KY26 Automatic Die Cutter Upgrade Kit
with Integrated Waste Stripping

Why the Semi-to-Full-Auto Upgrade Is Now a Strategic Priority in Packaging

For packaging manufacturers operating semi-automatic flatbed die cutting equipment, the economics of manual operation have fundamentally shifted. Rising labor costs in key manufacturing markets, increasing customer demand for shorter lead times, and pressure on per-unit margins have converged to make automation not just desirable — but operationally necessary.

The traditional response has been capital expenditure on new fully automatic die cutting lines, with acquisition costs ranging from $150,000 to over $300,000 for modern sheet-fed presses. For mid-volume producers, this represents a significant balance sheet commitment that is difficult to justify — particularly when existing semi-automatic equipment still has productive service life remaining.

“The KY26 gives us full-auto performance on our existing press — we doubled throughput, eliminated two feeding operators per shift, and added in-line waste stripping. The capital investment was a fraction of a new machine.” — Production Manager, corrugated packaging manufacturer

The KY26 Automatic Die Cutter Upgrade Kit: Capital-Efficient Automation

The Kylin Machines KY26 Automatic Die Cutter Upgrade Kit addresses this gap directly. Rather than replacing the host die cutting press, the KY26 robotic arm system integrates with the existing machine frame to add automated sheet feeding, servo-controlled registration, and — in the KY26-1-930 configuration — integrated waste stripping, all within a compact footprint of 5m × 2m to 6m × 2m.

The system’s servo motor and PLC-controlled swing arm picks sheets from a pile of up to 1,100mm and feeds them to the existing die cutting station with consistent ±0.2mm alignment accuracy. Output is automatically transferred to the waste stripping table or receiving stack, completing the full die-cutting workflow without manual intervention.

Waste Stripping: The Critical Second Function

In folding carton and corrugated box production, waste stripping (also referred to as waste cleaning or matrix removal) is a labor-intensive secondary operation that typically requires a dedicated operator and workstation positioned downstream of the die cutter. This creates a production bottleneck and adds to per-unit labor cost.

The KY26’s integrated waste stripping module eliminates this step entirely. After each die cutting cycle, the paper pick arm transfers the cut sheet to the waste discharge table. Two adjustable waste stripping rods are positioned flush against the product edges, and the waste matrix is stripped automatically as the product moves to the receiving position. The result is a clean, finished product stack — no secondary handling required.

• Dual waste stripping rods with edge-alignment locking for consistent pressure
• Compatible with waste edge sizes of ≥5mm for reliable matrix separation
• In-line operation — no secondary station, no additional floor space required
• Supports cardboard, corrugated carton (3–7 layers), gray board, and film substrates
• Waste discharge dimensions for KY26-1-930: 1900×1710×2100mm

PLC Control, HMI Interface & Remote Support

The KY26 is controlled by a fully programmable PLC system with touch screen HMI. Operating parameters — including swing arm angles, suction timing, feed alignment, pressure values, and waste stripping rod positions — are configured through the touchscreen and stored as job recipes for quick changeover between product runs.

Kylin Machines provides remote PLC commissioning support and scheduled video call sessions with factory engineers for parameter verification, troubleshooting, and operator training. Monthly PLC program audits and data verification can be conducted remotely, reducing the need for on-site service visits and minimizing downtime for international customers.

Safety Engineering & Maintenance Standards

The KY26 operates under a comprehensive safety framework. Access to the robotic arm working area is restricted to trained, authorized operators. Emergency stop buttons are positioned for immediate accessibility. The servo system includes origin-reset verification before each shift start, and all photocells, sensors, and limit switches are designed for shift-by-shift cleaning to maintain detection sensitivity.

The recommended preventive maintenance schedule includes: daily lubrication of guide rails, chains, and bearings; bi-daily pneumatic circuit integrity checks; weekly chain, sprocket, and slide rail inspection; and monthly PLC program and parameter audits. This structured maintenance framework supports high-availability operation across multi-shift production environments.