod where you just have to stretch a little bit more. The GREAT DEAL!!!
good news is you have capacity to absorb more work right
now, don’t you? You are not completely full. You could do Pre-Owned Laser
more. So for the short-term you identify those opportunities
that will produce the most value with the least amount of 42 x 62 Coherent Laser, for producing steel rule dies.
cost. Every business has them. You just need to look, identify Rebuilt, in excellent shape. 550 watt with upgraded controller.
and seize. Really!
For more information:
5. “I just don’t do those growth or planning things Canadian Corrugated Packaging
well.” 411 The Kingsway
Toronto, Ontario M9A 3W1
This may be your most valuable insight and good for

SAMPLE
P: 1-416-894-6590 - F: 1-888-614-3904
you if this is true and you see it. But if it is true that you
aren’t a good strategist or you don’t execute well on growth Email: coradusk@hotmail.com

December 2014 The Cutting Edge 15

 SAMPLE
TechTeam™ Digest

Editor’s Note: Certain technical questions received kind of heat would help. PETG is pretty soft,
by TechTeam don’t lend themselves to a full ar- so it shouldn’t shatter. Crease height should
ticle write-up. However, since they may contain be half thickness of the material down on
useful tidbits of information, from time to time we
knife height. Not too much rubber.
present a digest of responses in a more casual for-
mat.
Reply
IADD TechTeam Members
Joe Adkison, Chair PETG Do you have any suggestions for punch
types to use? We are planning on going with
Adko, Inc.
Michael Barkin IADD TechTeam™ – Ticket 1422 0.25" (6.35 mm) inside bevel cup punches.
Advanced Die Supplies, Inc.
Barry Borrell
Alumni
Material: Plastic—PETG
Process: Diemaking—Flat Steel Rule
Answer
Peter Bendell
Pioneer-Dietecs A center bevel tube punch would work
Jeremy Guest
Diansuply, Inc.
Question best with proper ejection material (hard gum
rubber), but an inside bevel cup would also
Brett Johnson work. However, we would be concerned with
Arrow Cutters We have a question on the proper
diecutting materials (knife, crease, etc.) to use the inside bevel cup breaking and not cutting
Rich Kengott
AmeriKen Die Supply, Inc. for diecutting 0.030" (0.762 mm) PETG clear properly, not to mention they may need to
Dan Mathys plastic on an Autoplaten Bobst Vision press. change frequently. The 0.030" (0.762 mm)
Heidelberg USA We are specifically looking for what score material is probably OK to cut; any thicker
Robert McCann height to use, as well as any other pertinent would increase problems when using an in-
Bobst North America Inc. side bevel. [Note: the client also received
information you may have on overall mate-
Joe McDowell some personalized assistance from the
Channel Creasing Matrix/CCM rial to use on the die and best practices for
the customer during the diecut production TechTeam which, due to confidentiality, is not
Clint Medlock
Stafford Cutting Dies, Inc. run. reprinted here].
Mike Moravec
ABC Die Company
Randy Norman
We are looking at a 3 pt 0.937" (23.8 mm)
Teflon-coated long bevel knife; 2 pt 0.920"
Reply
Preco, Inc.
(23.368 mm) crease; 0.625" (51.875 mm) Thanks, I did get resolution on this issue.
John Passantino
Perfect Supply Company, Inc. maple dieboard; and 0.375" (9.525 mm) max Many of the suggestions were very helpful.
Craig Pepper point rubber with 0.25" (6.35 mm) Dynaflex Thanks again.
Pace Punches, Inc. foam inside the part. Any suggestions or ad-
Rick Putch vice are more than welcomed. Ticket #1422 was answered by TechTeam mem-
Dicar Inc. bers, including Brett Johnson of Arrow Cutters. You
Patrick Quinlan may reach Brett at 44-1628 529 796 or by email
Channel Creasing Matrix/CCM Answer at brett.johnson@virgin.net. For more information

Charles “Butch” Schomber
RotoMetrics
Bob Wax
Associated Pacific Machine Corp.
SAMPLE
on the IADD TechTeam, visit the IADD’s website at
PETG is easy to cut. Use the same setup www.iadd.org.
as for PVC. Use ground edge rule, and any

16 The Cutting Edge December 2014

Fluctuating Radial
Dimensions
SAMPLE
IADD TechTeam™ – Ticket 1428
Material: Corrugated Paper Double Wall
Process: Diecutting—Rotary Steel Rule Die—
Soft Anvil
Question
We manufactured a rotary steel rule die
with 360 mm (14.173") diameter. This rotary
die is made for double wall corrugated board,
AB-flute, 7 mm (0.2756") thickness. The cut-
ting rule height we used is 4 pt, 25.4 by 1.42
mm (1" by 0.0559") GNU(August Graef) cut
rule.
When the customer cut with this die, he
got dimensions as per his requirements. Now
the customer is using the same die, but he
got a reduction in the height of the box by 5
mm (0.1968 mm)—the original height is 549
mm (21.614"), but now he is getting 544 mm
(21.417").
Please let me know why the dimensions
are reduced. Moreover, some of our rotary
die customers are complaining about increas-
December 2014 SAMPLE
ing and decreasing dimensions in the radial
directions. Please give me your valuable sug-
gestions to solve such problems.
Answer
Your question is well-stated and is a very
Your question is
common phenomenon in the soft anvil well-stated and is a
diecutting of corrugated board. There are very common
many reasons the radial dimensions fluctu-
ate from time to time. Two of the most com- phenomenon in the
mon are the depth of penetration of the soft anvil diecutting
cutting rule into the anvil, and the anvil cover
thickness itself. We recommend you monitor of corrugated board.
this particular cutting die and measure the
depth of penetration into the anvil for several
production runs while recording the dimen-
sion of the diecut carton during the produc-
tion of each order. Also measure the anvil
cover thickness for each order you monitor.
Attached is a chart showing how a diecut
blank on a 360 mm (14.173") diameter ma-
chine can vary in dimension with the wear of
the covers. Assuming the cover is 10 mm
(0.3937") when new and 5 mm (0.1968 mm)
when removed, dimensions can vary almost
1.0% of their intended dimension throughout
the life of the cover. Note that at the mid life
of the cover—7.5 mm (0.2953")—the diecut
dimensions match the intended measure-
ment.
The Cutting Edge 17
 a suitable cut
for every style
SAMPLE Some machines are equipped
with variable speed servo motors to
compensate for such wear. Be sure
the motor is functioning properly if
this particular machine has one.
Lastly, if the double wall paper is
diecut directly from the corrugator,
the moisture content is significant.
Diecutting wet paper takes more
impression, therefore the knives are
penetrating deeper. Furthermore,
once the paper “cures” or releases
the excess moisture, the carton will
shrink.
Ticket #1428 was answered by TechTeam
member Rick Putch of Dicar Inc. You may
reach Rick at 1-412-979-3775 or by email
at rickp@dicarinc.net. For more informa-
tion on the IADD TechTeam, visit the
IADD’s website at www.iadd.org.
Rule Bending Over
IADD TechTeam™ – Ticket 1431
Material: Corrugated Paper Double
Wall
Process: Diecutting—Rotary Steel
Your supplier for flatbed- Rule Die—Soft Anvil
and rotary diecutting
Question
We are manufacturing rotary
steel rule dies with 25.4 by 1.42 mm
Essmann + Schaefer GmbH + Co. KG (1" by 0.0559") for double wall cor-
Precision steel rules
rugated boards. For front edge (lead
Tel.: + 49 (0)202 94 68 - 0
Fax: + 49 (0)202 94 68 - 120 edge) and back edge (trail edge) we
service @ essmannrules.com are using 26.1 by 1.42 mm (1.0276"
by 0.0559") axial rule. At the same
Our Distributors
Canada: Central Die Supplies Inc. time we are providing stripping
www.centraldie.com
USA: Wagner Die Supply knives for front and back edge rule
www.wagnerdiesupply.com support knives. Even though we are
CCM Die Supply Inc.
www.ccmdie.com
manufacturing with the above qual-
ity, our customers are complaining
that the front and back edge are
bending (blunting). Is it our rule se-
lection? We are attaching the die layout,
along with radial strippers and supporting
knives [not reprinted here due to confidenti-
ality].
Answer
You may want to look at using a differ-
SAMPLE
ent type of cutting rule that has more of a
pointed edge versus the rounded edge. Us-
ing the rounded tip requires the paper to fully
18 The Cutting Edge
compress before it is cut, thus requiring more
pressure, resulting in deeper penetration into
the anvil. With deeper penetration, the rule
is more likely to fold over.
Second, you want to look at the ejection
rubber type and height you have on the lead
knife. Make sure it is not more than 2 mm
(0.0787") above knife height and not very
hard. The harder the rubber, the more pres-
sure required and the more likely to bend the
rule over.
Last, we would consider using the same
height rule for horizontal rule that you use in
the vertical rules. If you can be there when
your customer sets up the job and ask them
to keep increasing pressure until it cuts, you
may see that the horizontal and vertical knives
cut at the same time with the same heights
versus having the taller knife on the lead/trail.
With the taller knife, you are penetrating the
anvil more thus creating an opportunity for
the knife to fold over. If you use a different
tooth profile for lead/trail versus vertical
knives, then you may want a different height.
We believe the bottom of the radius of
the serration should be the same height;
therefore, if you use an 8 tooth on the lead/
trail and 10 or 12 tooth on the vertical knives
then you will need taller rule in the lead/trail
to get to the same cutting level. Regardless
of what is happening, we would strongly sug-
gest you be there when they run this die to
ensure they are not putting too much pres-
sure on it. Based on what we see, you do not
appear to be doing anything wrong.
Reply
Thank you for your prompt reply. We are
using 25.4 by 1.42 mm (1" by 0.0559") ra-
dial, 26.1 by 1.42 mm (1.0276" by 0.0559")
axial rule, 8 tpi GNU rule from Germany for
double wall boards (AB-, BC-, BB-flute).
When we used 25.4 by 1.42 mm (1" by
0.0559") GNU rule for both axial and radial,
some customers complained that boards
were not cutting properly at the lead and trail
edges.
So we are using 26.1 by 1.42 mm
(1.0276" by 0.0559") 8 tpi GNU rule for lead
and trail edges. We are using 15 to 20 shore
16 mm (0.6299") cell rubber for lead and trail
See TECHTEAM page 20
December 2014
SAMPLE

SAMPLE
 SAMPLE
TECHTEAM
Continued from page 18
2010 issue of The Cutting Edge answers your
question. IADD members can view it by
searching the IADD online Resource Library.
Go to www.iadd.org and click on “Article
Search Engine. Search the keywords “recom-
If you look at the edges. If we use rules like this, they are bend-
mended specifications for rotary dies” and
ing (folding over/blunting) at the lead and trail
plate and it is edges. Please give your suggestions and let
the article you want is the first link.
gouged to high us know if there is some kind of rule selec-
For more information on the IADD TechTeam, visit
tion chart.
heaven, you know the IADD’s website at www.iadd.org.

something is wrong Answer

there. Excessive Dust
A previous answer, written up as a IADD TechTeam™ – Ticket 1367
TechTeam Potpourri article in the October
Material: Paperboard Carton Stock
Process: Diemaking
Tuesday, May 7, 2013, 12:54 PM
Davis & Pierce Die Service Question
Kansas City, Missouri
One of our customers is getting excessive
amounts of dust and fibers when diecutting a
610 micron (0.024") carton board. The board
type is Cadence brand. We’ve tried using long
center bevel rule in our dies but it made the
problem worse than using ordinary cutting
rule. Has anyone ever come across this board
type or this excessive dust problem?

