There are three label printing cutting options available today. 20 years ago, all labels were printed on a roll and then die-cut to the required shape. This process is still used widely today and despite improvements in digital label finishing technology, it still is the most reliable finish.
Die-cutting is the process where the labels are cut to the required shape. It is like a cookie cutter process because many cookies are produced that way. The cookie mixture can be put into a metal shape and cookies can be cooked in different shapes. The label printing process is similar but more complex. The great advantage of this process is that any movement can be avoided. If your product label has lots of colour and the printing goes right to the edge of the label, then the label will be exactly the right size and a good operator can ensure the label is exactly correct on its borders.
When it comes to cutting your printed labels to the right shape, and that is the key, you want your labels to be exactly as your artwork. Even a millimetre or less in variation can spoil the look of the product label. However, the big disadvantage of die-cutting labels is the initial setup cost. A die does not need to be rectangular but more often than not it is. There are literally an infinite number of possibilities for the sizes of these dies. The cost varies but is normally well over $200 per die. It is quite possible that you could have 1,000 dies. Over the years, this would come to a cost of over $200,000 and ultimately this cost is borne by the customer.
As well as accuracy, die-cutting your printed labels is faster than other processes as the rolls of labels can move over metal dies very quickly, i.e. at a similar speed to the label printing process.
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