The 6 Basic Converting Capabilities That You Need To Know if You Work With Flexible Materials

When you’re stuck navigating the ©2009 digital fossils that define the majority of manufacturing websites, how do you decide who can get the job done?

Strouse has spent 38+ years helping customers turn flexible materials into complex product solutions. While every project is unique, the capabilities remain relatively the same. That’s why we can help explain the basics for your project.

Understanding these basic capabilities will help you identify which solutions will work for your project.

Here Are the 6 Crucial Converting Capabilities

For a company to consider itself an experienced converter, it should possess the following manufacturing processes.

1. DIE CUTTING

Die cutting refers to the process of using a die cut tool to punch shapes out of material, like a cookie cutter, for increased production efficiency.

There are four primary die cutting types:

1. Rotary Die Cutting — uses a specially made die cut tool on a rotary machine press to punch out parts. A rotary machine press is a device with a rotating cylindrical surface that applies the tool to the material as it moves through.
2. Laser Die Cutting — uses a focused laser beam to cut pieces out of the material without physical tools. The laser beam is a highly concentrated light that melts or vaporizes the material along the cutting path.
3. Flat Bed Die Cutting — uses a custom die cut tool on a flat bed machine press. A flat bed machine press is a device with a flat surface where the material is cut by pressing the tool down into it.
4. Tool-Free Digital Converting — uses digital processes, not physical die cut tools, to make small quantities of adhesive parts in custom sizes and shapes. Digital processes are computer-controlled techniques for cutting materials.

See Strouse’s Die Cutting Capabilities

2. SLITTING

Slitting is the process of cutting a large roll (or log) of material into several smaller rolls. The “logs” manufacturers sell can reach up to 15,000 feet long, so slitting makes them more manageable for machines or for regular use.

See Strouse’s Slitting Capabilities

3. LAMINATING MULTIPLE MATERIALS

Laminating in converting means joining two different materials, such as adhesive tape and backing liners, to form a custom product. Each material (a liner, film, or adhesive) brings its own properties to the final result, and combining them can create features that are better than using any one alone.

Lamination is an alternative to bonding (joining by glue, heat, or mechanical fasteners) that your converter can perform during die cutting, completing both processes in a single machine pass.

See Strouse’s Material Lamination Capabilities

4. FLEXOGRAPHIC PRINTING

Flexographic printing, or "flexo printing," uses rollers to transfer ink from a tray to the material. The rollers ensure the ink is spread evenly. Flexographic printing is a common industrial printing method because of its speed and flexibility.

Converters use flexographic printing on adhesives, liners, and labels to print custom logos, product instructions, or identification labeling. Strouse integrates printing into die cutting services so individual parts can be cut and printed more efficiently.

See Strouse’s Printing Capabilities

5. AUTOMATED ASSEMBLY

Automated assembly can mean anything from a single placement machine to 50 placement machines assembling your product in a complex line.

The goal of automated assembly is to reduce labor costs while improving efficiency through cutting-edge technology. In manufacturing, human interaction in automation is limited as machines assemble components into a product.

See Strouse’s Automated Assembly Capabilities

6. CLEANROOM MANUFACTURING

Many products and materials require a strict manufacturing environment to pass FDA guidelines or function properly:

• Medical devices
• Genetic/DNA test strips
• Microfluidic products
• Bandages
• Wound dressings
• Hydrogel

An environmentally controlled cleanroom is an enclosed space equipped with a highly powerful air filter and an industrial humidifier to keep parts free of biological contamination and moisture during production. This is often a must for medical, electronic, and optically clear part components.

See Strouse’s Cleanroom Capabilities

Determine Your Desired Level of Converting

When creating a product, you may not need all of the bells and whistles.

While simple projects can be handled with basic equipment, advanced designs often require specialized converting expertise and technology.

Ask yourself the following before you invest:

• Will my project use multiple converting processes?

1. Complex part designs often lead to complex machine setups that require additional process trials. If this is the case, you’re likely better off outsourcing parts from a converter.

• Do I have the necessary equipment and skilled personnel?

1. Converting machines can cost hundreds of thousands of dollars… definitely not a careless investment.
2. Assembling a custom press set-up and performing test runs requires a high level of technical know-how.

These factors will decide whether it is more cost-effective to acquire machines yourself or to use a converter.

Will Strouse’s Converting Capabilities Match Your Project?

At Strouse, we believe in providing clear recommendations for our clients based on what is best for their manufacturing objectives. If you’re looking for product solutions, this section will help determine whether our manufacturing capabilities align with your project needs.

DIE CUTTING

Strouse handles the majority of jobs on our rotary die cut presses, which produce large part quantities, but we’re more than capable of handling the following specifications:

Depending on your needs, Strouse can cut MOST flexible materials. However, all materials have different levels of processability, which can result in higher pricing due to press setup and complex tolerances.

SLITTING

If you need a material, but it only comes in huge lengths, Strouse can slit your larger rolls into smaller, individual sizes:

LAMINATING MULTIPLE MATERIALS

We can combine up to 15 materials on many of our machine presses and 20+ on specialized presses, depending on your needs.

Other laminating specifications:

At Strouse, we offer:

• Multi-layer lamination
• Extended liner lamination
• Zoned adhesive lamination
• Heat lamination
• Liner substitution
• Island placement/Dispensing
  
  

PRINTING

These are Strouse’s printing capabilities:

Certain ink chemistries, such as white ink, contain abrasive or more challenging elements to process. While Strouse often can process these chemistries, they require more tooling at greater expense.

As long as you understand the size limitations and potential costs, Strouse can handle a wide variety of printing processes.

AUTOMATED ASSEMBLY

Strouse partners with component placement manufacturers to develop automated solutions and uses their machines to produce parts through highly accurate automated assemblies.

Whether you’re considering automated assembly or have already established an automated system, Strouse has the skills and experience necessary to optimize your component design for assembly. Regardless of where you are in the automation process, we can help you figure out a product assembly setup that works for you.

CLEANROOM MANUFACTURING

Strouse’s cleanroom has ISO 7 certification, meaning the maximum air particle count (0.5 microns) cannot exceed 352,000 particles per cubic meter. Air cleanliness is also referred to as “Class 10,000,” as it contains 10,000 particles per cubic foot.

In addition, the ISO 7 system filter undergoes at least 60 air changes per hour and maintains a relative humidity of 10-25%, while the filtration system must be 9-16 CFM per square foot. To put this in perspective, the air inside our ISO 7 cleanroom is more than 100x clener than ordinary air.

Although Strouse covers many industries, there are certain services we don’t offer. We’re primarily a flexible material converter, but lead times for materials or die cut tools can be out of our hands. Here are the most commonly asked examples of projects and services Strouse does NOT cover:

• Warehousing Material — Strouse primarily stores materials for jobs we’re currently working on.

• Building Tools — Strouse doesn’t produce die cut tools. After you submit your part drawing, we make adjustments and forward it to a die cut toolmaker who then constructs a tool.

• Project Design (from scratch) — If you don’t have any rudimentary design or napkin drawing with measurements, we cannot definitively confirm whether we can make it.

• Sterilization — While Strouse can produce parts in a sterile environment, you’ll need to outsource complex sterilization processes to other companies.

What Can Strouse Do For My Manufacturing Project?

Ultimately, Strouse has other abilities beyond those listed. Still, the majority of our operations fall under those categories.

If you’re still unsure whether Strouse can complete a project to your specifications, reach out to us directly to see whether we can help you find a solution:

Otherwise, feel free to check out our Learning Center for more educational resources on our services.

Originally published: March 7, 2023