Challenge
Based on outstanding work with a long-time healthcare customer, the converter earned its first transdermal product. They designed a die layout with extremely close nesting to minimize waste because disposing controlled substance material was the highest cost driver.
Once the die hit the press, the plan unraveled. Ragged cuts appeared even below target press speeds and part rejection skyrocketed, creating unplanned waste. Their customer recommended Midway due to our familiarity with the material.
Solution
Midway engineering evaluated the die layout, nesting, and planned press window. We reconfigured the layout so parts were not cut simultaneously across the entire die face, which kept quality intact at higher speeds and, counterintuitively, increased calculated yield even with more spacing.
We also machine-sharpened the die for uniform blade height so tight-tolerance materials cut cleanly with equal wear. Because the layout was unconventional, we guaranteed the converter could return the die if it did not perform.
Results
A Midway technical representative supported the first press run. The job ran flawlessly at speed, operators hit spec, and first-shift yield beat projections by 17%.
Most importantly, controlled-substance waste dropped by more than 10%, saving cash and reducing disposal risk. The converter's leadership called it their most profitable job to date.
17% higher yield
First shift exceeded the converter's projections by 17%.
10%+ waste reduction
Controlled-substance scrap dropped despite higher press speeds.
Most profitable job
The converter's NPD lead said the project now tops their margin list.
“With Midway Rotary Die as our die partner, we are aggressively going after even more challenging medical work. Our profitability on this job not only beat projections, but it is our most profitable job by far.”
Head of New Product Development, Medical Converter
