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Sharpening the edge

In label and narrow web production, where milliseconds matter and microns make the difference, die cutting is no longer just about cutting shapes – it’s about cutting waste, costs and complexity.

7 May 2025
in Efficiencies
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01 New ROTOCON DieCut ED

For Patrick Aengenvoort, director of print technology specialist ROTOCON, the revolution is already here, driven by intelligent automation, precision engineering and a hunger for relentless optimisation.

‘The days of slow, manual set-ups and inconsistent cuts are long gone,’ Patrick says from ROTOCON’s sleek Johannesburg-based facility. ‘With our CHROME range of high-speed die cutting equipment, we’ve completely changed the pace and precision converters can expect.’

The CHROME range is powered by advanced servo motor systems and robust drive mechanisms that allow for production speeds once thought impossible. Rotary die cutters now churn out volumes that effortlessly meet the demands of today’s hyper-efficient print operations. But, as Patrick is quick to point out, speed without control is meaningless. That’s where the integration of Wink’s SmartGap® system comes in.

‘This system gives you pinpoint control over cutting depth on both sides, with a construction so stable it practically eliminates vibration,’ he explains. ‘It’s the difference between good and flawless.’

In an industry where set-up time can devour profit margins, ROTOCON has made automation its not-so-secret weapon. Die stations are engineered for fast, intuitive set-up – allowing operators to move from job to job with minimal downtime. The synergy between these stations and the SmartGap® technology slashes waste and boosts efficiency, while protecting components from excessive heat and premature wear.

‘It’s not just about speed, it’s about smart speed,’ Patrick notes. ‘Everything we’ve built into the CHROME range – from the software to the cylinder tolerances – reduces material usage and keeps your cutting tools running longer.’

02 DieCutting ROTOCON Apr25 ED
04 New ROTOCON DieCut ED

Precision is equally pivotal. ROTOCON’s in-house manufactured rotary and flexible dies, paired with its meticulously balanced magnetic cylinders, create consistently clean cuts – even for the most intricate label designs. As a result, converters enjoy better yield, less scrap and higher aesthetic appeal – essential in today’s competitive marketplace.

‘You’re not just saving time, you’re saving money,’ says Patrick. ‘Speed plus precision equals lower cost per unit. That’s where the value lies.’

02 New ROTOCON DieCut

To keep up with the growing appetite for complexity – delicate substrates, tight tolerances and eye-catching embellishments – ROTOCON has significantly invested in new high-precision machinery and advanced CAD software. Its Johannesburg facility, a cutting-edge hub of tooling production, is geared to meet the escalating demands of both local and export markets.

‘Our goal is to increase production capacity while staying at the forefront of innovation,’ he reveals. ‘We’re building the future of die cutting right here.’

And that future is green. ROTOCON is quietly yet diligently embedding sustainability into every layer of its operations. From R&D into eco-friendly materials and waste-minimising processes to exploring renewable energy sources, the company understands that tomorrow’s success hinges on responsibility as much as it does on performance.

‘The industry is moving towards cleaner, leaner production,’ Patrick concludes.

In ROTOCON’s world, die cutting isn’t a static function. It’s a dynamic, evolving dance of speed, precision and purpose. And with each new innovation, the edge gets sharper.

03 New ROTOCON DieCut
01 DieCutting ROTOCON Apr25
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