THE MAIN

TITEL DES SUCCESS

WIHTEPAPERS
FACTORS
FOR MINIMUM MAKE-READY
TIME DURING DIE-CUTTING.

How to reduce knife make-ready times during

die-cutting to a minimum and thus increase
your productivity as well as tool life. For
Subhead
m
­ aximumdesperformance
Withpapers in die-cutting your
packaging.
TABLE OF CONTENT.
EXECUTIVE SUMMARY 3

I. INTRODUCTION. 4
WHAT IS MAKE-READY FOR? – THE INFLUENCING FACTORS. 5
MAKE-READY RESULTS. 5

II. MAIN PART. 6

THE MAKE-READY PROCESS: AREA MAKE-READY AND LOCAL MAKE-READY 6
EXCURSION: MAKE-READY MATERIALS 7
AREA MAKE-READY 8
LOCAL MAKE-READY 9
DOS & DON‘TS IN LOCAL PATCHING. 11
THE MOST IMPORTANT SUCCESS FACTORS FOR MINIMUM M
­ AKE-READY TIMES DU-
RING DIE-CUTTING. 13
THE INFLUENCING FACTORS DURING MAKE-READY 13
EXCURSION: SHORTER MAKE-READY TIMES DUE TO RADIUS FREE GRINDING 15
OPTIMIZATION OF MAKE-READY TIMES 20
EXCURSION:
TOOL TECHNOLOGIES AND SERVICES FOR SHORT MAKE-READY TIMES 21

III. SUMMARY. 24

Marbach Group I Karl-Marbach-Str. 1 I 74080 Heilbronn I Germany | marketing@marbach.com I experience.marbach.com| 2

 EXECUTIVE SUMMARY
The demands on packaging manufacturers are
­increasing: Ever higher, faster, ­further. And with
the constantly increasing number of short run
orders. High productivity, low machine down-
times and high-quality packaging are r­ equired –
­regardless of the production run length.
In order to meet these requirements, the make-
ready time of the machine must be kept as short
as possible. A key factor influencing this is the
knife make-ready.
In our whitepaper, you will find out how you can
significantly reduce knife make-ready times in
the production of your packaging.

Marbach Group I Karl-Marbach-Str. 1 I 74080 Heilbronn I Germany | marketing@marbach.com I experience.marbach.com| 3

I. INTRODUCTION.
The cutting-die is a flat tool: in theory, all cutting rules
hit the cutting plate at the same time during the die-
cutting process. In practice, however, there are various
tolerances which cause the rules to cut through the
die-cutting material in some places but not in others.
This is where a height compensation becomes neces-
sary: patching.
During make-ready, the various tolerance factors are compensated for with the help of
make-ready paper to level out areal tolerances and the placement of make-ready tape
­behind the cutting rules – which have not yet cut through. This height compensation
­ensures that the blank is fully cut in all places and can be perfectly further processed. A
difference is made between area make-ready to compensate for machine unevenness and
a local patching of the cutting rules. Depending on the job and complexity, the make-ready
process can take several hours.

Die-cut test sheet

The result shows where the
tool is not yet cutting.

Repeat the process until the tool die-

cuts in all places.

Area make-ready Local make-ready

Compensation of major Compensation of missing
machine unevenness with height by sticking make-rea-
finishing paper. dy tape onto the make-ready
sheet in different thicknes-
ses.

The make-ready process.

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WHAT IS MAKE-READY FOR? – THE INFLUENCING FACTORS.
There are various tolerance factors that influence the cost of a knife make-ready. Each of
these factors in itself produces different tolerance ranges. It is therefore not just a matter
of compensating for the cutting rule tolerance, which is hardly a challenge at a maximum
of 0.02 mm, but of the overall “die-cutting” system.

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Factors influencing make-ready time.

MAKE-READY RESULTS.
At the end of the make-ready process, the result is a clean cutting edge for high-quality
packaging. The height compensation ensures that the die-cutting machine and tool are
protected in the best possible way. This means a longer service life. Clean make-ready also
ensures stable machine operation and thus an efficient die-cutting process in which fewer
nicks are required.

