Label Cutting Options

Die Cutting or Laser Cutting: Which Is Right for Your Labels?

Modern label production offers two different methods for cutting labels from a material: conventional die cutting and laser cutting technology.
With conventional die cutting, a physical cutting tool is mounted onto a die-cutting cylinder. As the cylinder rotates, the desired label shape is cut from the material.

Laser cutting, on the other hand, uses a highly precise laser beam to cut the material. Because no physical cutting tools are required, virtually any shape can be produced. The laser is controlled digitally, allowing for maximum flexibility and fully automated production.

Laser Cutting

Laser cutting is a state-of-the-art process that uses a laser beam to cut labels to the required shape and size.

Advantages:

1. Flexibility: no cutting tools need to be manufactured, meaning virtually any shape or size can be produced immediately.
2. Price: laser cutting is generally more economical for short production runs, as it requires less set-up time and less material for machine calibration.

Disadvantages

1. White Edges on Dark Designs: this mainly affects fully printed labels with dark colours such as black, navy blue or dark brown. Depending on how the laser cuts the label, tiny white edges may occasionally become visible. On dark containers or bottles, this can affect the overall appearance of the finished product.
2. Large Formats: for large labels, two laser beams may be used during production. In rare cases, the point at which the beams meet may not be perfectly aligned, creating a very small edge.
3. Backing Material Marking: the laser can leave slight marks on the release liner (or backing material), which may occasionally affect further processing.

Conventional Die Cutting

With conventional die cutting, a custom-made cutting tool is manufactured to match the exact shape and size of the label. The tool is then mounted onto a magnetic cylinder within the finishing equipment.

Advantages

1. Suitable for All Materials: there are virtually no restrictions regarding material choice. Papers, films and thicker materials can all be processed regardless of shape, size or material thickness.
2. Cost-Effective for Long Runs: although set-up takes slightly longer, conventional die cutting becomes more economical for larger production runs. Once production begins, running speeds are generally higher and more efficient than laser cutting, while consuming less energy.

Disadvantages

1. Higher Set-Up Costs: conventional die cutting is typically more expensive for shorter runs because a custom cutting tool must be produced and additional set-up time is required.

Get in Touch With Us

Where both cutting methods are available, the best choice will depend on your specific requirements, artwork and order quantity.
If you would like to learn more about the differences between conventional die cutting and laser cutting, our team will be happy to help.

Call us on +44 203 588 1080 or email info@label.co.uk.