1. Start with the label job, substrate and press details
Before any drawing or cutting starts, please tell us what the die must do on press. The same label size can behave very differently on paper, film, foil or laminated stock, especially when the job is running on a narrow web press in Johannesburg or a high-output line in Durban.
We need the full job picture so we can advise on the right die type, whether you need a rotary solid die, flexible magnetic die or a magnetic cylinder. If the job is a repeat, include the previous order reference, any known wear issues and whether the last tool had burrs, uneven pressure or premature wear.
- Label size and shape
- Substrate type and thickness
- Web width and repeat length
- Press make and model, if available
- Quantity needed and how often you repeat the job
2. Send the artwork and cutting details that matter
Clean artwork saves time and avoids confusion at CAD stage. We do not need decorative images or marketing copy for die making, but we do need the cutting path, registration marks if used, and any special features such as rounded corners, windows or peel tabs.
If you are sending a repeat label, make sure the file matches the current version on press. Small changes like a 0,5 mm corner shift can affect stripping and bleed if the substrate is sensitive. A clear file is also helpful when a production team is balancing load-shedding windows and trying to get proofing out before the afternoon rush.
- Artwork file in the latest approved version
- Cut lines clearly marked
- Any kiss-cut or perforation notes
- Text or graphics that must stay clear of the cut
- Special finishing notes for varnish, lamination or hot foil
3. Confirm tolerances, repeat length and registration expectations
Rotary dies depend on accurate repeat and registration. If the repeat is wrong, even a good tool will struggle to stay in register on press. Tell us the exact repeat length in millimetres and whether the job must line up to printed artwork, a window opening or a pre-printed panel.
For many South African converters, the practical challenge is not just cutting accuracy but keeping the job stable across long runs and different shifts. Coastal humidity in Cape Town or Gqeberha can affect stock handling, while heat in inland plants can change how film behaves through the converting section.
- Exact repeat length in mm
- Required cutting tolerance
- Register mark position and size
- Any known web wander or slitting issue
- Whether the job will run cold, warm or in variable conditions
4. Share press setup details before we cut the tool
A die should match the press it will run on. If the bearer setting, cylinder condition or mount is not right, the best-made tool can still give trouble. That is why we ask about the press setup, cylinder condition and any past issues with chatter, uneven impression or drag.
If you are running frequent repeats, mention whether you need a new die only, or whether a cylinder refurb, die regrind or magnet check is also due. In some cases a slightly worn setup causes the problem not the design itself, and fixing that first saves time and money.
- Press type and station details
- Condition of the existing cylinder or mount
- Any pressure or impression problems
- Current stripping method and waste removal
- Whether you need press trial support after delivery
5. Choose the right service level for the order
Not every order needs the same level of attention, but it helps to say what you want from the start. Some customers need full die design and CAD proofing, while others only need a repeat match from an existing sample. If the job is urgent, tell us early so dispatch and production can plan around it.
For converters in Germiston, Pretoria, Pinetown, Bellville and the wider metro areas, delivery timing is often just as important as manufacture. We can coordinate packing and dispatch for collection or delivery, and urgent remakes are easier to manage when we know the deadline up front.
- New design or repeat match
- CAD proof required or not
- Urgent remake or standard lead time
- Delivery address and access details
- Any stock advice needed for the next run
6. Check the order before approval and production
Once we have the details, we prepare the proof or technical confirmation for approval. This is the stage where a careful check prevents costly rework. Please review dimensions, cut path, count of impressions and any special notes around stripping or waste removal before you sign off.
If something looks off, say so immediately. A fast correction now is much easier than changing a finished tool later. Keep the proof with your production records so repeat orders can be matched quickly next time, especially when multiple operators are involved.
- Check dimensions against the approved artwork
- Confirm the correct die type
- Review repeat length and register
- Approve only when the cutting notes are right
- Keep the proof for future repeats
7. Receiving, storing and repeating the die job
When the die is ready, inspect the packing before the first press run. Check that the tool arrived clean, undamaged and correctly labelled. Good storage also matters, especially for magnetic tools stored near moisture, dust or heavy stacking in a busy production area.
After the first run, note any setup settings that worked well. Keep a simple record of impression, speed and stripping performance. That helps us support repeat matching later and makes the next order faster. It also helps when a job comes back months later with a changed press team and nobody wants guesswork.
- Inspect the tool on arrival
- Store in a dry, labelled place
- Record press settings from the first run
- Report wear or damage early
- Keep repeat notes with the job card