Answer
The first thing we would look into is
whether the makeready is being done on
press. Dusting is often caused by the edge of
the cutting rule being flattened in the cutting
process. The flattening of the rule then causes
the material to be pulverized, rather than cut
with a clean edge, creating dust.

We would say that the example you gave

about using long bevel rule goes on to prove
this theory even more. Long bevel will create
dust when excessive tonnage or an improper
makeready is used for two reasons. First, long
bevel rule generally has a ground edge which

Sweet Sixteen!
In May 1997, the first EasyBender in North America was installed at Davis
& Pierce in Kansas City. Today — right now, actually — that machine is still
in production. Two shifts a day for 16 years and it's still going strong. It
has produced approximately 60,000 dies, is routinely used for high tolerance
(±.005" ) jobs, and has required only minimal maintenance. AdamsTech and
EasyBender, still changing the way the world makes dies.
is micro-serrated and will dull much faster
than shaved edge. Secondly, there is less ma-
terial at the edge to give the rule stability. We
would first double check the makeready. If
you look at the plate and it is gouged to high
heaven, you know something is wrong there.
As far as a type of rule to use, we would
recommend moving to an edge hardened

SAMPLE
product with a shaved edge. Stay away from
info@adamstech.com long bevel. If you feel that you need a sleeker
phone: 303–798–7110 AdamsTech See TECHTEAM page 22

20 The Cutting Edge December 2014

 SAMPLE



49¶*`JSLZ
 49¶*`JSLZ
9¶*`JSLZ
9¶*`JSLZ
-VYJL7:0






     

SAMPLE

Many thanks as
always to the
TechTeam for all
your help.
Have an alternative sugges-
tion? We want to hear from
you! Email jholliday@iadd.org.
The IADD TechTeam is a dedi-
cated and experienced team of
industry professionals who
quickly research and answer
IADD Members’ technical
diecutting and diemaking ques-
tions in an unbiased, confiden-
tial, current, and direct manner.
Any use of the suggestions pro-
vided by the TechTeam is at the
user’s risk and should always
be implemented with full adher-
ence to all pertinent laws and
proper business practices.
TechTeam does not endorse
any products contained in its
answers. All product, trade-
mark, company or service
names mentioned herein are
the property of their respective
owners.
22 The Cutting Edge
SAMPLE
TECHTEAM
Continued from page 20
bevel, we would recommend just getting
some rule with a 42 degree bevel instead of
the standard 52 degree bevel. The 42 degree
will have more stability and will cost less than
long bevel.
Reply
As it turned out, the excessive dust on the
board was caused by the type of ink used in
the printing process. By using a 42 degree
bevel cutting rule, we found that the dust build
up was reduced greatly. Many thanks as al-
ways to the TechTeam for all your help.
Ticket #1367 was answered by former TechTeam
member Justin Smith of Shreiner Company. You may
reach Justin at 1-330-276-7201 or by email at
justin@shreinerco.com. For more information on
the IADD TechTeam, visit the IADD’s website at
www.iadd.org.
Magnetic Material
IADD TechTeam™ – Ticket 1087
Material: Magnetic Sheet
Process: Diecutting—Flat Steel Rule Die
Question
I have a customer trying to cut magnetic
material against a steel plate on a clamshell
press. The magnet obviously sticks to the plate
and causes problems in cutting. They have
tried to slip something hard enough in be-
tween, but then the surface they are cutting
against becomes too high and too hard and it
damages the rule. Do you have any sugges-
tions? I have been told to have them switch
to an aluminum plate. Is this the best option?
If so, where can they purchase this plate?
Answer
Most companies cutting magnetic sheet
stock in clamshells will cut against stainless
steel which is non-magnetic (magnets don’t
stick to it). A standard grade 316 stainless
steel is readily available in sheet form and
SAMPLE
will be hard enough to cut against (approxi-
mately 25 Rockwell C hardness). It will far
outlast most aluminum plates. If you are
making very long runs you may be able to
find a spring-tempered stainless in some sort
of a 300 series that will do the job (maybe in
the area of 35 Rockwell C hardness). It may
have to be stress relieved to get back to its
non-magnetic characteristics.
A current die/press supply shop should
be able to supply this cut to the right size for
the press. A local sheet metal-type shop will
also be able to supply it.
We would recommend using a stainless
plate instead of aluminum. Aluminum is too
soft. Even using stainless, you are going to
see the cutting plate wear out where the steel
rule dies cut. Magnetic material is very soft
but because of the metal flakes in the mate-
rial, it is very abrasive to the cutting plates
(and steel rule). The plate needs to be at least
0.125" (3.175 mm) thick otherwise the mag-
netic material will magnetically adhere to the
steel under the cutting plate.
You did not say what type of material is
laminated over the magnetic material. If it is
vinyl, we would recommend a long center
bevel that is ground and polished. You will
get between 8,000 and 12,000 die rule life. If
the laminate over the magnetic material is
paper, die life will be much greater. Finally, if
you are using a clamshell and if you increase
the height of the cutting plate, then you must
decrease the height of the steel rule so you
don’t smash the rule. In other words if the
cutting plate in increased by 0.125" (3.175
mm) then the steel rule height must be de-
creased by 0.125" (3.175 mm) to level out the
cutting area.
If your customer has already gone down
the road with aluminum, it will work. There
are quite a few shops using plastic, heavy
paper, etc., but eventually they often find the
stainless steel option the best.
If your customer is going to continually
cut this material, the above suggestion is the
best. However, if they only have a limited use,
then clay-coated Kraft will work in the short
run. You have to play with the thickness of
the stock depending on the strength and thick-
ness of the magnet.
For more information on the IADD TechTeam, visit
the IADD’s website at www.iadd.org.
December 2014
 SAMPLE

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 SAMPLE
Blame Makes You Weak
Denise Ryan, Firestar Speaking, Raleigh, NC, USA
Blame is everywhere these days. I’ve seen articles blam-
ing doctors for people’s addictions to pain medicines; blam-
ing the food industry for the obesity epidemic; and blaming
the US Congress for everything. If that doesn’t cover you,
you can blame genetics, your parents or an ex-lover. We’ve
all done it—I’ve blamed Krispy Kreme’s hot doughnuts light
for my tightening jeans for years.
Blame is a waste of time that does nothing but make you
weak. If you are addicted to pain meds, it is up to you to get
help and stop taking them. Sitting around blaming others
isn’t going to help you. Also, since when are you not a re-
sponsible adult? I make the decision when I see the hot
doughnut light to drive my car into the Krispy Kreme park-
ing lot. If I eat the hot doughnut, it is 100% my fault. Blaming
Krispy Kreme makes me weak; it puts Krispy Kreme in charge
of my life. Who are you putting in charge of your life?
In an effort to help people feel better about themselves,
we have told them that nothing is their fault. They maxed
out their credit cards? It’s the evil businesses who tricked
them into buying things they couldn’t afford. We don’t tell
them they need to learn about budgeting and finances. While
this might make them feel better in the short-term, it doesn’t
help them in the long run. They still have no clue about how
to manage their money. I could give you a thousand examples
in every aspect of our lives where we blame someone or some-
thing else for the results we have gotten.
Sure, maybe sometimes there really is blame on another’s
part. They outright lied to you or attacked you. Go ahead,
blame away. Is it changing anything? Is it making you feel
powerful? Blame is useless. I’m going to help you take your
power back.
Start by honestly asking yourself...
Who or what have you been blaming (the competition,
your lack of time, your ex, the weather, Little Debbie, etc.)
SAMPLE
for not having what you want in your life (health, money,
love, etc.)? If you say you blame no one/nothing for anything,
you’re not thinking hard enough, being honest enough or
you are way too enlightened for the rest of us.
24 The Cutting Edge
Realize you have put whatever you are blaming in
charge of your life.
Are you good with that? Does your ex or boss or the US
Congress control your destiny? They do if you keep blaming
them.
Take responsibility.
So your marriage didn’t work out and your ex is a psy-
chopath. You have two choices—you can keep blaming your
ex and trying to change him/her or you can man (woman) up
and ask yourself, “What can I do to make my situation bet-
ter?” Who cares who is to blame? Apparently you chose to
date and then marry a psychopath, so you played a part as
well. But I don’t even want you to blame yourself—the power
lies in asking what you can do now. You are responsible for
your life.
Focus on you.
When you stop blaming, it puts the focus back where it
needs to be—on you and what you can do. If I don’t drive by
Krispy Kreme, I don’t know the light is on. (I also can take
the hot doughnut app off my phone.) Blaming your boss for
your crappy job? Maybe you need to get better so you can
find another job. Or focus on what you love about your job
and stop thinking your boss is going to change.
Stop taking the easy way out.
Blame is easy. You don’t have to do the hard work; you
can just blame others for your situation. I can blame a lack
of time for not exercising, or I can admit that I chose to do
other things. Every time you find yourself blaming, ask in-
stead “What can I do about this?” Do you want to be power-
ful or do you want things to be easy? Keep blaming and you’ll
get weaker and weaker.
Think!
Use the most powerful weapon in your arsenal. Your
mind should be freed from all that blaming and now you can
put it to productive use. You are in control of your life and
December 2014
 SAMPLE
IADD & INDUSTRY CALENDAR

Dec 11, 2014 IADD CAN-AM CHAPTER MEETING

Location: Ramada Hotel, 2402 North Forest Rd, Getzville, NY14068 USA
Overview: Randy Norman of Preco Inc will present "Cutting Different Substrates." He will dscuss the different
types of steel rule blades, bevels, angles etc, suggesting the type of blade that works best for each material.
Bring your questions and/or samples for on-the-spot answers.
Registration Fee: $55/IADD or FSEA member; $65/non-member. Fee includes dinner.
Contact: Margaret Bussan, IADD Chapter & Meeting Assistant, Tel 1-815-455-7519, Email:
margaret.bussan@iadd.org
Jan 15, 2015 IADD EXECUTIVE COMMITTEE MEETING
Location: Orlando, FL
Feb 10, 2015 -- WESTPAK - Location: Anaheim, CA, USA
Feb 12, 2015 Overview: Returning in 2015, WestPack continues to bring leading packaging industry professionals together
to source a comprehensive array of cutting-edge equipment, products, and services.
Contact: www.westpackshow.com
Feb 10, 2015 -- ICE
Feb 12, 2015 Location: Orlando, FL, USA
Overview: Join several thousand converting professionals from nearly 50 countries who will come together in
Orlando, Florida, February 10-12, 2015, to see all the latest converting machinery and technologies on display
from over 350 leading suppliers.
Contact: www.ice-x-usa.com
May 13, 2015 -- IADD/FSEA ODYSSEY
May 15, 2015 Location: Renaissance Hotel and Convention Center, Schaumburg (Chicago), IL, USA
Overview: The IADD•FSEA Odyssey is the only event in 2015 targeted specifically to diecutting, diemaking, foil
stamping, embossing and bindery. As an attendee of Odyssey, you will experience a unique, world-class
amalgam of education and technology.
Contact: info@OdysseyExpo.org, www.OdysseyExpo.org

you need to think about what you should do to improve it. Do
you need to ask for help? Do you need to take a class? You
need a strategy that focuses solely on what you can do. Ceas-
ing to focus on the blame and instead thinking about what
you can do gives your enthusiasm back. You are moving for-
ward, creating your destiny. You are powerful. Let your ex,
Congress, your boss and Krispy Kreme do whatever they
want. You have a great life to live.
Learn from your mistakes.
So you married a psychopath—we all make mistakes.
Were there a few red flags? Did you commit too quickly?
Take time to learn. Life is a great teacher if you don’t just
blame someone or something else and move on.
encouraging blaming. When I got bad grades, my parents
didn’t blame the teacher, they told me to study harder. What
do you tell your kids? We are all much more powerful than
we give ourselves credit for—but we have to stop blaming to
realize it.
Every time you work this process, you will get
stronger.
I can blame Krispy Kreme all day, but all that will hap-
pen is I’ll get fatter. Even if Katie Couric closes Krispy Kreme
to save me from myself, I still haven’t learned discipline and
proper eating habits. But if I gather knowledge and make
better choices, I get more powerful against Krispy Kreme,
Little Debbie and all their minions.