WATCH OUT!
Make-ready of the cutting rule by using patching tape costs time and therefore money.
In day-to-day business, print shops aim to keep make-ready times short for economic
reasons.
It is therefore a common practice to simply increase the die-cutting pressure of the
­machine as soon as a largely acceptable die-cutting result has been achieved.
However, what is not considered in this process is that this means high forces on the
tool and the machine:
• those cutting rules that hit the cutting plate with – already enough – pressure
• the cutting plate (the cutting rule digs in)
• the machine (possibly uneven pressure distribution)
• negative influence on productivity and packaging quality

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II. MAIN PART.
Die-cutting is precision work. The more precise the
make-ready, the more consistent the machine will run,
the higher the output, the cleaner the cut, the lower
the die-cutting pressure, the smaller the nicks, and
­ultimately the more precise and therefore more beau-
tiful and functional the die-cut packaging. Make-ready
is therefore an important stage that affects both the
productivity of the die-cutting process and the quality
of the packaging. But how can this process become as
efficient as possible?
In order to answer this question, the make-ready process itself and the exact steps ­involved
must first be examined. Optimization potential can then be identified from this, the exact
operations can be understood, and optimization potential can thus be uncovered.

THE MAKE-READY PROCESS: AREA MAKE-READY AND LOCAL

MAKE-READY
The make-ready process is very complex. First, a test imprint is made, which is used to
check how the individual blanks are die-cut in the current machine setting and without
make-ready: where does the cutting rule already cut through the paperboard, where does it
only score it, are there places that do not cut at all yet? This imprint is used as the basis for
area make-ready, which compensates for machine unevenness. Local make-ready is then
carried out with make-ready tape.
In concrete terms, a new cutting-die - including special technologies such as embossing,
reverse-cutting or Braille - as well as make-ready sheets are first set up in the die-cutting
machine and the machine is then started up empty – without paperboard material – for 3-5
minutes under low pressure so that the rule material can settle. Then the cutting pressure
is slowly increased until approx. 30% of the cutting rules cut. The result of this test die-­
cutting is then checked: this often reveals irregular cutting in the middle cutting area and
at the gripper edge. This is mainly due to the machine and can be roughly compensated for
by zone levelling.

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 EXCURSION: MAKE-READY MATERIALS
Various consumables are required for make-ready: a make-ready sheet on which the
layout is printed or plotted as a basis, as well as calibrated silk paper for zone levelling
and make-ready tapes in various thicknesses and widths for local patching.
While the silk paper is used for zone levelling, it primarily compensates for the ­tolerances
of the die-cutting machine, the make-ready tape used for local patching compensates,
among other things, for the tolerances that could not be compensated for in the course
of area make-ready.
A make-ready sheet is calibrated to withstand high pressure in the die-cutting ­machine.
It consists of two or three layers, depending on the application. The three-layer make-
ready sheet has a foil in between two paper layers. Its advantage is maximum pressure
stability and edge stability - due to the foil inside, the edges cannot tear. The sheet
can be easily printed with a plotter or printer. The two-layer make-ready sheet, on the
other hand, consists of one paper layer and one foil layer. The foil side can be written
on with a permanent marker. It is easier to remove make-ready tapes from this side
after sticking than from the paper side. The make-ready sheets are moisture-resistant
and -regulating and have good dimensional stability as well as high temperature resis-
tance.There are make-ready sheets for all common machine sizes.
The 0.03 mm thick silk paper used for zone levelling is also calibrated with high­
­pressure. The silk paper is usually glued to the back of the make-ready sheet so that it
sits directly on the chase base plate.
Make-ready tapes for local rule patching are self-adhesive and thus easy to apply to
the make-ready sheet. The different thicknesses of the tape – 0.03 mm; 0.05 mm and
0.08 mm – are easily distinguished by different color coding. All three thicknesses are
available in standard widths which are intended for different applications.
In the folding carton industry, 3 mm wide make-ready tapes are used as standard, while
in the corrugated industry the tapes with 6 mm width are used. The 12 mm tapes are
mainly utilized when two cutting rules next to each other or one area has to be patched
– for example a reverse-cutting anvil or for making-ready of embossing. The make-
ready tapes are pressure-resistant, moisture-resistant and temperature-­resistant.
They are characterized by very good adhesion and are also suitable for being stuck on
top of each other without slipping sideways.
All make-ready materials are available from Marbach Die Supplies.
More information can be found at: www.marbach.com/materials

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Area make-ready
The so-called area make-ready or zone levelling is carried out Tip:
The silk paper should not be cut
with the aid of hand-torn, calibrated 0.03 mm thick silk paper. For
with a knife or scissors, but torn,
this purpose, the paper is attached to the make-ready sheet with as this creates a smooth transition
a glue stick. The layout of the cutting-die is printed on the make- when several layers of paper are
used.
ready sheet so that it is clear where the make-ready has to be
carried out.

