What processes follow label printing? Detailed explanation of 3 processes: die-cutting / slitting / rewinding

Last week, a client running an emerging beauty brand asked me: "The labels are printed — what else needs to be done after printing?"

I said: "Three processes — die-cutting / slitting / rewinding. Each one determines the final quality."

He asked, "Determines what?"

I said: "Die-cutting determines the shape (whether it can be peeled off), slitting determines the size (whether it can be applied), and rewinding determines the quality (whether it is easy to use). This article will not cover 'how to print labels' — it explains the three post-press processes in detail, and for each process it tells you 'what to do + common issues + quality control.'"

Overview of 3 Post-Press Processes

Process 1: Die-Cutting (Determines Shape)

3-Step Process

Step 1: Mount the Die-Cutting Plate

Operation:

• Install the die (steel blades assembled into the design shape) on the die-cutting machine
• Adjust the die plate position (using laser positioning)
• Secure the die plate (pneumatic / manual)

Die Plate Types:

• Rotary-to-Rotary Die Plate: continuous die-cutting, high efficiency (10,000-20,000 sheets/hour)
• Rotary-to-Flat Die Plate: high precision (±0.1mm), medium efficiency (5,000 sheets/hour)
• Flat-to-Flat Die Plate: small batches, low efficiency (1,000 sheets/hour)

Step 2: Adjust Machine Pressure

3 Pressure Parameters:

• Paper Thickness——80-100g coated paper, low pressure
• Synthetic Paper / PET——high pressure (rigid material)
• Die-Cutting Depth——cut through the face stock but not the liner (half-cut)

Step 3: Batch Die-Cutting

3 Types of Die-Cutting Machines:

3 Common Die-Cutting Issues

Issue 1: Die Wear

Symptom: Cut edge not vertical, burrs on the edge

Cause: Die plate wears out after 1 million uses

Solution: Replace the die every 1 million uses (cost 500-1,500 yuan)

Issue 2: Die-Cutting Misalignment

Symptom: Label size deviation of ±0.5mm

Cause: Unstable paper tension / insufficient die-cutting machine precision

Solution: Use a Class A precision rotary-to-flat die-cutting machine (±0.1mm)

Issue 3: Rough Edges

Symptom: Burrs on label edges, not smooth

Cause: Die-cutting depth too deep (cuts through liner) or too shallow (incomplete cut)

Solution: Fine-tune die-cutting pressure + laser positioning

Process 2: Slitting (Determines Size)

3 Precision Controls

Precision 1: Slitting Blade Accuracy

3 Types of Slitting Blades:

Precision 2: Tension Control

3 Tension Requirements:

• Stable web tension during slitting (avoid stretching)
• Excessive tension: label deformation
• Insufficient tension: label wrinkling

Precision 3: Winding Neatness

3 Acceptance Checks:

• Flat roll ends (≤ 0.5mm deviation)
• No obvious wrinkles
• No lateral offset

3 Common Slitting Problems

Problem 1: Misalignment

Symptom: Uneven roll edges

Cause: Slitting blade wear / unstable tension

Countermeasure: Replace blade + adjust tension

Problem 2: Tensile Deformation

Symptom: Labels elongated by 1-2%

Cause: Excessive slitting speed + excessive tension

Countermeasure: Reduce speed + lower tension

Problem 3: Wrinkling

Symptom: Uneven roll ends

Cause: Uneven rewinding pressure

Countermeasure: Adjust rewinding pressure for uniformity

Process 3: Rewinding (Determines Quality)

3 Core Functions

Function 1: Appearance

Standard: Neat roll ends, no wrinkles, accurate count

Function 2: Counting

3 Counting Methods:

• Manual counting (high error)
• Electronic counter (±1 sheet error)
• Laser counter (±0 sheet error)

Function 3: Packaging

3 Rewind Packaging Methods:

• Single-roll shrink film (most common)
• Multiple rolls per carton
• Single roll + individual box (premium)

3 Common Rewinding Issues

Issue 1: Inaccurate Count

Symptom: Roll specified as 1000 sheets but actually contains 1001 sheets

Cause: Counter not properly calibrated

Solution: Weekly calibration + cross-verification with multiple counters

Issue 2: Excessive Tension

Symptom: Labels stretched and deformed

Cause: Rewinder tension set too high

Solution: Reduce tension to appropriate value

Issue 3: Insufficient Tension

Symptom: Loose roll ends, prone to unraveling

Cause: Rewinder tension set too low

Solution: Increase tension to appropriate value

3-Process Workflow Linkage

Printing Complete → Die-cutting (determines shape) → Slitting (determines dimensions) → Rewinding (determines quality) → Packaging and Warehousing
   ↓             ↓              ↓                ↓              ↓
 Print sheet   Die-cutting plate + precision   Slitting blade + tension   Counting + tension   Roll / Sheet

5 Common Quality Issues Troubleshooting

Issue 1: Die-cutting Misalignment

Troubleshooting:

• Whether the die-cut plate is worn
• Whether paper tension is stable
• Whether the die-cutting machine precision is ≥ Grade A

Issue 2: Rough Edges

Troubleshooting:

• Whether the die-cutting depth is appropriate
• Whether the die is dulled
• Whether the backing paper thickness is sufficient

Issue 3: Slitting Deviation

Troubleshooting:

• Slitter blade precision
• Tension setting
• Roll material quality

Issue 4: Wrinkling

Troubleshooting:

• Rewinding tension
• Roll material moisture
• Rewinding pressure

Issue 5: Counting Inaccuracy

Troubleshooting:

• Counter calibration
• Manual vs. automatic comparison
• Error tolerance

If you would like to see die-cutting details — refer to the detailed explanation of label die-cutting process, or directly contact a LeXiang Packaging consultant, we will provide you with a post-print solution and quotation within 24 hours.