Act!
Decided you need to learn more about finances? Take a
class. Study hard. You will never make bad financial choices
again! Taking considered action is what will change your
situation, not blaming others.
It’s like that old saying—give a man a fish and he’ll eat
for a day, teach a man to fish and he’ll eat for a lifetime. You
can sit around and blame the fish for your hunger or say you
didn’t have enough time to actually fish or you can say it was
too hot to go fishing. Or you can just get in your car and go to
Krispy Kreme.

Empower others.

SAMPLE
Next time someone is blaming (we call it venting, but it’s
blaming), ask them, “So what can you do about this?” Stop
Denise Ryan, MBA, CSP is a motivational speaker and trainer who
lights the fires of enthusiasm and teaches others to keep them burn-
ing. She has many programs—see www.firestarspeaking.com for
video and more information.

December 2014 The Cutting Edge 25

 SAMPLE
Corrugated vs. Paperboard
Advantages and Limitations of Each Substrate
Kevin Koelsch, Dynamic Dies, Inc., Holland, OH, USA; Ian Young, Radiant Lasercut, Inc., Markham, ON, Canada
Editor’s note: This article was derived from a workshop presented
at the 2014 FSEA•IADD Joint Conference in Milwaukee, WI, USA.
The first portion of this article was published in the September/
October 2014 issue of The Cutting Edge and discussed the basic
differences in substrates—both the physical materials and how they
are currently applied in the packaging market. IADD members and
subscribers may read the first portion online at
www.webcuttingedge.org.
If someone were to ask what the problems are with con-
verting either corrugated or paperboard, they would rank
creasing, stripping and then maybe cutting, in that order. Or
it might be stripping, then creasing and cutting. But most
everyone will agree that stripping and creasing are the big-
gest problems in our industry with both of these materials.
Back to the design point of view, if we can improve the strip-
ping by modifying designs, that’s an important factor in all
cases. Die design or die engineering is probably one of the
most important parts that separate diemakers and their
value. And a lot of this stuff is unseen.
Take, for example, a job with slots that are 0.063" (1.6
mm) wide. In corrugated, it is just about impossible to strip
that. You will also have problems if you have a 0.063" (1.6
mm) slot on inline. In sheet fed, it can be stripped, but it is a
challenge. Whenever we receive a job from our customers,
the first thing we look at is all the pieces that need to be
stripped out. This determines how we’re going to build the
tool. It goes beyond laying out the tool according to specs;
more importantly, we have to take responsibility in terms of
understanding whether or not the tool will actually function
on the press. It’s possible to create a tool that will cut; but
will the pieces then need to be stripped out by hand? And
what kind of press is it going on? Is it old? New? Does it hold
good registration? Does the operator have the skill set to
align something of that nature? Will the tool itself withstand
collisions or smash-ups?
SAMPLE
When we get into the heavier paperboard and the micro
flutes, they become very similar in terms of the way they
behave when you are stripping them. They don’t behave the
same way when you crease. Let’s look at some examples.
26 The Cutting Edge
Diagram 13 shows a 23.5" by 15" (596.9 by 381 mm)
box that is going to be used for a 48-pack of candy pouches.
When you go to Costco, you will see a lot of these boxes; they
are called Kliklok tri-seal boxes. You are probably familiar
with the closure. You can see the male and female aspect of
it, and they are filled automatically and will hold a fair amount
of weight. This style is usually used in the paperboard or
small flute, but you won’t see it in the corrugated B- and C-
flute world. The small darts are 0.125" (3 mm), but we were
able to strip it because of the fact that it was connected to a
big piece of waste. Otherwise, we would never be able to fit
the male stripping counterpart in that tight area.
Diagram 14 is a standard box, one-piece top and bot-
tom; it has four corners and an attached lid. This is used for
frozen food, often using small flute or micro flute. A frozen
food company chain in Canada called M&M predominantly
uses this style, and it’s all E-flute with fairly basic printing.
They decided to go totally micro flute (the thickness is equiva-
lent to the SBS board that they used previously), and every-
thing that goes in there is in a plastic bag. There’s no sizing
done or poly on the inside of the carton.
Interestingly, if they were using a thicker corrugated,
the flap cuts in relationship to the crease line would need to
be offset to make room to bypass the thickness of the mate-
rial when they fold, so this is actually one of those that is a
crossover item, but could not be done out of E-flute without
any offset. As it is, the only offset on this one is the lid that is
maybe a 0.031" (0.79 mm) bigger in one direction and 0.063"
(1.6 mm) in the other, and that’s just because it has to fit
over the base. We don’t have to worry as much about the
caliper thickness with boxboard.
You might wonder why M&M would choose to go to a
micro flute when it seems like they would need to use more
material. In terms of the medium we’re talking about, the
total paper being used is three separate pieces of paper, but
in many cases when you take the compressed value of micro
flute corrugated, it’s smaller than paperboard. So if we are
talking about the amount of material being used as a com-
December 2014
 SAMPLE

Diagram 14
Diagram 13
parison micro flute is less that paperboard (it’s the volume
in comparison). The other factor is that their boxes are done
on a flexo with basic 2-color because their theme is an or-
ange and a blue logo—it’s not upscale printing. They are
taking advantage of the strength of the medium that can
compensate for less material, because everything in paper-
board is about the amount of material that you use. For the
average paperboard carton, 50-60% of the cost is the board
itself. The trend is in downsizing; the less material you can
use, the cheaper in general the carton is going to be. Of
course this needs to be weighed against whether there is
more cost for the process.

We have a number of customers printing in E-flute on a

litho press, and they are printing on a white top liner. In
some cases a folding carton company is driven by their
customer’s desire or need to go towards fluted material.
While they would prefer not to learn another discipline, Diagram 15
many folding carton manufacturers realize they will lose
business if they do not.

Speaking of carton strength, Diagram 15 is a beverage
box on 28 pt board which is 41.75" (1060.4 mm) wide. You
don’t often see a blank this big in folding carton paperboard;
this is very unusual, and much more common in corrugated.
This box is built to hold 40 cans of beer—40 cans in a 20 pt
SUS. In order to strengthen the carton, they will put layers
inside which they glue to the sidewall. There’s also one that
is a bit taller that holds 48 cans, and there is also a 60-pack
in the works. These kinds of things are possible on paper-
board; this is actually done on an inline web on a flat
diecutter. The machine direction is actually up and down,
with the paperboard grain in the running direction.
It’s very unusual to make a folding carton with the grain
going vertically because it wants to curl and turn into a
tube when you erect it. We have to add cuts to the vertical
the gluing process in paperboard (and probably similar in
corrugated), the glue flap has a pre-break, maybe to 130
degrees, and then they are prefolded so that once they are
glued, they will be flat. The other two are folded 180 de-
grees. This is what happens with paperboard when you want
to build strength.
Fluted materials don’t present the same challenge as
much because there are actually three plies, and then when
the flap that gets folded over comes in, by the time it fin-
ishes, there are four plies. The “handle” that is formed is
actually 4 plies for holding strength. This is common on
every beverage box you see on paperboard and SUS board
so you can pick it up without tearing, especially when it is
wet. Interestingly, some breweries will actually use the

SAMPLE
folds because we are folding parallel to the grain. The fold-
ing scores actually have more cuts and creases in them than
in the center score or the glue score. The reason is that in
same carton size and style as their competitor for filling
machine purposes, but they have a different opening fea-
ture because they want to differentiate themselves from
their competitor.