Example of zone levelling with silk paper.

After the first zone levelling pass, a test sheet is die-cut again
and the result checked. If poor cutting results continue to ­occur
in ­areas, these zones must be covered with another layer of
large-area silk paper.

Example of zone levelling with two layers of silk paper.

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This process is repeated until a reasonably consistent die-cutting Tip:
result is obtained. No more than 4 - 5 layers of silk paper should The time required for area make-
ready can be reduced to a mini-
be used, otherwise the make-ready loses its – in the die-cutting
mum for each individual job with
­process necessary – pressure stability. It is also important to the aid of long-term zone levelling
­ensure that each new layer is smaller than the previous one and in the die-cutting machine, which
compensates for the individual
does not exceed it. Otherwise, too large steps and holes will be tolerances on the machine side.
created in the make-ready, causing other areas not to die-cut. This is possible, for example, with
the DZL|plate digital zone levelling
Now the die-cutting pressure can be increased slightly and a new system.
test die-cut can be performed until approximately 80% of all cut-
ting rules die-cut through the paperboard.
Zone levelling locally increases the cutting force, also of creasing
rules, perforation rules and embossing. It simplifies and shortens
local make-ready. Die-cutting is quickly stabilized and no longer
needs to be corrected during production. In addition, zone level-
ling promotes a smooth stripping and blanking process.

Local make-ready
After zone levelling, local patching follows. In this process, the cut-
ting rules that do not yet cut through are individually backed with
make-ready tapes in various thicknesses between 0.03 to 0.05
mm. In this way, they are elevated until they die-cut through the
paperboard. After each die-cutting pass, additional test sheets
are die-cut and checked to see where there is still not enough
patched. This process is repeated until all cutting rules cut through
the die-cutting material.
In the example below, the left cutting rule is already die-cutting
the paperboard, while the right cutting rule is not yet cutting the
paperboard.

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Die-cutting process without height compensation of the tolerances: the left cutting rule
completely die-cuts the material, while the right one does not.

For consistent die-cutting, it is therefore necessary to underlay

the right cutting rule. This additional increase compensates for
the existing height differences.

Die-cutting process with height compensation of the tolerances: the left cutting rule
completely die-cuts the material. The right patched cutting rule now die-cuts as well.

After gluing make-ready tape to the make-ready sheet, the right

cutting rule is now elevated and also cuts through the paperboard
completely. The aim of make-ready is to achieve this for all cutting
rules.

As soon as a complete, clean die-cut result has been achieved, Tip:

approx. 20-30 sheets are die-cut one after the other and the cut- The test sheet during make-
ting result is checked on the package. By doing this, even a small ready should never be die-cut in
manual mode of the machine, but
unclean diecut area can be seen better than on the one ­individual
always at a higher running speed
sheet. If necessary, make-ready is carried out again with thin (e.g. 4,000 rmp), otherwise the
make-­ready paper. dynamics of the machine are not
taken into account and the result
is incorrect.
Important: There are a few important rules to follow during local
patching.

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DOS & DON‘TS IN LOCAL PATCHING.
1. Center the make-ready tape
The make-ready tape must always be centered to ensure consistent make-ready.

Centered make-ready tape.

2. Mind the spreading effect

During make-ready, the so-called spreading effect causes the pressure to increase not only
directly where the make-ready tape is applied, but also to spread in a wave-like ­manner to
the surrounding areas. To avoid the scattering effect of the chase back plate, the make-
ready tape should never be applied completely over the non-cutting surface, but a small
distance should be maintained.

Spreading effct of patching.

3. Avoid holes in the make-ready

When sticking several tapes on top of each other, the second tape should be slightly short-
er than the first, so that the step to the non-targeted area is not too large. Otherwise, a hole
will be created there, allowing a neighboring rule to bounce and thus no longer cut.

4. Avoid overpressure on lips

Never apply two make-ready tapes on top of each other at rule joints (double thickness), as
this puts overpressure on the lips and they can break off very easily. Make-ready tapes of
different thicknesses are available for this purpose.

