Cut Inefficiency Out of Converting Lines with Intelligent Rotary Cutting Solutions
Production Challenges Undermine Line Performance
High-speed converting lines face a variety of challenges, especially when they are not monitored closely or running optimally. Rotary die cutters can wear prematurely, causing frequent tool changes that reduce productivity and inflate costs. Cutting precision can be lost at high speeds, resulting in quality issues and unnecessary material waste. And the technical resources needed to maintain performance and troubleshoot issues are often limited.
As converters process increasingly more expensive materials, such as nonwovens for wound care or separators for lithium-ion batteries, the demand for cutting accuracy and durability increases. Traditional tools often fail under these conditions, creating inefficiencies that negatively impact the bottom line.
Intelligent Tools Create Smarter Production Lines
Hyperion’s IQUT intelligent rotary cutting extension transforms cutting into a measurable, controllable process that maximizes uptime. By embedding sensors into rotary cutting modules to monitor critical cutting parameters and ensure optimal operation, IQUT delivers:
- Extended tool life to reduce changeovers and stabilize production
- High-speed precision cutting for more consistent quality and better material utilization
- Predictive maintenance through continuous monitoring and real-time alerts
- Remote access and guided troubleshooting to support lean teams
- Performance insights for continuous improvement and cost efficiency
Prevent Failures Before They Disrupt Production
IQUT continuously monitors critical parameters such as temperature, vibration, vacuum levels, and cutting performance to detect deviations before failure occurs. Real-time alerts enable proactive maintenance, reducing downtime and extending production runs.
With the ability to shift from reactive to proactive maintenance, converters achieve:
- Longer intervals between cutter replacements
- Reduced operating costs for spare parts and labor
- Improved throughput and operational stability
For operators seeking a retrofit option when sensors cannot be embedded, Hyperion’s KITQUT extension delivers IQUT’s core functionality.
Learn how IQUT and KITQUT can cut inefficiency out of high-speed rotary cutting. Discover all the details in the full article and request a consultation to find out how Hyperion can optimize your operation.