December 2014 The Cutting Edge 27

The manufacturing process SAMPLE
Let’s do a little bit of comparison when diecutting:
Corrugated
• Platen and rotary
• Sheet delivery • Platen and rotary
• Counters (matrix) • Sheet or web
• Strippers (basic) • Counters (steel, com-
• Reverse cut, perf posite)
• Retail ready • Strippers, blankers
• Reverse cut, cut/cut
Folding Carton
• Retail ready
As you can see, both processes have the platen and ro-
tary vehicles, and they are quite different from the carton
side on the rotary. It’s quite a bit different than the corru-
gated on the soft anvil, but as far as the dynamic of the cut-
ting process, they are quite similar.
On the folding carton side, there will be two methods for
cutting—flat (platen) or rotary. Both are a steel knife against
a steel anvil. There are two ways to deliver the stock. It will
either be on a roll (referred to as web fed) or the roll stock
will be parceled into sheets (hence the name sheet fed). On
web inline, when we are looking at paperboard again, a lot
of it has to do with stripping and with the abrasion of the
web running over the plate. When running carton work inline,
all female counterparts are generally made from steel. One
option for the counter is to be made from phenolic. If you
use phenolic, it won’t last very long because of the fact that
the abrasive web runs over it. Also, it can catch, snag, etc.
Generally speaking, if you are running web fed inline, you
are going to see a steel counter. If you run sheet fed, it could
be steel or, most likely, phenolic.
When comparing the micro corrugated to paperboard,
the stripping is not significantly different other than the fact
that in folding carton the preference is to run the stripping
tools without the use of auto pins. Everybody has different
ways of doing it. Another recommended stripping technique
is dynamic stripping. This is where you basically deform the
piece of waste so you build up potential energy. Then once it
fires through, it clears the restrictions of the female, that’s
converted into kinetic energy and it will move out very rap-
idly. It requires a great deal of attention to detail and accu-
racy because you need to make sure all the scrap pieces are
positioned properly on the restrictions so that you can get
an even deflection.
I’m not sure actually on the flute or micro flute if that is
SAMPLE
necessarily being done because it is more rigid, but with
paperboard, you must contend with the flexibility. It’s easier
with the grain instead of against the grain.
28 The Cutting Edge
One of the significant differences between blanking a
paperboard substrate and a micro corrugated substrate—
and we’ve even seen corrugated as thick as B-flute being
blanked at high speed—is the male counterpart. It is built a
little bit differently where the cartons are joined, and if you
have to break it over a bar or when bending, it will make it
crack. One method to avoid this is the outside of the male
blanker, the periphery is a sponge or rubber so it can bend
down about an inch (25.4 mm) as opposed to paperboard,
Or we can leave the harder edge and allow the bend within
reason; you may still get some marking because the mate-
rial takes the fold, you can get it to bend.
Regarding reverse cuts, with folding carton when you
have an opening device where there is a 0.5" (12.7 m) cut,
now I call it a score so I don’t get everybody confused be-
cause I know in corrugated you have half cuts. A score is
what I call a crease and half cut is what I call a score. So it
can get very confusing when somebody is ordering some-
thing. It is most preferable when you have half cuts coming
from opposite directions and when you open it you get the
lamination across the fiber. It’s a great opening because it’s
sealed and you can tell if it’s been tampered with. With Green
Mountain Coffee, you see all the K-cups like this. All those
boxes come with a reverse score opening. It’s also being used
on the corrugated side. Micro flute is going to be a little easier
because you have more density. I’ve seen it done all the way
up to B-flute. In folding carton, when you look at the box, it
is normally retail ready.
The last two points are the reverse cut and the cut/cut.
Rule manufacturers are trying to make multiple heights cut-
ting rule. Very close in the same height or half by half that
is cut and cut. Of course, this poses the need to manipulate
the counters which are quite interesting because there are
a lot of things going on to enhance the folding beyond what
we have already experienced with the retail or shelf ready
packaging market. This was a big topic on the thicker cor-
rugated side, but we see it across the board as ganged,
multiple outs become more and more prevalent. These ad-
dress the movement for the reduction of the total package,
the sustainability part of it. There will be less inner packs,
and designers will use a lot of this corrugated migration
into just finding more of where the protection sweet spot is
and how to open without it looking terrible.
Does the equipment matter?
The basic answer is yes. As the flutes get smaller and
the board gets thinner, you want to make sure that your press
feed and grippers can transport that sheet through the press.
Some presses will come ready-made with the proper equip-
ment on the feed side of it. The other area that is sensitive to
the material is the blanking, so it is most important to check
your machine specifications. The majority of Bobst machines
are capable of delivering an E-flute with no problem. It would
See CORRUGATED page 30
December 2014
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Continued from page 28
SAMPLE
depend on the condition of the feed section and/or if there is
a requirement to do a retrofit on the delivery table.
If you are going to do 0.004" or 0.005" (0.10 or 0.12
mm) paper, there is a specific upgrade to handle that. One
of the biggest challenges with the micro flute on a sheet fed
press is the sheet warp. You don’t have a lot of good control
over how everything is drying, and we see a lot of chal-
lenges with getting it into the gripper because it is warped.
It’s bad enough on a paperboard sheet, let alone micro flute.
Plant environment conditions such as humidity control
are much more important. This winter has been difficult
with lack of moisture control, even in converters with tem-
perature and humidity control. Micro flute presents even
greater challenges. With micro flute, the air is allowed to
pass through the fluting and this makes the combined pa-
per more susceptible to the environment than solid paper-
board would be.
The plant needs some kind of control with vapor mis-
ters, and materials being brought in require acclimation to
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30 The Cutting Edge
the environment before use. We also recommend that once
you have printed it, you get it diecut as soon as possible.
When converting micro flute, we suggest having the printer,
diecutter and gluer all on one line. Then you can control the
process and not get moisture loss, and you can also go back
and make changes on the fly. Of course, that is not always
doable, but that’s where you sometimes have an advantage
with web fed printing and diecutting which are done one
after the other.
Creasing micro flutes
There is a good amount of study currently underway
regarding creasing micro flutes. One study on the creasing
of paperboard versus micro flute actually revealed much
tighter creases on micro flute. Numerous IADD programs
emphasize the drive towards very, very tight reduced bead
creasing. Although reduced bead creasing initially gained
visibility in the 90s, success in this area is key to being able
to have micro flute cartons perform at the same level as
paperboard in regards to filling and gluing.
Challenges
As the process becomes more automated and the
timeline gets compressed, there is no time to make second
guesses. A major struggle diemakers have with being able
to influence the carton design is that often by the time the
die is ordered, the diecutter has already put a sample in
front of their customer and has been given a delivery date
when they have to make these boxes. The diecutter feels it
makes them look bad to go back to their customer and say
they want to make a change in their box, and so the chal-
lenge is trying to get it right to start with. This means
diemakers need to work with their customers’ designers to
educate them in advance.
A related problem may lie in the CAD system because
most of the designers are bringing up a standard design that
may have little offsets in there that we cannot do and they
don’t change them. It’s too much work for them to go in and
make these small changes. It might be helpful for diemakers
to work with the CAD companies to help them understand
this concept, so they can write programs that take these prob-
lems into consideration and automatically change them.
Conclusion
The most important lesson in packaging is to keep your
eye on packaging trends, embrace change and use all avail-
able resources to move forward.
Kevin Koelsch is the Vice President - Operations at Dynamic Dies, Inc.
and a former member of IADD’s Board of Directors. You may reach
him at 1-419-865-0249 or by email at kevin_k@ dynamicdies.com.
Ian Young is the President of Radiant Lasercut, Inc. and the VP of
Media and Content for IADD. He may be reached at 1-905-415-5930
or by email at iyoung@radiantlasercut.com.
December 2014
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Is Employee Cynicism Killing
Your Culture?
Ten Strategic Ways to Reconfigure It Around Trust
Rich Karlgaard, Forbes, San Francisco, CA, USA
In an age of cynicism and irony, Northwestern Mutual
is a throwback to a more innocent time. The company is the
antithesis of “cool.” It has the kind of culture in which people
embrace plain suits and sincere handshakes, take pride in
wearing achievement ribbons, kick off conferences with pa-
triotic music. It’s the very portrait of wholesomeness and
earnestness—the Boy Scout of the insurance and financial
services industry. There’s no place for hipster lingo, inside
jokes about customers and snarky tweets.
Oh, and Northwestern Mutual has been in business for
over 157 years and is worth $25 billion US in sales. It might
not be hip to be square, but it’s very good for business.
Mocking irony, snark and cynicism are very much in
vogue, but they are also toxic to your company’s culture.
Once cynicism gets a foothold in your culture, it spreads—
just like an ill-advised tweet or blog post. You need to
proactively fight it.
Most of us can agree that cynicism is ugly. It trivializes
the gravity of bad behavior and normalizes superior atti-
tudes toward customers and, often, coworkers. But wide-
SAMPLE
32 The Cutting Edge
spread cynicism is also a red flag that something is seri-
ously awry in your company. And that “something” centers
on trust.
Cynicism is the defense mechanism of people who feel
unsafe and powerless. It’s an expression of the uncertainty
that comes from working in an environment where ethics
are lax, employees don’t feel valued and information is with-
held. When it thrives in an organization, it signals a lack of
employee trust—a problem that’s gotten significantly worse
over the last generation.
The example of Northwestern Mutual makes it clear:
Building trust is not just a nice thing to do. It’s a strategic
thing to do.
Trust underlies effective working relationships. It im-
proves group effectiveness and performance. It underpins
organizational credibility and resilience. All of these fac-
tors contribute to creating a sustainable competitive ad-
vantage, because trust attracts talent, strengthens
partnerships and retains customers.
The good news is you can tap into the strategic power
of trust by consciously shifting your company’s culture.
Here’s how:
Know that trust has two
dimensions: external and internal.
First, there’s the external trust between an organiza-
tion and its customers: Will a company stand behind its
products? If something goes wrong, will they do the right
December 2014
 SAMPLE
thing? The second dimension is the internal trust between
employees, managers and top-level management. Do lead-
ers keep their promises? Can employees speak up without
censure? Do people have each other’s back (or stab them in
it)? Generally, what’s true externally is also true internally.
When employees can trust leaders and each other, cus-
tomers can trust employees. And vice versa, of course. Cyni-
cism cannot be eradicated if trust doesn’t extend in all
directions. But know that you need to start internally, with
the employees on whose commitment and engagement your
success depends. If they don’t feel that they can trust your
company with their careers, you’re in trouble.
Get clear on what a culture of
trust and earnestness looks like.
No doubt your employees have (probably very strong)
opinions on trust within your company and where they’d
like to see improvements. Hold a company-wide summit
where everyone can share those opinions and include an
anonymous component like a suggestion box or survey. Get
everyone’s input, from the C-suite to the custodian. Your goal
should be to pin down exactly how a culture of trust trans-
lates to leader and employee behaviors.
Ask, “Who do we want to be?” Identify the ways cyni-
cism manifests—for instance, through snarky comments,
manipulating customers, talking behind coworkers’ backs
and so forth. Then, together, establish some ground rules
aimed at dissolving cynicism and promoting old-fashioned
values.
Then, get the “rules” in writing.
Put the results of your trust summit in writing and ask
all employees to sign this document. It should spell out ac-
tions like, “I will not badmouth customers,” or, “If I have
something to say to an employee, I’ll say it to their face.”
Some companies have even gone so far as to prohibit blind
cc’ing in order to promote a culture of trust.
Of course you can’t simply outlaw cynicism and snark or
talking behind someone’s back. Trust can thrive only when
employees are treated like the self-respecting adults that they
are. However, you can “formalize” values and ask people to
abide by them. That’s the need these contracts serve.
Creating an official “standards of behavior” document
helps crystallize the attitude you’re hoping to cultivate. Just