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Make-ready tape without overpressure at the joints.

5. Maintain distance to creasing rules

The make-ready tapes should always be at a distance from the creasing rules so that the
creasing force is not intensified and creasing bulges are thus prevented from bursting.

Make-ready with distance to the creasing rules.

6. Avoid overpressure on closely spaced rules

If two rules are close together and only one of these rules needs to be patched, the make-
ready tape should be moved inward and away from the rule that is already cutting to avoid
overpressure on the rule.
If, however, both closely spaced rules do not cut, the make-ready tape can also be posi-
tioned between them.

Make-ready of closely spaced rules when one of them does Make-ready of closely spaced rules when both of them do
not cut. not cut.

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 ATTENTION!
Producing a make-ready sheet for a job is very time-consuming. Nevertheless, it may
not be possible to use it again for a repeat job:
• If the repeat job is produced on a different die-cutting machine, a new make-ready
sheet needs to be prepared.
• The last required pressure of the die-cutting machine should be noted on the make-
ready sheet. Then the machine can be set the same way again for the repeat job.
• If the job is made on the same die-cutting machine, the make-ready sheet used again
must be in perfect condition. Make-ready sheets that are torn, damaged by moisture
or ones with careless handling are unusable and must be remade.

THE MOST IMPORTANT SUCCESS FACTORS FOR MINIMUM

­MAKE-READY TIMES DURING DIE-CUTTING.
Make-ready is essential for the die-cutting process, but also costs a lot of valuable time in
the day-to-day business of a print shop. Therefore, there is a great desire for die-­cutting
without make-ready. In theory, this may be possible. If all the influencing variables are
­perfectly right, this could theoretically also work in small formats. Technologies such as
digital zone levelling – which at least reduces the time needed for area make-ready for
each individual job – are an advantage here. In practice, however, die-cutting without make-
ready is not yet possible.
However, you can find out how to reduce die-cutting make-ready times to a minimum and
thus increase your productivity here..

The influencing factors during make-ready

1.The die-cutting machine
Every die-cutting machine comes with inevitable tolerances in terms of machine design.
On new machines, these are usually only in the range of a few hundredths. In the course of
production, however, further deviations occur.
These can be both general wear effects in the overall environment of the drive technology,
such as insufficient tool-specific pressure compensation, changing pressure loads due to
different die-cutting formats, and special wear effects, for example in the area of the first
knife, the cutting chase cover plate, and the cutting chase plate.

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In addition, there are possible dynamic deformations of the Tip:
­machine cutting area when pressure is applied: the larger the Platen cleaning
For optimal condition of the
platen area, the more significant the dynamic deformation. die-cutting machines, we
­Tolerances can also be caused by improper care and contami­ ­recommend cleaning them every
six months. Dirt and rust are thus
nation of the cutting platen or cover plate.
removed from the cutting platen.
All these tolerances usually occur over a wide area, thus influenc- Cleaning smoothes out uneven-
ness and significantly minimizes
ing zone levelling in particular. A good condition of the machine the effort required for make-ready.
ensures shorter make-ready times. Clean make-ready will in One platen cleaning device, for
example, is the mplaten|cleaner:
­return help to ensure that the machine remains in good condition.
this universal device is compatible
with all common machine types.
2. The cutting-die The platen can be cleaned very
A very large factor influencing the necessary make-ready time quickly and easily by the machine
operator.
of the knives is the quality and equipment of the cutting-die. Of
course, it is primarily the die supplier who has an influence on the
tolerances of the cutting-die and thus on the cutting process.
But even the installation of the cutting-die in the cutting chase can
influence the make-ready time. It is therefore essential to check
the back of the cutting-die beforehand and remove any contami­
nation.
For faster make-ready, the cutting-die should also already be
equipped by the diemaker with the appropriate mounting holes
for the chase back plate. This allows the cutting-die to be quickly
fastened and secured from the rear.
A cutting-die consists of many different components. However,
it is mainly the cutting rules within the cutting-die that ensure
­tolerances in the die-cutting process. With commercially available
cutting rules, production-related tolerances of approx. +- 0.02
mm are possible. Mechanical processing – e.g. bending a radius –
causes the cutting tip to dip downwards in the area of the bending
radius. However, the tool manufacturer can counteract this with
the channel grinding process. Due to the permanent load on the
cutting tip during production, there are also irregular wear effects
and the resulting different height losses of the cutting rule.

