Automated large format cutting for Daytona

Print Solutions

Investment in technology over the last two years has seen Staffordshire based Daytona Visual has installed a Dyss X5-1630C digital die cutter with an automatic sheet feeder from AG/CAD.

Whilst its three print machines have been installed to improve productivity and capacity, the X5-1630C was installed to improve process control as well as throughput, whilst reducing costs.

Technical director Oliver Wassall commented, ‘We have two platen presses and we use an external supplier to manufacture the cutting formes. However, our die cutters can’t always facilitate the large format sheet sizes available on our large format digital flat beds that can be up to 3 metres by 1.6 metres. To make full use of the bed size, we had to get large cutting formes produced externally and then send these and the large format sheets to an external supplier for cutting. The sheet sizes and quantities could often make this a logistical problem that disrupted our workflow. This is why we invested in the Dyss digital die cutter. It has improved lead times, throughput and workflow whilst giving us more flexibility.’

Daytona bought a Kasemake KM603A cutting table from AG/CAD over 10 years ago for its prototype work. The build quality, reliability, consistency and customer support associated with the KM603A and the three licences of Kasemake CAD software were key factors in the purchase. Oliver continued, ‘In the time that we have had the KM machine, it has never failed us and the service has been outstanding. The new Dyss machine is for the production floor whilst the Kasemake KM603A will stay in the design department producing prototypes. Additionally, our Kasemake CAD software accommodates all our design needs. It has even used in our CNC routing department.’

The ability of the machine to cut, crease, score and fold the most intricate of designs has made it a necessity for prototyping and small batch sample production of complex designs for many print, packaging and signmaking businesses.

To do this, Daytona specified a sheet feeding device to automatically load the X5. The sheet feeder can support a maximum load of up to 800 kg with a total stack height of 650 mm. Furthermore, the suction cup pressure of the pneumatic auto loader can be adjusted to lift the thinnest, most sensitive and lightweight materials through to thick and heavy sheets. This bolt-on feature was a must for the company, as Oliver said, ‘We run two shifts and the X5 was brought in to streamline our production. The new TruPress large format printer is capable of high quality printing at speeds of up to 150 square metres per hour. Depending upon the complexity of the cutting profile, the X5 easily keeps pace with the printer. With the automatic feeder, we can load 100s of sheets and we just need one operator to remove the sheets, strip and palletise them for collation or shipping. Without the loading table, our processing speed would have required one operator for loading and another unloading. As the X5 runs continuously for two shifts each day, this could potentially be two additional staff – a cost saved by using the auto loader.’

By much reducing subcontracting-out large format cutting and the associated cutting forme production and costs, the savings re-couped will pay for the complete installation in less than three years.

To put the cutting forme savings in perspective, Oliver concluded, ‘We used to store anything from 200 to 400 cutting formes at any one time. This is now less than 100 tools. This is saving factory floor space, which has now been added to our finishing area. The cost of regularly producing these cutting formes was significant. Now, we have almost eliminated the cutting forme cost as well as bringing the majority of the short to medium run externally subcontracted work back in-house. The cost savings are significant and most importantly we are in complete control of our production process and this can take as much as two to three days off our lead times. We have achieved all this, whilst gaining significant capacity that will help us to continue our growth strategy.’