saying “let’s all be trustworthy now” means nothing. Creat-
ing the document shows that your organization is willing to
go beyond mere lip service. Plus, people are just more likely
to abide by an agreement if they’ve signed their name to it.
SAMPLE
December 2014
Let only “Boy Scouts” lead. (And
Girl Scouts too, of course!)
People will emulate leader behavior, whether it’s good
or bad. It’s just human nature. Leaders who roll their eyes
when a certain customer calls are giving permission for
employees to be similarly disrespectful. Complain about your
boss in the break room and you can expect to overhear your
own team making fun of you as you approach the water
cooler. The key is to hire and promote leaders who truly do
live the values your company espouses.
It doesn’t matter how intelligent, charming or techni-
cally capable leaders are if they don’t uphold the agreed-
upon values. The negative impact they have on your culture
will more than offset any talents and skills they bring to the
table.
Never lie or hide the truth.
There are many things you’re thrilled to share with your
employees. “Our customer satisfaction scores are 15 per-
cent higher this year!” Or, “Our first quarter profits exceeded
our goal!” Yet there are other things you might not be so
eager to share, like, “We’re going to have to downsize,” or,
“There aren’t going to be any raises this year…and by the
way, we may have to reduce your benefits.” Tell them any-
way.
Even when the news is bad, people should never feel
they’re being kept in the dark. Transparency and trust must
coexist.
Show employees that you care.
When people don’t believe their leaders care about them,
not just as workers but also as human beings, of course trust
can’t thrive. And while it’s true that fake or contrived caring
only increases cynicism, genuine caring dissolves it. This
means leaders must be “people persons” who stand up for
their employees’ best interests and don’t mind showing (ap-
propriate) affection.
NetApp is a company that truly gets this. Consider the
following quote from its vice chairman, excerpted from my
book, The Soft Edge:
“I believe in leadership rather than management,” Tom
Mendoza of NetApp explained. “You can be loud, you
can be quiet, but leadership is what you are, not what
you say. So my overriding principle of leadership is people
don’t care what you know unless they know that you
care. All industries have one thing in common, which is
people come through for their leaders not because they’re
afraid, not because they’re intimidated, but because they
just don’t want to let them down.”
The Cutting Edge 33
Aspire to predictability. SAMPLE
It sounds a little dull, doesn’t it? Most of us want to be
known as creative, outside-the-box thinkers. We don’t want
to be bound by routine or limited by “the way everyone else
does it.” And that’s fine—embrace innovation to your heart’s
content in areas like product development and marketing
campaigns. Just don’t be unpredictable in your behavior,
priorities and values.
Unpredictability destroys trust. The couches of psycho-
therapists are filled with people whose parents were unpre-
dictable. As a leader, your team should have total confidence
that you’ll do what you say you will. They should have no
doubt that you’ll keep your promises, act with integrity and
look out for their best interests.
By the way, predictability in the matter of trust is differ-
ent from predictability in tactics. Good leaders and coaches
will shake things up. Legendary basketball coach Phil Jack-
son once held a Chicago Bulls practice in the dark. He wanted
to see how well his players really knew the plays he was
teaching!
Make it safe to speak up.
When your employees make an honest mistake, can they
admit it without being scolded and belittled? What about
input and ideas? Can they share those things and expect to
be taken seriously? Hopefully, the answer to both questions
is “yes.” Everyone should feel confident that they can par-
ticipate in meetings and projects, say what’s on their mind,
be respected for their opinions and ideas and admit mis-
takes.
Either trust rules your organization, or fear rules it—
you have to choose. A fear-based culture kills employee cu-
riosity. It quells exploration, dulls creativity and stunts
growth. In a climate of fear, people are afraid to make mis-
takes. Fear saps performance, synergy, teamwork and mo-
rale. It makes people feel powerless—and if you have no
power over your own work life, of course you’ll be cynical.
Celebrate grit and gumption.
If you want employees to be worker bees—performing
the tasks you designate, on a timeline you set—compensate
them with paychecks only. But if you want your employees
to be partners, you’ve got to reinforce them when they act
like partners. In other words, take notice when they display
passion and motivation (grit) and initiative and guts (gump-
tion).
When employees do the things you want them to do—
SAMPLE
persevering through tough tasks, innovating, taking calcu-
lated risks—reward them. A simple thank-you can go a long
way. So can public recognition at a meeting or through a
34 The Cutting Edge
company-wide email. And of course perks like “free” vaca-
tion time or bonuses are always welcome. The point is, no-
tice and celebrate the behaviors you want more of.
When people are truly engaged, they can’t be cynical.
Engagement and cynicism can’t coexist in the same moment.
Constantly drive home the meaning
of the work people do.
One of the best methods to increase trust is to identify
your greater purpose, your “true north,” as I call it. Why do
you exist? What meaningful value do you offer to employ-
ees, customers or society? A great purpose should be
aspirational, not merely financial. It should create a com-
mon cause and promote a collective effort. It should answer
all the tough questions of why: Why commit? Why persist?
And, most important, why trust?
At Northwestern Mutual, employees with whom I’ve spo-
ken say they aren’t driven by dollar signs. They truly feel
that their life’s work is helping people. When clients call and
ask, “Am I going to be okay?” they take pride in being able
to say “yes.” They’ve found a meaning in selling insurance
that goes much, much deeper than balance sheets and prof-
its. And, ironically, that’s why so many Northwestern field
reps are the millionaires next door.
My point? Figure out what meaningful things your com-
pany provides customers, whether that’s peace of mind,
easier lives, reliable support or something else, and look for
ways to convey that purpose at your company. It’s hard to be
cynical about your work and your customers when you ac-
tually do believe in what you’re doing.
The next time you’re considering how to make your or-
ganization a better place to work, think beyond an in-house
masseuse, climbing walls and free, fresh-baked cookies.
While employees will certainly appreciate fun perks like
these, they don’t mean anything if your culture isn’t grounded
in trust. Trust is, and always will be, the foundation of creat-
ing an award-winning environment and culture that leads
to high performance and success.
Rich Karlgaard is author of The Soft Edge: Where Great Compa-
nies Find Lasting Success. He is also the publisher of Forbes maga-
zine, where he writes a column, Innovation Rules, known for its
witty assessment of business and leadership issues. He has been a
regular panelist on television’s Forbes on FOX since the show’s in-
ception in 2001. Karlgaard is also a serial entrepreneur, having co-
founded Upside magazine, Garage Technology Partners and Silicon
Valley’s premier public business forum, the 7,500-member Churchill
Club. He is a past winner of Ernst’s “Entrepreneur of the Year”
award. Karlgaard’s 2004 book, Life 2.0, was a Wall Street Journal
business bestseller. A graduate of Stanford University, Karlgaard
and his family live in Silicon Valley. For more information, visit
www.richkarlgaard.com.
December 2014
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 SAMPLE
Rethink Employee
Retention
7 Guidelines for Engaging and Accommodating Your
Older Staff
Ruth Crocker, Riverlight Wellness Center, Stonington, CT, USA
Mary loved her job as a recreational therapist in a skilled
nursing facility. Her co-workers marveled at her ability to
assess the needs of residents and propose exactly the right
activity for a patient recovering from a brain injury, stroke
or other trauma. Her thirty plus years of experience in all
manner of expressive arts therapies helped her serve her
patients well. She worked efficiently and effectively with
quiet compassion.
And then came the inevitable hours of paperwork. For
Mary, writing long detailed notes in medical charts was a
normal part of her day. But, she wasn’t as speedy as she
had been in the past and documentation requirements were
increasing. While a physicians’ notes are usually transcribed
from a dictated recording, medical support staff still struggle
through pages of writing by hand in many facilities. Her
immediate supervisor, fifteen years her junior, pushed her
to speed up. Mary felt stressed and unable to cope with the
continuing pressure. After starting to dread her job and
feeling like she was getting worse instead of better, she ap-
plied for and received a medical leave of absence. Was this
the best solution for Mary and her employer? Probably not.
Mary is one of many valuable older workers who could
have stayed productive on the job with some modifications
in her work environment. Employers today are facing the
fact that we need to keep our older workforce in place longer
and we need to help them stay healthy. Baby boomers make
up about one-third of the U.S. workforce and for the first
time in several generations, there are not enough younger
workers to replace them. Key industries, especially those
that rely on workers with proven performance, knowledge,
skills and self-confidence, will be forced by labor shortages
to rethink employee retention and how best to ensure health
and safety by adjusting equipment and the work environ-
ment.
SAMPLE
There are many fears and myths about “getting old” in
our culture, but the reality is that people are living longer
36 The Cutting Edge
and healthier and can remain robust contributors to the
workforce much longer than any previous generation. While
age does not determine fitness, there are predictable
changes that occur with age and can be accommodated.
The following are guidelines for employers who want to
maximize the working environment for their most valuable
asset: the reliable, responsible, loyal, conscientious, co-op-
erative, collaborative, wise older worker.
• Maintaining an unmoving position for a long time is
very tiring, especially standing, which puts pressure on blood
vessels. Repeated and prolonged static work can be harder
on the body than dynamic work. Provide opportunities to
change posture or position during the workday. Adjust
work surfaces to encourage position changes.
• Sitting is generally good if chairs are well designed
and adjustable. To avoid the dangers of prolonged sitting
(weakened abdominal muscles, digestion and breathing
problems and damage to spinal discs), provide training
and information on sitting properly and permit oppor-
tunities to walk about and stretch.
• Provide appropriate equipment for assisting in
any type of lifting. Workers of all ages are vulnerable to
injury by improper lifting technique and lifting objects that
are too heavy. Teach them to decrease the need to twist the
trunk of the body during lifting, using leg strength rather
than leaning over, and placing the load as close to the body
as possible.
• Because hand grip strength gradually decreases as
we get older, the right grip or handle becomes important.
Smaller handles become more difficult to use. Provide tools
and controls with user friendly handles.
• Light reaching the retina of the eye declines by as
much as 75 percent from age 20 to 50. Improved lighting
helps all workers. Problems with adjusting to lighting con-
December 2014
 SAMPLE
trasts can be improved by ensuring that the level of lighting
in the room is similar to the light level on computer screens
in the environment. Reduce glare by using low or non-
glare computer screens.
• Gradual, age-related hearing loss and decreased
ability to hear high-pitched sounds can be addressed. In-
stall sound-absorbing material to neutralize sound and
minimize air-conditioning noise.
• Offer incentives to encourage people to take part
in fitness classes and quit-smoking campaigns. Older
workers are more vulnerable to the possibility of sudden-
onset and lasting health problems especially if they are unfit
and overweight.
The previous tradition of older supervisors and younger
workers has changed especially where workers are opting
to stay on the job longer. It is important that younger super-
visors be aware of different generational values and atti-
tudes and avoid adopting a “child to parent” attitude towards
an older worker. At the same time, treat older workers with
December 2014 SAMPLE
the same requirements for performance and safety issues.
Whether older or younger, each individual is different. In
Mary’s case, her facility eventually adopted a voice-activated
recording system which helped staff at all levels of the or-
ganization to get their notes written in a timely manner.
Businesses can improve their employee practices by
having supervisors attend workshops on aging and the
workforce. Talk to other employers who have successful
experiences with hiring older employees and encourage
employee feedback on aging issues by surveying your em-
ployees and listening to their concerns and suggestions. Hir-
ing and retaining older workers can help your business grow.
Ruth W. Crocker, Ph.D is an author, writing consultant and expert on
recovery from trauma and personal tragedy. Her book, Those Who
Remain: Remembrance and Reunion After War describes her expe-
rience following her husband’s death in Vietnam and how she found
resources for healing. An excerpt has been nominated for a Push-
cart Prize in 2014. She is Writer-In-Residence at Riverlight Wellness
Center in Stonington, CT, USA where she teaches the art of writing
memoir and personal stories. She is available for workshops, read-
ings and public speaking. Contact her at www.ruthwcrocker.com.
M ODULAR T OOLING
M ULTIPLE B ENDS
The Cutting Edge 37
 SAMPLE
SAFETY CORNER