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 EXCURSION: SHORTER MAKE-READY TIMES DUE TO RADIUS
FREE GRINDING
When cutting rules are bent during the production of a cutting-die, tension and
­compression zones occur in the deformation area of the bending edges. The cutting
edge tip is located in between. In the case of sharp-edged bends (radii of approx. 0.5
- 3.0 mm), the inner rule layer is compressed and the outer rule layer stretched. This
causes the cutting tip to dip downwards. Depending on the cutting rule hardness, bend-
ing radius and bending angle, the cutting edge may lower by 0.03 - 0.06 mm in the
­deformation area (bending area).
This height reduction must be compensated for in the rule patching process by placing
make-ready tapes behind it in order to achieve a clean cutting pattern.
Here, the diemaker can already take countermeasures during the production of the
cutting-­die and thus influence the make-ready times: utilizing the channel grinding
technique, the inside of the radius is ground out by approx. 0.25 - 0.3 mm to stropping
just before the tip of the cutting edge in order to reduce this material compression – and
thus also the height reduction of the cutting edge.
This mechanical intervention moves the tip of the cutting edge from the neutral middle
area into the compression area, so that the cutting edge can no longer migrate into the
tension area during bending.

0,25-0,3 mm

centered cutting tip

Channel grinding, unbent rule Channel grinding, bent rule

approx. 0.01 mm
0.03-0.06 mm dip
dip

Conventionally bent cutting rule. Cutting rule wich channel grinding.

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It is important that no low-quality rule material is used by the die- Tip:
maker and that the cutting-die is properly manufactured. The use Special cutting rules can handle
overpressure better with their
of special techniques, such as channel grinding and tension-free
rounded cutting tips, e.g. mpower
rule assembly, also ensures lower tolerances. Also, different types and mpower+.
of cutting rules should not be used in a cutting-die. Generally
speaking, high-quality manufactured cutting-dies with optimum
pressure distribution positively influence make-ready times.

3. The counter cutting plate

A very important parameter in knife make-ready is the plane-­
parallelism of the cutting plate used and its hardness. The
­absolute thickness primarily has no effect on the patching effort.
This tolerance source can be neglected with high-quality plate
materials - such as those used at Marbach. In the course of time,
however, continuous pressure at the same point - e.g. the gripper
edge - can lead to grooves in the cutting plate and thus increasing
tolerances.

4. The material to be die-cut

Paperboard influences also the make-ready time. Primarily from
its thickness tolerances. These are specified by the paperboard
manufacturer as up to 5%. Theoretically, a paperboard with a
­target thickness of 0.4 mm thus has a possible variation of 0.38
mm to 0.42 mm. This does not sound dramatic, but it can have a
major impact on knife make-ready.

Die-cut paperboard.

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5. Material quality
In order to make the patching process as efficient as possible, high-quality make-ready
materials should be used that are standardized and comply with certain standards. For
example, the dimensions of the make-ready sheet should at least correspond to the di-
mensions of the complete cutting-die – including all stripping rules and balancing rules.
The thickness of the make-ready sheet should have a value of 0.1 mm, with only small
­tolerances of no more than 0.01 mm across the entire sheet. The make-ready sheet should
be pressure-stable as well as moisture-resistant, dimensionally stable and temperature-­
resistant.
In the case of calibrated materials up to a maximum thickness of 0.1 mm should be used
as make-ready sheet. This can be neglected as an influencing factor. If this is not the case,
unnecessary height tolerances occur in the overall system, which must also be compensa-
ted for in the course of local patching.

Local patching with make-ready tape.

However, it is not only the material properties of the make-ready sheet that are important,
but also how the cutting-die layout is applied to the make-ready sheet. It is important that
all rules and contours of the cutting-die are visible on the make-ready sheet. This applies
in particular to cutting rules, reverse cutting and embossing bases. Nowadays, the make-
ready sheet is normally supplied directly by the diemaker. On the one hand, this ensures
that the layout of the cutting-die is correctly transferred, and on the other hand, it saves
make-ready time, since there is no need to print the make-ready sheet at the die-cutting
machine using carbon paper or to create it on a plotter.

ATTENTION!
Makeshift materials – such as a printed paperboard or normal adhesive tape – must not
be used for make-ready under any circumstances for reasons of accuracy.

