What are union sentences?
Union sets are embossing rollers with a positive and a negative roller structure. The accuracy of the union sets is in the micrometer (one millionth of a meter) range, as both rollers rotate against each other.
Union rollers are used, among other things, in embossing systems for the lid industry (die-cutting), but can also be used for all other embossing applications where an embossing cassette is available.
Union dies can be manufactured for logo rollers, lettering rollers and standard embossing of all kinds, as well as for all applications.
The smallest roller sets that can be manufactured today are 100 mm wide and have a diameter of 60 mm. The largest rollers that can be manufactured are 2,650 mm wide with a diameter of 477 mm. The minimum depth of structures can be in the micrometer range, while the maximum depth is 1 mm.
Union statements – What is important in 2020
The conventional method of manufacturing union fittings is long outdated due to its high environmental impact. Furthermore, the traditional manufacturing process requires the use of large quantities of acid, which poses a health risk, particularly for the employees who manufacture the tools. In addition, the acid must be neutralized at considerable expense.
Therefore, it is essential to adapt to the current zeitgeist and to utilize innovative and completely acid-free technology that revolutionizes and overshadows the outdated manufacturing method.
In addition, the significantly improved process operates with much higher precision, resulting in greater consistency of the embossing result across the entire roller width and thus representing an enormous improvement, for example, in terms of stackability or the reproducibility of embossings.
For short production runs, in addition to plasma nitriding variants, it is now also possible to laser-harden rollers using the new process.
In the plasma-nitrided version, the surface hardness is altered by approximately 0.2–0.4 mm using a plasma nitriding process. However, the surface hardness decreases between the surface and the deepest point, meaning that the hardness is not consistently increased throughout.
In the area of the deep-hardened roller, 1.5 mm to 3 mm are hardened, which reduces wear and tear.
Conclusion
Considering the significant advantages of the novel method for manufacturing union assemblies compared to the conventional process, it becomes clear how much this area needed innovation. Furthermore, taking into account extensive testing and the statements of professors who essentially confirm that the latest technology can also compete in terms of lifespan and that, contrary to some opinions, no drawbacks are apparent, there is no longer any reason to oppose adapting the manufacturing processes to a new, significantly improved standard, which can be expected in 2020.
