case study - folding carton die life

CHALLENGE   

A large folding carton manufacturer experienced blade breakage during production runs.  This was an ongoing problem and their current vendor offered no solution. The firm reached out to Midway for the first time. The Plant Manager remembered meeting a team from Midway at Pack Expo the prior year and was impressed with their familiarity and trouble-shooting knowledge of folding carton design.

 MIDWAY SOLUTION

The team at Midway went to work, seeing only a picture of the die that broke. Evaluating the die layout, the technical team recommended modifying the design in two ways:

  1. Revising the standard reverse tuck with a radius to aid material separation and relieve a known pressure-point on folding carton dies.
  2. Revising from 4-across layout to 3-across, because the 4-across width created difficult scrap removal areas that slowed production speed. Midway indicated the press speed could be increased from 350 ft/minute to 500 ft/minute – more than making up for the loss in width because of the better-running radius tuck design.

Based on the high-volume, long-running nature of the job, the Midway engineering team recommended the die be made with the firm’s Max-Life D2 Tool Steel with its exclusive deep-cryogenic treatment. Midway’s sales guys were mindful that the deep-cryo treatment would raise the price about 15% over a die without it, and this customer had no experience with Cryo dies or Midway. They quoted the job and described the rationale for the layout and material changes vs. the spec provided. 

Because this customer records all tool performance statistics, Midway offered the deep cryo treatment with the promise that if they did not experience exceptional performance gains, the cost of the cryo treatment would be refunded.

CUSTOMER RESULTS

The customer purchased a replacement die from their original die supplier, because getting the line up and running quickly with a new die was mission critical. But, they also purchased the Midway die for a side-by-side comparison. Midway’s “guarantee” is what convinced them to give it a try. Midway guarantees* your satisfaction or they will repair, replace, or refund. Period. 

“We found the Midway die ran about twice as long as the die we had been using. We’re a Midway convert,” the firm’s Plant Manager said when he called to ask about the first Retool, which was processed and returned in about a week. The Plant Manager shared a few additional statistics:

  • 65% faster line speed than before, close to 600 ft/minute, with no hang-ups or downtime
  • 30% more finished product per shift
  • 15% lower tooling cost over a year (dies, retools, shipping)
  • 23% lower cost per thousand cartons 

DISCOVER WHAT DROVE THIS SUCCESS

case study - folding carton die life

CHALLENGE   A large folding carton manufacturer experienced blade breakage during production runs.  This was an ongoing problem and their current vendor offered no solution. The firm reached out to Midway for the first time. The Plant Manager remembered meeting a team from Midway at Pack Expo the prior year and was impressed with their familiarity and trouble-shooting knowledge of folding carton design. MIDWAY SOLUTIONThe team at Midway went to work, seeing only a picture of the die that broke. Evaluating the die layout, the technical team recommended modifying the design in two ways:Revising the standard reverse tuck with a radius to aid material separation and relieve a known pressure-point on folding carton dies.Revising from 4-across layout to 3-across, because the 4-across width created difficult scrap removal areas that slowed production speed. Midway indicated the press speed could be increased from 350 ft/minute to 500 ft/minute – more than making up for the loss in width because of the better-running radius tuck design.Based on the high-volume, long-running nature of the job, the Midway engineering team recommended the die be made with the firm’s Max-Life D2 Tool Steel with its exclusive deep-cryogenic treatment. Midway’s sales guys were mindful that the deep-cryo treatment would raise the price about 15% over a die without it, and this customer had no experience with Cryo dies or Midway. They quoted the job and described the rationale for the layout and material changes vs. the spec provided. Because this customer records all tool performance statistics, Midway offered the deep cryo treatment with the promise that if they did not experience exceptional performance gains, the cost of the cryo treatment would be refunded.CUSTOMER RESULTSThe customer purchased a replacement die from their original die supplier, because getting the line up and running quickly with a new die was mission critical. But, they also purchased the Midway die for a side-by-side comparison. Midway’s “guarantee” is what convinced them to give it a try. Midway guarantees* your satisfaction or they will repair, replace, or refund. Period. “We found the Midway die ran about twice as long as the die we had been using. We’re a Midway convert,” the firm’s Plant Manager said when he called to ask about the first Retool, which was processed and returned in about a week. The Plant Manager shared a few additional statistics:65% faster line speed than before, close to 600 ft/minute, with no hang-ups or downtime30% more finished product per shift15% lower tooling cost over a year (dies, retools, shipping)23% lower cost per thousand cartons DISCOVER WHAT DROVE THIS SUCCESS

case study - Optimizing yield of medical controlled material

CHALLENGE   Based on outstanding work with a long-time Health Care customer, a Medical Converter earned a new project, their first-ever transdermal product. They regularly perform complex medical converting of a variety of materials, including hypoallergenic medical tapes, films, non-woven fabrics, foams and other flexible materials used in the production of medical devices, equipment and skin contact application.Working with a controlled substance material for the first time, the converter’s engineering team designed a die layout with extremely close nesting to minimize waste, because waste disposal of a controlled substance was the highest cost of the entire job. After the die vendor manufactured the die to spec and they began running the job, the die didn’t work. They experienced two critical issues they couldn’t resolve:Ragged cuts, which couldn’t even be resolved at slower than required press speed, and;Excess part rejection, meaning extreme unplanned controlled substance waste.Taken together, this meant what had started as a highly profitable project quickly turned negative. The converter reached out to the product manufacturer 3M for help, who suggested they contact Midway because of familiarity with the material.MIDWAY SOLUTIONThe Midway Engineering team went to work on the challenge. Our familiarity with the material and the firm’s Caulder press helped us identify the issue and develop a solution. Evaluating the die layout and planned press speed, the Midway technical team recommended two primary modifications:Reconfiguring the die layout to eliminate parts being cut simultaneously across the entire width of the die; this allows increased press speeds while maintaining part quality. While parts are farther spaced, the calculated yield increased.Machine sharpening to produce unparalleled consistency and uniformity of blades, further enhancing part quality with tight-tolerance materials with the added benefit of equal wear across the die, enhancing die life.Because of the unconventional layout, Midway guaranteed the converter that if the die didn’t perform as expected, they could return the die for a refund.CUSTOMER RESULTSMidway sent a technical representative to be on-hand at the converter for the die’s initial run. The job ran flawlessly. The parts were on-spec. The press operator and production manager were amazed that by the end of the first shift, yield surpassed the converter’s original projections by 17%. Best of all, the costly waste was reduced by over 10%, saving money and also mitigating risk the waste material could be disposed of improperly by mistake.“With Midway Rotary Die as our die partner, we’re aggressively going after even more challenging medical work,” the firm’s head of New Product Development told Rich Seeley, president of Midway. Sharing more of the good news with Rich, he continued, “Our profitability on this job not only beat projections, but it’s our most profitable job by far.”DISCOVER WHAT DROVE THIS SUCCESS

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