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The make-ready materials used (silk paper and make-ready tapes) Tip:
should also meet certain requirements so that they can be used Standardized make-ready materi-
als are available from Marbach Die
reliably. These include factors such as pressure stability, moisture
Supplies. More at: www.marbach.
resistance and temperature resistance. The tapes should be used com/materials
in different thicknesses. Good adhesive properties ensure that
they can be taped over several times.
You can find out more about suitable patching materials in the
excursion on page 7.

6. The machine operator

It is not only the machine and tool that influence the height
Tip:
­tolerances in the die-cutting process, but the machine ­operator Different trainings for machine
also plays a role. This is because improper handling of the operators are available at the
­Marbach Academy!
cutting-­die or die-cutting machine can result in tolerances. The
same ­applies if the cutting-die is started up with too much cutting
­pressure during initial use or if the platen is not regularly main-
tained and cleaned. The machine operator should be well trained
and should know and follow the make-ready rules.

7. The company
In addition to the machine operator, there are other people in the
printshop whose decisions can indirectly promote tolerances and
thus extend the make-ready time. This is the case, for example,
if cutting-dies are ordered and used without balancing rules, if
incorrect or low-quality make-ready material is provided, or if
­insufficient time is scheduled for machine care and maintenance.

TIPS:
• Attach a sign with the basic make-ready rules to your machine.
• Create a maintenance plan for each machine with regular checkups.
• A make-ready sheet can only be used on one and the same machine.
• Make a note on the make-ready sheet: date, machine, operator, pressure, settings, ...
for repeat jobs.

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 Examples: „Good“ and „Bad“ Make-ready
The goal in make-ready is to carry out zone levelling in such a way that as little local
make-ready as possible is required afterwards. This is very time-consuming.
If too little zone levelling has been carried out, the cutting rules must all be individually
patched with make-ready tape. This is not only time-consuming, but can also result
in the make-ready sheet losing printing stability and thus not achieving a consistent
die-cutting result. In practice, this means that rules that initially cut well suddenly cut
poorly.

Result of "bad" zone levelling: time-consuming local make-ready with tape is necessary on
many cutting rules.

Result of "good" zone levelling: local make-ready with tape is only necessary on a few cutting
rules.

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OPTIMIZATION OF MAKE-READY TIMES
The make-ready of a cutting-die is done directly at the die-cutting machine. All work ­carried
out on the machine extends the time during which the machine is at a standstill and cannot
produce. How long make-ready takes depends on various factors. In addition to the factors
already mentioned, the size of the format, packaging layouts, and the number and length of
the cutting rules also have an influence on the make-ready time. The more meters of cut-
ting rule are installed in a cutting-die, the more rules can require patching. The efficiency of
a make-ready can be increased by various factors. For example, make-ready times can be
optimized by using the right cutting-die equipment and by outsourcing individual services
to the die manufacturer.
The following overview shows the savings potential through the use of technologies and
services of the tool manufacturer during make-ready:

Time spent with tech-

Time spent at the Technology / Service
Work nology / service of tool
machine tool manufacturer
manufacturer

1. imprint of the 5 min make-ready sheet 0 min

make-ready sheet (plotted)

2. Zone levelling 15-20 min DZL|plate 0 min

mplaten|cleaner

3. Local make-­ simple: 30 – 45min mpower|+ package Up to 90 % less effort

ready medium: 45 min – 1,5h
complex: >1,5 h

4. Set-up process Connect|M Positive effects on the

in general Performance Paket entire set-up process

1. For example, the time required to produce a make-ready sheet can be saved completely if it is
­supplied directly by the diemaker.
2. Job-related zone levelling is usually not necessary if a machine is regularly cleaned and main-
tained and is equipped with digital zone levelling, which compensates for the wear-related, surface
tolerances of a die-cutting machine.
3. Most time is spent on local make-ready. There are technologies that reduce make-ready to a
­minimum, such as the mpower|+ package. Thanks to its various components, there is a potential for
saving up to 90% of the make-ready time.
4 The more influencing factors create optimum conditions and the better the tools are designed by
the diemaker to reduce make-ready time, the faster make-ready can be achieved. The shorter the
machine‘s make-ready time, the more jobs can be produced on the machine.