Compressed Air
Source: Integrated Loss Control, Inc.

Through horseplay, numerous accidents are caused each Here is an example of what can happen through the
year in the use of compressed air. misuse of compressed air, according to the Royal Society
for the Prevention of Accidents:
Many of these accidents can be prevented if you:
Employees in a British woodworking shop were using
1. Use only sound, strong hose with secure couplings compressed air to clean sawdust off their clothes. One man
and connections. pushed the hose between the legs of another worker and the
results were:
2. Be sure there • bruises and
are no sharp bleeding
points on
metal hose • shock
parts.
• abdomen and
3. Close control hernia canals
valves in por- ballooned
table pneu-
matic tools • bowel torn open
before turning in three places
on the air.
• abdominal cavity
4. Turn off the filled with fluid,
air at the con- blood and other
trol valve be- matter
fore changing
one pneumatic • abdominal cavity
tool for an- membranes torn
other. Never in several places
kink hose to
stop air flow.
Operations failed
to save the man’s life.
5. Wear proper He died within three
goggles, mask days. Investigation
and protective showed that air pres-
clothing or sure at the time was
safety devices. about 12 lbs (5.44 kg).

6. Never use air to blow dust or chips from the hair, Remember to use air with care. Horseplay can begin in
clothing or work bench. fun and end in tragedy.

7. When using compressed air, see that no nearby work- Integrated Loss Control, Inc. (ILC) is a progressive consulting firm

SAMPLE
ers are in line of air flow.
8. Never point the hose at anyone. Practical jokes with
compressed air have caused many painful deaths.
specializing in a range of loss control services. ILC has been pro-
viding quality, hands-on consultation services for more than 20
years to a wide range of private, commercial and public sector cli-
ents. For more information, visit www.ilci.com.

38 The Cutting Edge December 2014

Lockout Standard
SAMPLE
Ensure Compliance with OSHA’s
Source: www.blr.com
The US Occupational Safety and Health Administration’s
(OSHA) lockout/tagout standard (29 CFR 1910.147) requires
employers and employees to take proper steps to prevent
unexpected machine startup accidents.
Here’s what you can do to prevent unexpected startup
incidents and ensure compliance with OSHA’s lockout stan-
dard:
• Develop and implement a written hazardous energy
control program, including lockout/tagout proce-
dures, employee training and inspections before any
maintenance or service work is done.
• Be sure that workers have a clear understanding of
when hazardous energy control procedures apply
and training on how to properly apply the proce-
dures.
• Ensure that procedures on lockout/tagout are de-
veloped that are specific to each machine.
• Provide training to production workers in addition
to maintenance workers in methods of energy isola-
tion and control (see 29 CFR 1910.147[b]).
• Ensure that workers are provided with a sufficient
number of lockouts and tagouts and other hardware
that may be needed to effectively isolate each en-
ergy source (see 29 CFR 1910.147[c][5][i]).
• Clearly label isolation devices, such as breaker pan-
els and control valves.
• Be sure that all employees who operate or work with
the machine, as well as those in the area where ser-
vice or maintenance is performed, know that the
lockout devices have been removed after servicing
and that the machine is capable of being re-ener-
gized (see 29 CFR Part 1910.147 [e][3]).
• Ensure that no one under the age of 18 works on
machinery declared hazardous by child labor laws
(see Fair Labor Standards Act).
• Ensure that workers receive training in their pri-
mary language.
SAMPLE
Here’s what your employees can do:
December 2014
•
•
Follow the regulations contained in your hazard-
ous energy control program.
Complete all training on hazardous energy control
procedures.
• Before beginning machine adjustment, maintenance
or servicing work, do the following:
1. De-energize all sources of hazardous energy by
disconnecting or shutting down engines or mo-
tors, de-energizing electrical circuits, blocking
fluid (gas or liquid) flow in hydraulic or pneu-
matic systems and/or blocking machine parts
against motion.
2. Lockout and tagout all forms of hazardous en-
ergy, including electrical breaker panels and con-
trol valves.
3. Block or dissipate stored energy by discharging
capacitors; releasing or blocking springs that are
under compression or tension; and venting flu-
ids from pressure vessels, tanks or accumula-
tors (but never vent toxic, flammable or
explosive substances directly into the atmo-
sphere).
• Make sure that only one key exists for each of their
assigned locks and that only they hold that key.
• Verify by test and/or observation that all energy
sources are de-energized.
• Inspect repair work before removing their lock and
activating the equipment.
• Make sure that only they remove their assigned lock.
Keys to Forklift Maintenance
Source: www.blr.com
When it comes to forklift safety, a lot of emphasis is placed
on operators and their training. But maintenance is also criti-
cal to forklift safety—and workers who perform forklift re-
pairs and maintenance face hazards that must be addressed
with worker training and attention to the work environment.
Identifying Maintenance Issues
There are two ways to identify a forklift that is in need of
maintenance.
1. Daily inspections. Forklift operators are required to
inspect forklifts before each shift, for forklifts that
are in continuous use. These daily inspections are
supposed to identify issues that require attention.
The Cutting Edge 39
 SAMPLE
2. Malfunctions during use. Sometimes an issue arises
while the forklift is in use—the forklift may over-
heat or dramatically malfunction (sparks or flames
coming from the exhaust are one possible example).
Make sure that operators who have identified a poten-
tial safety issue with a forklift know to take it out of service
immediately until it is repaired.
Training for Forklift Maintenance Workers
Only “authorized” persons may make repairs to and
perform maintenance on forklifts. A worker’s authorization
may be only for a specific task, such as refueling or battery
replacement. OSHA’s training requirements for workers who
perform forklift maintenance are found in the Powered In-
dustrial Trucks Standard, 29 CFR 1910.178, in paragraphs
(f), (g) and (q).
Fuel handling and storage (1910.178[f])
Workers must know how to properly handle and store
fuels. Specifically:
• Liquid fuels (gasoline and diesel fuel) must be stored
and handled in accordance with the National Fluid
Power Association (NFPA) Flammable and Combus-
tible Liquids Code (NFPA No. 30-1969).
• Liquefied petroleum gas (LPG) fuel must be stored
and handled in accordance with NFPA Storage and
Handling of Liquefied Petroleum Gases (NFPA No.
58-1969).
Changing and charging storage batteries (1910.178[g])
Workers who change and charge storage batteries must
know:
• To properly position trucks and apply brakes be-
fore attempting to change or charge batteries;
• Not to pour water into acid;
• To assure that vent caps are functioning and that
battery (or compartment) cover(s) are open to dis-
SAMPLE
sipate heat
40 The Cutting Edge
• Not to smoke in the charging area;
• To take precautions against open flames, sparks or
electric arcs in battery charging areas; and
• To keep tools and other metallic objects away from
the top of uncovered batteries.
Maintenance of Industrial Trucks (1910.178[q])
Forklift maintenance workers should know, at a mini-
mum:
• To repair the fuel and ignition systems of industrial
trucks only in locations designated for such repairs;
• To disconnect the batteries of trucks before repair-
ing electrical systems;
• To only use replacement parts that are equivalent
with respect to safety to the truck’s original parts;
• Not to alter industrial trucks so that the relative
positions of the various parts are different from what
they were originally;
• Not to add extra parts not provided by the manu-
facturer without the manufacturer’s approval; and
• Not to eliminate parts without manufacturer’s ap-
proval.
Jim Lehrke is President of Safety Connections, Inc., a safety advi-
sor company capable of working with businesses of all sizes and
types. Their focus is about changing the work culture and focusing
on safety first. The result is dramatic reduction of injuries and
worker’s compensation costs. The bonus is increased productivity
and quality. Safety Connections provides a weekly safety tip at no
cost. Workplace safety is a vast area and Safety Connections offers
products and services that address all safety aspects. Further, Jim
speaks at seminars, does team building training and motivational
speaking. Safety Connections, Inc. is committed to RESULTS. If
you’re interested in talking with someone from Safety Connections,
Inc. please don’t hesitate to call 1-920-457-4866.
December 2014
SAMPLE

SAMPLE
 SAMPLE
MEMBER NEWS

IADD Welcomes New Members Pontus Nilsson has taken on the role of Vice President
in charge of companywide operations. Before joining Wagner
Patron Members Die Supply, Pontus was with Sandvik for 28 years where he
held various positions in several divisions, both in Sweden
CHANNEL CREASING MATRIX, INC./CCM DIE SUPPLY
and the US. For the past 12 years he was President for
Patrick Quinlan (AssociateMember)
Martinsburg, WV, USA Sandvik Thermal Process located in California, USA for
1-304-616-1288 Fax: 1-866-708-4686 manufacturing and sales of electrical resistance heating el-
ement and furnaces. For three years in the mid-90s Pontus
Company Members was the General Manager for Sandvik’s global diecutting
ARTISTIC DIE CO. operation and steel rule unit.
Michael C. O’Keefe (Voting Member)
Cincinnati, OH, USA
1-513-751-3755 Fax: 1-513-751-0329 Pontus earned a Master of Science degree in metallurgy
CLEARCUT NEW JERSEY
and material science from Royal Institute of Technology in
Joseph Zingaro (Voting Member) Stockholm, Sweden. In his new role with Wagner Die Supply,
CAROLINAS: Mike Kush (Affiliate Member) he is based in Ontario, CA, USA.
GEORGIA: Mike Kush (Affiliate Member)
VIRGINIA: Mike Kush (Affiliate Member)
Rick Ruckh is now the Wagner Midwest Regional Sales
Pennsauken, NJ, USA
1-856-661-0900 Fax: 1-856-661-0919 Manager. Based in the Chicago, IL, USA area, Rick has been
in the converting industry for over 25 years. He has first-
DURABLE DIES INC.
Cesar Vasquez (Voting Member) hand knowledge and experience in the operation of a mul-
Ontario, CA, USA titude of different printing and diecutting machines. Before
1-909-390-5700 Fax: 1-909-390-5701 joining Wagner, Rick was a Sales Engineer with the Atlas
HIP LIK PACKAGING PRODUCTS FTY. LTD. Die sales team from 2003 to 2014. One of his favorite projects
Lee Ming Tat (Voting Member) involved introducing Braille into a steel rule die for a Euro-
Hong Kong, China pean pharmaceutical project. Rick was able to find a solu-
852-2363 3383 Fax: 852-2330 6128 tion that met the European standard while acting as an
Individual Members educational resource for the customer.
INDUSTRIAL RUBBER AND GASKET
Luis Arturo Juarez Before joining Atlas, Rick worked in the label printing
Monterrey, Nuevo Leon, Mexico industry for 14 years and was involved in all areas of pro-
52-81-81442500 duction as well as applications and planning.
SANTA ANA PACKAGING INC.
Peter Yen Contact: Tom Knutson, President, Wagner Die Supply.
La Mirada, CA, USA
1-714-670-6397 Fax: 1-866-752-7270
Phone 1-800-423-4478; Email tknutson@wagnerdiesupply.com.
UFP TECHNOLOGIES
David Baum Heidelberg Celebrates 100th VLF Press; Speedmaster
Costa Mesa, CA, USA CD 102 with X-Package; Prinect Packaging Workflow
1-714-922-9416 Fax: 1-714-622-2718
RockTenn, a major industry producer in the folding car-
ton, corrugated box and merchandising display global mar-
Wagner Announces Hiring of Nilsson and Ruckh kets, has purchased the 100th Heidelberg Very Large Format
(VLF) Press, which will be installed at RockTenn’s Clinton,
Wagner Die Supply, the leader in punch manufacturing
IA, USA location. In recent years, RockTenn has invested in
and one of the largest steel rule die suppliers in the US, is
numerous installations of the Heidelberg VLF format in both
very proud to announce the hiring of two experienced in-
their folding carton and merchandising displays facilities.
dustry leaders.

