Rotary vs Flat-Bed Die Cutting Machine for Hologram Labels
By Rajneesh Sharma, Owner, Kiran Holographics
A hologram label is not finished until it is cut to shape. Round seals, oval logos, rectangles, custom shapes with tamper-evident cuts: all of these are made on a die cutting machine. The die cutter decides how clean your labels look, how fast you can deliver, and how easily you can take on new shapes.
There are two main types: rotary and flat-bed. This guide explains how each works and which one suits your plant.
What does a die cutting machine do?
A die cutter uses a sharp, shaped tool called a die to cut labels from a roll of hologram material. For self-adhesive labels, the die usually cuts through the label layer but not the backing liner. This is called a kiss cut. The waste around the labels is then stripped away, leaving finished labels on the liner, ready for an applicator or for hand use.
Rotary die cutting
In rotary die cutting, the die is a cylinder. The material runs continuously between the die cylinder and an anvil roller, and labels are cut as the roll moves, roll to roll, without stopping.
Advantages:
- Very high speed, because the material never stops
- Consistent cutting over long runs
- Well suited to large, repeat orders
Things to consider: rotary dies usually cost more and take longer to make, so they make the most sense when you run the same shape again and again.
Best for: high-volume labels for regular customers, such as pharma, FMCG and liquor brands.
Flat-bed die cutting
In flat-bed die cutting, the die is flat. The material moves forward, stops, and the die presses down to cut, then the cycle repeats. Our flat-bed die cutter runs at up to 960 mm per second.
Advantages:
- Flat dies are generally lower in cost and quicker to make
- Easy to change shapes between jobs
- Good for larger label sizes and complex shapes
Things to consider: because the material stops for each cut, flat-bed is usually slower than rotary on very long runs.
Best for: short runs, new designs, sample orders and plants that handle many different label shapes.
Rotary vs flat-bed: quick comparison
| Point | Rotary | Flat-bed |
|---|---|---|
| Cutting motion | Continuous, roll to roll | Stop and press |
| Speed on long runs | Higher | Lower |
| Die cost | Higher | Lower |
| Changing shapes | Slower, new cylinder die | Quick, new flat die |
| Best for | Large repeat orders | Short runs, many shapes |
Which one should you choose?
Choose rotary if most of your work is large, repeat orders of the same label shapes, and speed is your main goal.
Choose flat-bed if you handle many small orders, change shapes often, or are just starting and want lower die costs.
Many established plants run both: rotary for their big regular customers, and flat-bed for new designs and short jobs.
Die cutting and tamper-evident labels
Tamper-evident hologram labels often have special cuts that make the label break apart if someone tries to peel it off. Clean, accurate die cutting is what makes these features work. Learn more in our guides on types of holograms and pharma hologram labels.
Where die cutting fits in your plant
Die cutting sits in the finishing stage, after slitting and before labels go to an applicator. Its width and speed must match the rest of your line.
Die cutting machines made in Jaipur
At Kiran Holographics, we make both rotary and flat-bed die cutting machines in-house in Jaipur, built to work with our full hologram production line. Buy a single machine or a complete turnkey hologram plant with installation and training.
We have been in the holographic industry since 2002. Tell us your label shapes and monthly volume, and we will suggest the right die cutter. Get a quote and we will reply within one working day.
About the author: Rajneesh Sharma is the owner of Kiran Holographics, Jaipur, a security hologram manufacturer since 2002. He leads the work from client designs and origination to exports and plant projects.