Marbach Group I Karl-Marbach-Str. 1 I 74080 Heilbronn I Germany | marketing@marbach.com I experience.marbach.com| 20

 EXCURSION:
TOOL TECHNOLOGIES AND SERVICES FOR SHORT MAKE-
READY TIMES
There are many factors that can affect the make-ready time. Below we present the
suitable Marbach technologies that are available depending on your job structure and
your individual requirements.

Digital zone levelling DZL|plate

Digital make-ready for low machine tolerances.
The die-cutting machine is subject to tolerances due to wear. As a result, zone level-
ling must be carried out for every job.
The DZL|plate digital zone levelling is an individual-
ly manufactured cover plate with a digitally printed
height profile - specific to the particular die-cutting
machine. It largely compensates for the height toler-
ances of the machine in the area of the cutting plat-
en and levels out the disadvantages of conventional
zone levelling.
The DZL|plate ensures optimum pressure conditions during die-cutting and minimum
make-ready times. It is both faster and longer lasting than conventional area make-
ready and can be reordered at any time.
Amortization calculator at www.marbach.com/dzl

CONNECT|M
Die-cutting 4.0 for KPIs at the touch of a button.
Connect|M is a specially developed software com-
bined with various hardware components. Cameras,
sensors and QR codes provide a cloud-based, digi-
tal connection between the tool, die-cutting machine
and user in the production of a packaging manu­
facturer. This digital connection enables perfor-
mance tracking and efficient die management.
The result: trends are identified at an early stage on the basis of the key figures
­determined and potential is revealed: a perfect basis for decisions relating to the die
cutting process. For maximum transparency in packaging production.

Marbach Group I Karl-Marbach-Str. 1 I 74080 Heilbronn I Germany | marketing@marbach.com I experience.marbach.com| 21

 mpower|+ technology
The power package for short make-ready times.
The mpower|+ package can save up to 90% make-
ready time. At the heart of the package is the special
cutting rule, which delivers the best cutting results
with its rounded cutting tip and is also very robust.
The higher stress resistance during die-cutting and
the associated lower number of damaged rules
­ensure consistently good die-cutting quality, clean cut edges, no angel hairs and
­significantly less dust. This results in lower machine loads than with tools with stan-
dard rules. The die-cutting machine runs more quietly, and die service life is increased.

In addition, there are further package components, such as a special laser cutting
process and special tool package equipment with regard to dimensioning technol-
ogy, rubbering and make-ready sheets. In addition, the calculated starting tonnage
and expected cutting pressure are predefined. This eliminates the need for a slow
­approach to the optimum cutting pressure. All this saves valuable make-ready time
and thus costs.

Regular cutting rule. mpower cutting rule. Regular cutting rule mpower cutting rule
after 1 x overpressure. after 1 x overpressure.

Marbach Group I Karl-Marbach-Str. 1 I 74080 Heilbronn I Germany | marketing@marbach.com I experience.marbach.com| 22

 mplaten|cleaner
The platen cleaning device for efficient cleaning.
The mplaten|cleaner is a cleaning device for die-cutting machines. It can be used to
clean the platen of a die-cutting machine efficiently by the machine operator and to
increase the productivity of the machine.
The mplaten|cleaner is easy to handle: it simulta-
neously removes dirt and rust from the upper and
lower platen and smoothes out unevenness – even
in hard-to-reach places. It is not necessary to dis­
mantle the chain in the die-cutting machine. Clean-
ing by the machine operator takes around one hour.
This time investment pays for itself very quickly thanks to the positive effects on
make-ready time. The clean platen saves time during zone levelling and the cutting
pressure can be reduced. This extends the service life of the tool. In addition, the cut-
ting result is also positively influenced by a clean cutting platen.

Performance Package
Efficient processes for reduced set-up times.
The Marbach Performance Package is a special
­service package for increasing efficiency “around
the die-cutting process”. It consists of five modules:
Analysis & Planning, Machine Upgrades, Tooling
Technology, Machine Environment and Training.
First, the set-up process at the packaging manu­
facturer is filmed from various perspectives. In this way, the processes are o
­ bjectively
recorded. Then the set-up process is sequenced and analyzed with video editing soft-
ware and the savings potential is calculated in minute detail. In addition, the experi-
enced Marbach application engineers inspect the machine and its environment. This
way, they can identify correlations and work out causes for inefficient setups. The
results are then presented to the customer and optimization potentials are discussed.
As just mentioned, the Performance Package shows optimization potential and
thus ensures a smooth production process, more safety and the maintenance of
competitive­ness.