SAMPLE
Steve Voorhees, RockTenn CEO, and Craig Gunckel, ex-
ecutive vice president of merchandising display and folding

42 The Cutting Edge December 2014

 SAMPLE
carton, were on hand at Heidelberg’s Hall 11 assembly cen- partner like RockTenn, representing world-class manufac-
ter, part of the Heidelberg Wiesloch-Walldorf Factory com- turing practices at the highest level, help Heidelberg per-
plex, to inspect the press and participate in a special event form at its best. Getting to know the RockTenn team and
with Heidelberg executives and employees to salute the working closely with their plants has definitely moved our
100th press accomplishment. Mr. Voorhees stated, “Our in- VLF product line to peak performance status.”
vestment in VLF presses is consistent with RockTenn’s strat-
egy to deploy high quality assets that allow us to lower our “Our strategic partnership with Heidelberg has gener-
cost, improve our quality and ultimately, to service our cli- ated great results for RockTenn and our clients,” Gunckel
ents more efficiently. We are honored to be part of the cel- commented. “We look forward to working with Heidelberg
ebration.” to find new solutions that will help our customers continue
to win in their respective markets.”
Launched in 2008, the XL VLF platform is the newest
press platform in the industry. Heidelberg’s investments in Speedmaster CD 102 with X-Package
research and product development resulted in this large
How do you make a great press even better? Just ask
format press, which received numerous industry awards
the growing number of commercial and packaging printers
for innovation and design
across the US who have placed orders for the new and im-
excellence, including the
proved Speedmaster CD 102 with X-Package, Heidelberg’s
prestigious InterTech™
most recent offering in the 40" (1016 mm) sheetfed press
Technology Awards for in-
category.
novative technology. With
systematic advantages in
the makeready process Already the most popular 40" (1016 mm) press in the
and industry-leading world, Heidelberg’s Speedmaster CD 102 boasts more than
speeds of up to 18,000 9,000 installations worldwide. Each year, more CD 102 units
sheets per hour, the press are built than all other competitive 40" (1016 mm) models
is an excellent choice to combined. Newly enhanced with more than 12,500 new
serve both the short-run components, many incorporated from Heidelberg’s proven
display markets as well as XL format, the Speedmaster CD 102 with X-Package in-
the high-volume leaders in creases productivity up to 50 percent over older-genera-
the packaging industry. tion CD 102s and new competitive press models. It also
offers the best price-to-performance ratio in its class.
Heidelberg customers Craig Gunckel of Heidelberg and
around the world have in- Steve Voorhees of RockTenn show the Mid-York Press of Sherburne, NY, USA, a $12–15 mil-
stalled the most modern, certificate for the 100th VLF press. lion USD pharmaceutical packaging specialist, views the
technically advanced and six-color Speedmaster CD 102 with X-Package they installed
fully automated large format presses available in the in- this November as a perfect companion to the UV-capable
dustry today. Heidelberg’s investments in customer support Speedmaster CX 102 the company purchased in 2011—the
services and global parts supply logistics provide custom- first US customer to do so.
ers with the most efficient process for maximizing machine
performance and uptime. Highly integrated software sys- According to President and CEO Bob Tenney, “When we
tems provide remote diagnostics capability for analysis of first looked at the CX 102, we were intrigued by the Preset
machine performance on a 24/7 basis, clearly meeting the Plus Delivery and fast set-up times. It was an equally im-
rugged manufacturing demands that the industry leading portant consideration in our decision to purchase the CD
customers require. 102 with X-Package. Makeready reductions are more im-
portant to us than machine speed, since we typically handle

SAMPLE
Heidelberg Management Board Member Harald Weimer up to 15 short runs averaging 4,100 sheets during an 18-
stated, “Relationships with a strategic industry leader and hour shift.” In addition, “We already have hundreds of thou-

December 2014 The Cutting Edge 43

 SAMPLE
sands of dollars in repeat plates we’ll be able to run inter-
changeably on both the CX and the new CD 102,” Tenney
said. “We also placed a great deal of emphasis on substrate
flexibility, since we run everything from flimsy 33 lb (14.97
kg) paper to 24 pt board on a regular basis.”
The new press—Mid-York’s sixth six-color Heidelberg—
will replace the company’s existing 2008 Speedmaster CD
102.
A commercial print and marketing services provider and
fine art publisher of high-quality art prints and companion
pieces, Orlando, FL, USA-based SunDance Marketing Solu-
tions also upgraded from its existing 40" (1016 mm) press to
a Speedmaster CD 102 with X-Package this year. Director of
Operations JohnHenry Ruggieri said he welcomes the new
CD 102’s ability to handle a range of substrates from 50 lb
(22.68 kg) stock to 24 pt board and higher, and expects that
color management via Prinect Image Control will minimize
color fluctuations and enable the company to work with stan-
dardized, reproducible color values at all times. Thanks to
the Preset Plus Delivery and highly automated components
of the new press, he said,“We’ll be able to do what we do
now—and more—in less time.” To lock in these and other
advantages, the company also will install a thermal
Suprasetter A106 CtP system with automatic cassette loader
to image Heidelberg Saphira plates both for the new CD 102,
as well as for a pair of Printmaster QM 46 machines installed
to help the company meet the growing demand for small-
format offset work.
“Heidelberg’s reputation for quality and customer ser-
vice and support were also extremely important to the pur-
chase decision,” Ruggieri said. “We expect to achieve an
extremely favorable price-to-performance ratio.”
Jack Stoughton, president of Stoughton Printing Co. of
City of Industry, CA, USA, explained his company’s critical
need for a press that would enable the company to meet the
“exploding” demand for vinyl record packaging. The niche
market has been a company specialty for 50 years, together
with CD and DVD boxes, litho labels, folding cartons, POP
displays and a wide range of commercially-printed items from
blister cards and catalogs to game boards, sports and trad-
ing cards and posters.
With its new-generation Speedmaster CD 102-6+L 2X
with X Package (the first of its kind in the North, Central or
South American markets) Stoughton said, “Our mission will
be to offer our customers faster turn times,”—a key require-
ment for Stoughton’s hit-conscious customers—“and be able
to produce materials that are simultaneously as good as,
but also more durable than, the originals.” To accomplish
this, he said, “We’ll use a battery of new technologies—pre-
press, inks, coatings, paper—that didn’t exist in the mid-
SAMPLE
44 The Cutting Edge
1960s, all while keeping the colors vivid and true to the
originals.”
The company is confident that the new CD 102’s shorter
makeready, higher running speeds and excellent color con-
trol will enable it to satisfy a buying public that “wants that
hit album now. If it isn’t available, they are likely to choose
another selection that is.”
The new Speedmaster CD 102’s “incredible flexibility”
also will give Stoughton the freedom to work with thin pa-
pers, heavy board, foils and odd specialty substrates up to
40 pt thickness. The company also traded in a pair of aging
SM 102’s—a five-color perfecting press with coater and a
straight six-color with coater—to accommodate the new
machine, which was expected to be installed in October.
The new CD 102 with X-Package is targeted to commer-
cial and packaging printers requiring maximum flexibility in
the substrates they use. Equipment supplied as standard in-
cludes the Preset Plus Feeder and Preset Plus Delivery,
AutoPlate and Prinect Press Center with Intellistart press
control, together with a closed-loop spectrophotometer for
precise color management. The new Speedmaster CD 102
can be integrated fully into the Prinect workflow and also
can be connected to the Prinect Image Control color measur-
ing system for even greater color management, including the
ability to work on multiple press models within a single shop.
Prinect Packaging Workflow
For small commercial print shops through large indus-
trial packaging environments, Heidelberg offers complete
integration through its Prinect Packaging Workflow, the first
and only fully integrated workflow for packaging printers.
Beginning with the introduction of the Prinect Packag-
ing concept at drupa 2008, Heidelberg has steadily added
special functions that extend the functionality of its flagship
Prinect software suite. By adding a single module to their
existing Prinect commercial workflow, both commercial and
packaging printers can enjoy comprehensive integration of
all print shop processes to accommodate the development
and production of folding cartons and labels.
Inland Label of LaCrosse, WI, USA is a satisfied, long-
time user of Heidelberg’s Prinect workflow solution. The cus-
tom label printing company currently operates three
generations of Heidelberg’s flagship Speedmaster XL 105
presses, in addition to a recently installed Speedmaster XL
106 9-color press.
“Heidelberg’s Prinect Workflow provides Inland with
tools to establish and maintain a custom color management
system,” said Amy Jungerberg, Inland’s Prinect Prepress
See MEMBER page 46
December 2014
 SAMPLE
PATRON SALUTE
Join the Patrons. Show your support for the IADD and gain industry-wide recognition.

ABC DIE COMPANY JONCO DIE CO. INC.

ABC DIE CUTTING AND EMBOSSING LASERCOMB GMBH
ACU-GAGE SYSTEMS LES PLIAGES APAULO, INC.
ADAMS TECHNOLOGIES, INC. MANUFACTURERS SUPPLIES COMPANY
ADKO, INC. KARL MARBACH GMBH & CO. KG
ADVANCED DIE SUPPLIES, INC. MARCO DIE SUPPLIES, INC.
AMERIKEN DIE SUPPLY, INC. MARK TRECE, INC.
AMERITEK, INC. MARK-MAKER COMPANY, INC.
ANDERSON INTERNATIONAL TRADING MASTERWORK USA INC.
WALTER G. ANDERSON, INC. MCCAUSEY SPECIALTY PRODUCTS
ARDEN SOFTWARE NORTH AMERICA METSA BOARD AMERICAS CORPORATION
ARMOR STEEL CO., LTD. MIDWEST STEEL RULE CUTTING DIE
ASSOCIATED PACIFIC MACHINE CORP. MONROE RUBBER & PLASTIC, INC.
ATLAS DIE, LLC NATIONAL STEEL RULE CO.
BCSI SYSTEMS BV PG WOOD IMPORTS, LLC
BAR-PLATE MFG. CO. PSC GLOBAL INC.
BERT-CO PACE PUNCHES, INC.
BESSE FOREST PRODUCTS GROUP PACIFIC STATES FELT & MFG. CO., INC.
BOBST NORTH AMERICA INC. PALADIN SOFTWARE
BOHLER UDDEHOLM PRECISION STRIP LLC BRUNSWICK C.A. PICARD INC.
BRAUSSE GROUP POLYMX B.V.
BURD & FLETCHER CO. PRECISION FORME CUTTING PTY. LTD.
C & K PRODUCTS, INC. PRECO, INC.
CENTRAL DIE SUPPLIES INC. RADIANT LASERCUT, INC.
CHANNEL CREASING MATRIX, INC./CCM DIE SUPPLY RAYNER DIESUPPLY LLC
CIMEX CORP. RELIABLE STEEL RULE DIE CO.
CITO-SYSTEM GMBH ROTA DIE PTY. LTD.
CONTAINER GRAPHICS CORP. RYCO DIES
DRD SRL SRD LASER STEEL RULE DIES INC.
DAVIS & PIERCE DIE SERVICE, INC. SANDVIK DIECUTTING PRODUCTS
DECOUPAGE M.P.S. INC. SEAGA GROUP AUSTRALIA PTY. LTD.
DIAMOND PACKAGING SERVIFORM SRL
DIANSUPLY, INC. W.R. SHARPLES COMPANY, INC.
DICAR INC. SHENZHEN FUQUAN DIE-CUTTING MATERIAL SUPPLIES CO.,
DIE GUYS, INC. SHREINER COMPANY
DIE SUPPLY GUYS INC. STAFFORD CUTTING DIES, INC.
DIEBEC LTD. SUN AUTOMATION GROUP
DIECO, INC. TECHNIPLY, LLC
DITECH GROUP - YORK THORO PACKAGING
DYNAMIC DIES, INC. TRIANGLE DIES AND SUPPLIES, INC.
ESSMANN + SCHAEFER GMBH. + CO. KG TSUKATANI HAMONO MFG. CO., LTD.
EURACIER UNIVERSAL ENGRAVING, INC.
GERBER INNOVATIONS VISY - CENTRE LINE DIE FORMES

SAMPLE
GRAPHIC TECHNOLOGIES INC. & JOHNSBYRNE CO. WAGNER DIE SUPPLY
HEIDELBERG USA, INC. WUI HING MOULD LTD
J.A. RICHARDS DIV. OF PORTH PRODUCTS CO. ZIMMER INDUSTRIES INC.

