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SOLID DIES

A wide variety of high-precision steel types are used for our solid dies using long lasting materials for longer die life

There’s no challenge too great for Midway Rotary Die Solutions. Our solid dies types cover any product challenge you’re facing by providing solutions for food and medical grade products, and those are dealing with very abrasive materials. Our high precision tooling, made for tight tolerances, is long lasting and beneficial to your bottom line.

steel types

MRD1000: CORROSIVE RESISTANT TOOL STEEL

Food Grade
Medical

MRD2000: Versatile TOOL STEEL

Most Commonly Used
Average Yield Jobs

MRD3000: Superior TOOL STEEL

Medium-High Yield Jobs

MRD4000: abrasive RESISTANT TOOL STEEL

Cryogenically Treated
Used for Abrasive Materials

MRD5000: Premium Proprietary Tool Steel

High Yield Jobs
Used for Challenging Abrasive Materials

FEATURES

Slug removal methods, perforations
and die coatings for solid dies

SLUG REMOVAL

DIE COATINGS

PERFORATIONS

Slug Removal

There are several different methods for removing slugs and other waste from converted parts or the web.  They range from low tech to high complexity; cost-effective to expensive; and have pros and cons to each method.  Finding the perfect combination for customers is the goal, and Midway has the most comprehensive solutions in the industry for removing web waste.

This method utilizes an air probe inserted through the journal of the die to deliver forced air through the die cavities with each rotation of the die.  It is a relatively low cost solution, and is simple to set up and use.  It is most effective with smaller diameter dies.

Midway’s Pulse Air™  system offers an improvement over standard air eject tools.  This system utilizes a special air manifold to control and direct the burst of air to each cavity as the tool rotates. This means you achieve the most effective slug removal while reducing the amount of air pressure required. Pulse Air™ dies require no press modification.

Advantages of the Pulse Air™ System

  • Reduced air consumption
  • Higher air velocity
  • Highly directional air delivery
  • Superior slug removal
  • User friendly
  • Effective at high press speeds

 

Sometimes due to press constraints it is not convenient to eject a slug immediately after cutting.  The Vacuum-Transfer method allows slugs to be held in the die cavity under vacuum and transferred around the die to a preferred point of ejection into your collections system.

This method also allows you to separate an inner slug from a finished (OD) part without using separate die stations.  This eliminates the need for die-to-die registration between die stations.

This System uses a matched die and anvil configuration. This scrap removal system has been run at press speeds over 800 feet per minute with 100% scrap removal. Matched set tooling uses a “pin” to stab the scrap and pull it down through a removal comb. Some minor modification is required to the support/drive rolls for pin clearance, and the addition of the comb for stripping the pins.  All modifications can be performed by Midway and are adapted for each specific application.

Advantages of the Pin Point™ Removal System

  • Highest press speeds
  • 100% removal rate
  • No interference with normal
    press operation
  • Minimal operator involvement
  • Pins are removable/replaceable

Vacuum dies offer an effective means for removing small die cut waste from the web.  A vacuum die uses suction to pull waste through the center of the die, and out the end of the journal using a vacuum assist block. Removable inserts are used to provide increased clearance for the waste slugs that must pass into the die’s core, reducing the chance of buildup that could cause blockage of the air passage.

Vacuum dies are most effective on:

  • Small cavities
  • Thin materials
  • Tag stock
  • Polyesters
  • Materials without adhesive

Screw-in spring plungers offer positive slug removal from die cavities when cutting stiffer materials.  The spring-loaded plunger “pushes” out the scrap, freeing it from the die to be collected with a vacuum collection system.  The plunger extends beyond the blade of the die, but retracts as the die rotates in the press.  This method is highly effective for ejecting stiff materials such as metal, thick tag, rigid vinyl, and polycarbonate. Screw-in design allows for easy replacement on-site.

Advantages of Spring Plunger Ejection

  • Low cost
  • No press modification required
  • Easy replacement
  • Quiet
  • Very strong ejection capability

SPECIAL DIE COATINGS

Non-stick coatings are available from Midway for applications such as cutting exposed adhesive.  This coating does not affect the blade quality or cutting performance. The coating is applied with base coat at our facility and the tool is ready-to-go upon arrival. Additional applications of the non-stick coating may be purchased from Midway and applied at your facility if desired. Other coatings offering corrosion protection, extra durability, or special release properties are also available.

Our standard non-stick is a white silicone release coating that is applied on the die evenly in house prior to shipment. This coating can be removed easily prior to retooling and re-applies as needed. 

 The clear non-stick is a treatment coating on the die that actually impregnates into the steel and provides a non-stick surface to the die that won’t flake off. Though this coating has a longer cure time than our standard non-stick, retooling does not require removal of this coating but rather a quick re-application with a quicker cure time.

Many converters using material with high moisture content seek this option for coating their dies to prevent corrosion of the steel.

PERFORATIONS

Midway was the first to incorporate “invisible” perforation into engraved cutting tools.  Once only achieved using steel rule dies, now irregular and complex shapes can have all the aspects of an invisible perforation in fully-hardened rotary dies.  Clean edge perforations up to 50 TPI are available. 

3/32″ cut, 1/32 tie is industry standard, fold perforation for folding carton is typically 0.125″ cut & 0.125″ tie. Customers can request custom perforation specs as needed.

.030″ or less tie is considered a micro perforation. Midway has precise machining capable of creating micro perforations as small as .010 tie with a .020″ cut.

multi-level cutting

Midway’s multi-level cutting tools enable the converter to manufacture complex parts with a single rotary die.  Tools have been successfully created with up to five different cutting levels in the same tool.  

The production advantages are obvious:

  • Lower cost due to reduced number of tools required to accomplish all needed cuts

  • Less waste due to elimination of registration between stations

  • Reduced press setup by combining several tools into one

  • Higher press speeds, leading to shorter converting runs to achieve the same volume

THE MIDWAY DIFFERENCE

we back our work with a guarantee – if your tooling does not perform to your satisfaction, we will repair, replace, or refund.

Most companies claim to create high-quality solutions, have great customer service, technical expertise – but at Midway, we back our work with a guarantee that if your tooling does not perform to your satisfaction, we will repair, replace, or refund. With experience in a wide range of markets, we approach each project with the confidence and understanding that no two applications are alike. We take the time to listen to our customers to truly understand their needs and find the best solution custom-fit to their unique challenge.

 

QUALITY COMES FIRST

Midway helps you exceed industry standards, regulations and environmental protection goals while maximizing long-term performance and reliability. With over 4 decades of industry-leading experience, we put quality first. Our facilities are ISO 9001 certified and have proudly met specifications for safety and contingency planning since 2002.