Marbach Group I Karl-Marbach-Str. 1 I 74080 Heilbronn I Germany | marketing@marbach.com I experience.marbach.com| 23

III. SUMMARY.
In the previous chapters, you have received the most
important information on make-ready and make-ready
time reduction. There are numerous challenges in the
patching process. In order to master them, it is import-
ant to follow the make-ready rules and to optimize the
influencing factors by means of appropriate technol-
ogies that are optimally suited to the respective job.
In the checklist at the end of this whitepaper you will
find an overview that will support you in reducing your
make-ready times.

Local patching of a cutting-die with make-ready tape.

In summary, it can be said that short make-ready times are becoming increasingly ­important.
To achieve this, the various influencing factors should be considered and ­optimized.
­However, despite all optimization of the make-ready time, the quality of the make-ready
must not suffer. This is because correct make-ready is important for extending the ser-
vice life of the tool. “Incorrect” make-ready, too much pressure or inferior materials can
stress both the cutting-die and the die-cutting machine. Therefore, attention should be
paid to the quality of cutting-die and make-ready materials, patching rules should be fol-
lowed, ­technologies and services should be taken from the die manufacturer, and the ma-
chine should be maintained. Regular training of the machine operators also helps to ensure
­efficiency during make-ready.

Marbach Group I Karl-Marbach-Str. 1 I 74080 Heilbronn I Germany | marketing@marbach.com I experience.marbach.com| 24

 Checklist for short make-ready times
Machine
 regular check of the machine condition (unevenness / wear)
 regular maintenance of the machine
 regular cleaning of the machine, e.g. with the mplaten|cleaner
 levelling the unevenness of a machine, e.g. with the DZL|plate
Cutting-die
 Quality of the installed cutting rules, e.g. mpower|+ with rounded cutting edge
 Removing impurities from the back of the cutting-die
 Fastening drill holes for chase back plate by the tool manufacturer
 Preventing dipping of the cutting rules at radii by channel grinding
 Optimum pressure distribution of the cutting-die (possibly balancing rules)
Counter cutting plate
 Check plane parallelism
 Optimum hardness & quality of the cutting plate for less wear and tear
Material to be die-cut
 High-quality paperboard material with few thickness tolerances
Make-ready materials
 Correct dimension of the make-ready sheet
 Make-ready sheet quality
 Make-ready sheet already supplied with cutting-die layout
 Quality silk paper
 Quality make-ready tapes
 Different thicknesses of make-ready tapes available and considered
 Good adhesive properties of the make-ready tapes
Machine operator
 Compliance with the make-ready rules
 Proper handling of machine and tools
 If necessary, training, e.g. at the Marbach Academy
 Optimal cutting pressure, if necessary mpower|+ package
Print shop
 Optimization of operations, e.g. through a process and environment analysis
with the Marbach Performance Package
 Determination and monitoring of key figures, e.g. with the Marbach system
­solution CONNECT|M
 Purchasing department pays attention not only to the lowest price, but also to
the quality of the tools & make-ready materials

Marbach Group I Karl-Marbach-Str. 1 I 74080 Heilbronn I Germany | marketing@marbach.com I experience.marbach.com| 25

You see: time savings in cutting-die make-ready is not impossible. And yet, in practice, there
are always difficulties in making the make-ready process not only efficient but also good.
The success factors explained in the whitepaper are the basis for an optimally ­functioning
patching process.

Do you still have questions or need support? Our experienced specialists will be happy to
help you and answer your individual questions in detail.

In addition, we supply you with the appropriate tool technologies including equipment and
training. For best functionality, high productivity, time and cost savings during make-ready.

Your contact person:

Bernhard Reisser, Industry manager paperboard Marbach Group
Phone +49 7131 918-191 | bernhard.reisser@marbach.com

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ABOUT MARBACH.
Packaging. Performance. You. This is the motto of the international leader in the fields
of die-cutting technology and tool making. With 1,600 employees worldwide, Marbach
continues to set the benchmarks in its industry. Since 1923. And delivers performance
pure, to all its customers. Individually. The right solution for every requirement.

Marbach Group I Karl-Marbach-Str. 1 I 74080 Heilbronn I Germany | marketing@marbach.com I experience.marbach.com| 26