December 2014 The Cutting Edge 45

 MEMBER
Continued from page 44
SAMPLE cut-and-stack, pressure sensitive, in-mold, roll-fed and
shrink labels. The company produces more than 25 billion
premium offset and gravure-printed package labels annu-
ally.

Manager. “This system has given us the knowledge and op-
portunity to reduce the number of spot colors printed on
press by replacing these colors with seven-color process.
This is becoming more and more favorable to our custom-
ers as it helps them reduce costs.”
Family-owned and -operated for three generations, In-
land Label has been exclusively dedicated to package deco-
ration since the 1970s. Product offerings include
We invented the technology.
We’ve reinvented the price.
“Prinect is used by several departments at Inland, from
planning layouts for single and combo runs in Prinect Signa
Station, to imposition and plating through Prinect Cockpit
and our Suprasetter CtP systems,” Jungerberg continued.
“The pressroom also benefits from the use of Prinect since
all ink information is available for every job, helping to re-
duce makeready.”
Like Inland Label, other Prinect users can easily change
custom Pantone colors into seven-color process with the
MultiColor Tool inside of Heidelberg’s Prinect
PDF Toolbox, and print every job with ink that
is already in the press. The addition of orange,
violet and/or green lets packaging and label
printers create hundreds of custom colors with
less makeready time and lower waste. To learn
how the Prinect MultiColor Tool can save
money in your pressroom, watch a demo here,
or contact your Heidelberg representative.

The concept behind Prinect Packaging

Workflow stems from the fact that the major-
ity of work performed by folding carton and
label printers consists of repeat orders. Be-
cause packaging from different production
batches often winds up side-by-side on store
shelves, every effort must be made to ensure
that precisely the same quality standards ap-
ply to each batch. As bulk goods, packaging
materials also must be manufactured as eco-
nomically and quickly as possible, sans error
and without wasting expensive materials.

Heidelberg’s Prinect Packaging Workflow

Waiting for the right time to buy?
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in a single linear process. Invest in proven, state of the art technology, at
a price you would expect to pay for a used bender.
deploys a variety of tools across prepress, press
and postpress to re-use data automatically in
order to improve quality and productivity. En-
tering data only once reduces error, saves
money and optimizes makeready time. Because
Prinect enables custom configurations for all
types of packaging jobs, users also benefit from
flexible job management, reliable costing and
maximum production reliability despite grow-
ing cost pressure.
Heidelberg’s Prinect offering integrates the
prepress department with the pressroom by
providing the press with up to 28 separate pre-
set parameters, in addition to ink key presets.
An important benefit of this capability is time

SAMPLE
saved. Ten minutes saved on makeready for a
info@adamstech.com 57" or 62" (1447.8 or 1574.8 mm) Speedmaster
phone: 303–798–7110 AdamsTech XL VLF press running six or more colors rep-

46 The Cutting Edge December 2014

 SAMPLE
resents a considerable savings—one that also comes with
significant error reduction, better consistency and repeat-
ability. Prinect also includes powerful calibration, profiling
and quality control tools for consistent, reproducible color
quality and matching with approved print sheets.
The heart of Prinect Packaging Workflow is Packaging
Pro, an add-on option to the Prinect Signa Station imposi-
tion and sheet assembly tool. With multiple functions to sup-
port the manufacture of labels and folding cartons, Prinect
Signa Station Packaging Pro enables the import, processing
and export of CAD data; preparation of complete signatures
including all color marks and control elements; definition
of clippings on the sheet with automatic or interactive con-
flict resolution in case of overlapping; and the optimum cal-
culation of gang forms for various print run volumes. Once
a sheet layout has been created, users can generate an in-
teractive, three-dimensional soft proof of the carton that
can be shared with the customer via email, eliminating the
need to produce a costly physical sample first.
Prinect Packaging workflow is flexible enough to ac-
commodate commercial printers that produce some pack-
aging work and are already familiar with the Prinect
platform; packaging converters like Inland Label that oper-
ate from one to three production sites; or very large pack-
aging concerns that may or may not have a global presence.
The most economical configuration offering the greatest
benefit would derive from the interplay of Prinect Sign Sta-
tion Pro (imposition), Prinect Prepress Manager and Prinect
Pressroom Manager (data preparation and output) and a
Heidelberg Speedmaster press.
Modular, scalable and open, Prinect adapts to individual
requirements and can grow with the customer, even where
components from other manufacturers are already in use.
Many businesses initially use Packaging Pro as an indepen-
dent solution, and then proceed to expand their packaging
workflow with Prinect, step by step, until all areas are fully
integrated.
Contact: Andy Rae, Senior VP, Equipment, Heidelberg
USA. Phone 1-770-576-0869; Email andy.rae@
heidelberg.com.
New PostPress Magazine to Launch in 2015
InsideFinishing, the official magazine of the Foil & Spe-
cialty Effects Association (FSEA) and The Binding Edge, the
official magazine of the BIA, will become one magazine cov-
ering the postpress industry. Beginning in 2015, PostPress
will reach graphic finishers, trade binderies, commercial
printers, folding carton and label manufacturers, loose leaf
manufacturers and other related industry segments with
articles on trends and technology advancements for the print
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decorating, binding and finishing industries.
December 2014
PostPress is projected to reach nearly 16,000 readers.
The print edition will be published quarterly and will be
supplemented by a quarterly digital edition magazine,
monthly e-newsletter and dedicated website. Each print edi-
tion of PostPress also will be distributed at industry-related
conferences and tradeshows through 2015, including GRAPH
EXPO, BIA Annual Conference, IADD•FSEA Odyssey, HBA
Global Expo and PACK EXPO International.
For more information or to subscribe to the new publi-
cation, visit www.postpresssubscriptions.com or call 1-785-
271-5801.
Contact: Dianna Brodine, Managing Editor, Peterson
Publications, Inc. Phone 1-785-271-5801; Email
dianna@petersonpublications.com.
AICC Elects Officers and Directors for 2014-2015
Members of the AICC—The Independent Packaging As-
sociation elected a slate of officers and directors at the
Association’s annual meeting, September 28–October 1, in
Long Beach, CA, USA. The slate was approved by acclama-
tion during the general session held September 30.
In addition to the regular slate of directors, the mem-
bership of AICC also named two delegates from the
Association’s Emerging Leaders group, Justin Mathes of Van-
guard Packaging in Kansas City, MO, USA and Sahar
Mehrabzadeh-Garcia of Bay Cities in Pico Rivera, CA, USA.
Jim Haglund, retiring as the Association’s Overseas Director
after 12 years of service, received the AICC “Independent
Ambassador Award,” and Paul Vishny, founding General
Counsel, who served AICC for 40 years from the day of its
founding, received a special tribute in gratitude for his ser-
vice.
The voting members of the Board of Directors are offic-
ers or employees of AICC’s regular-member companies, and
AICC’s Associate (supplier) members are represented by one
voting member. The complete list of AICC’s Officers and Di-
rectors for 2014-2015 can be found at: www.aiccbox.org/
News/News_Display.asp?ID=1876.
Contact: Steve Young, President, AICC. Phone 1-877-836-
2422; Email syoung@aiccbox.org.
The Cutting Edge periodically publishes press releases and corporate
announcements of general interest to the diecutting converting industry.
These announcements are obtained from the companies themselves and
a variety of other sources, and The Cutting Edge does not endorse any
products or statements contained in press releases and cannot vouch
for their accuracy. All product, trademark, company or service names
mentioned herein are the property of their respective owners.
The Cutting Edge 47
 SAMPLE CHAPTER UPDATE
Plug into the powerful world of IADD Chapters and
maximize the value of your IADD membership!

Can-Am Chapter
Technical Meeting & Holiday Dinner
Randy Norman, Senior Technical Adviser for Preco, Inc.
will lead a discussion on “Cutting Different Substrates.” He
will discuss different types of steel rule blades, bevels, angles,
etc, suggesting the type of blade that works best for each
material. He will also talk about types of ejection rubber and
cutting surfaces. The discussion will focus on magnetic ma-
terials, sand paper, gasket materials, polyethylene plastic,
vinyl, polypropylene, polyesters, felts, foams (open- and
closed-cell), etc.
Having trouble cutting, ejecting or knocking out materi-
als? Bring your questions and/or samples to the meeting and
Randy will troubleshoot them on the spot.
Date & Time: December 11, 2014, 2:00 PM—6:30 PM
Location: Ramada Hotel, 2402 North Forest Rd.,
Getzville, NY 14068 USA
Registration Fee: $55/IADD Member; $65/Non-Member
(Deadline: December 5, 2014)
For more information or to register, visit www.iadd.org/
calmain.html or contact Margaret Bussan, Chapter & Meet-
ing Assistant at 1-815-455-7519 or by email at
margaret.bussan@iadd.org.

This program will also feature a short presentation on See CHAPTER page 50
“Achieving Operational Excellence: A Result-Driven Ap-
proach” by Julie Zindle of Proserve Solutions.

IADD Chapter Contacts

Can-Am Gino Gualtieri 1-514-683-0999 Northwest Paula Kengott 1-775-882-4453
Central Die Supplies Inc. AmeriKen Die Supply, Inc.

Central Big 6 Ross Hutchison 1-913-541-0503 Rocky Mountain Kevin Ball 1-801-261-9401
Universal Engraving, Inc. Tru-Cut Steel Rule Die Inc.

Lake Michigan Harold Burkhart 1-847-437-7085 South Peter Quinlan 1-803-548-8663

Bohler Uddeholm Precistion Strip LLC Advanced Die Supplies, Inc.

Mid-Atlantic/ Kevin Sbriscia 1-413-323-1090 Southwest Martin Thornton 1-978-694-0055

New England Cimex Corp. Gerber Innovations

SAMPLE
Twin Cities Reg Cunningham 1-763-4971311

48 The Cutting Edge December 2014

SAMPLE

SAMPLE
 CHAPTER
Continued from page 48
SAMPLE

South Chapter
8th Annual Golf Outing
On August 21, the IADD South Chap-
ter held their 8th annual golf outing. The full recap was published
in the November issue of The Cutting Edge; please enjoy these
additional pictures.

SAMPLE
For more information, contact Margaret Bussan, Chapter & Meeting
Assistant at 1-815-455-7519 or by email at margaret.bussan@iadd.org.

50 The Cutting Edge December 2014

 Die
SAMPLE
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The extendable tongue of the chameleon was one inspiration

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