What Materials and Applications Can Be Die-Cut with the Swiss Die-Cutter™ B4?
Swiss Die-Cutter™ B4 – Precision and Versatility in Die-Cutting of Foil, Film, Paper & More
Die-Cutting Use Cases
Flat Lids
Recessed | Deep-Drawn Lids
IML In-Mold Labels
Bottle Labels
Die-Cutting Materials & Thickness Compatibility
Aluminium foil: 25–100 µm (microns)
Compound or laminated plastics: 30–200 µm (microns)
Plastic film / BOPP: 35–100 µm (microns)
Paper substrates: 60–200 µm (microns)
Die-cutting beyond the indicated material thickness range — potentially below 25 µm or up to 300 µm — may be possible but must be confirmed through testing with your original material or substrate.
👉 Contact us for a sampling, developments or feasibility check.
Die-Cutting Applications
Lids
Labels
Seals
Special Products
Lids for tobacco boxes (ALU / PP)
Laundry detergent label (synthetic paper)
Clear label for shampoo (OPP)
Laundry detergent label (synthetic paper)
Carrier film for contact lenses (ALU / PP)
Carrier film for contact lenses (ALU / PET / PP)
Lids for pharmaceutical products (ALU / PP)
Pet Food Supplement Label (Composite Material)
Pet food lid (ALU / PP)
Pet food lid (ALU / PP)
Pet food lid (ALU / PP)
Pet food lid (ALU / PP)
Label for beer bottles (paper wet glue)
Dessert lid (ALU / HSL)
Lid for milk drink (ALU / PE)
Lid for coffee capsules (ALU / PP)
Circuit board for coffee capsule (ALU / PP)
IML for salad containers (BOPP)
Label for ice cream cone (paper)
IML for margarine containers (BOPP)
Deckel für Fertiggerichte (PET/PP)
Lid for container (BOPP)
Multipack lid for quark (PET / HSL)
Lid for dessert (PET)
Lid for container (BOPP)
Lid for canned meat (ALU / PP)
Lid for cream cheese (ALU / HSL)
Yoghurt lid (ALU / HSL)
Lid for dessert (ALU / HSL)
Key Facts
Swiss Die-Cutter™ B4
227'000
Output up to 227'000 lids and labels per hour with tool 10up Ø 75.5 mm
500
Maximum 500 strokes/min
13
Up to 13 servo drives for an optimal production quality
450 x 510
Tool area 450 x 510 mm for maximal cavities
100
Up to 100 m/min. processing speed and 195m/s2 accelerate
1.9
Power consumption 1.9 kWh only, less than a hairdryer
Highlights
Swiss Die-Cutter™ B4
Output
Ultimate production output. Highest profitability. High-end punching for material widths up to 430 mm and punching speeds up to 500 strokes per minute. Perfectly suited for single-row, double-row and multi-station punching tools.
Drive
Digital punching drive. Highest precision. Freely controlled punching movement, adjustable opening stroke, digitally monitored cutting depth, new active foil guide in the punching tool for optimum dimensional accuracy.
Plug & Play
Intelligent networking. Data-driven service. Reliable monitoring of punching machines, RFID recording of tool and embossing data, dashboard with live data and data analysis, visualization of operating data, OEE and KPI's.
60+
More than 60 years experience in die-cutting
32+
More than 32 years experience in IML
30+
More than 30 years experience in remote support
10+
More than 10 years experience in robotics
7x
7-times Innovater
of the Year
1
The number one
in die-cutting
Info Sheet
Swiss Die-Cutter™ B4
CUTcontrol™ – Smart IIoT Service Platform for Die-Cutting
Boost die-cutting efficiency with real-time data, predictive maintenance, and intelligent monitoring. CUTcontrol™ offers full transparency, live dashboards, and optimized machine utilization to reduce downtime and maximize performance. Make data-driven decisions with our advanced IIoT solution. The basic CUTcontrol™ platform is free for all BERHALTER Swiss Die-Cutter™ B4 and B6 customers.
Die-Cutting Tools
High-precision die-cutting tools optimally tailored for every job. Small to large die-cutting jobs, simple to very complex die-cutting geometries, single-row and double-row die-cutting tools, single or multi-station die-cutting tools for deep drawing, perforation, creasing, die-cutting, doming and embossing.
Upgrade your System
Maximum added value with the additional options INNOVATION by die-cutting. Expand your die-cutting machine and increase quality, efficiency and productivity. This is made possible by our modular system with high-tech components, which can be tailored to your individual requirements.
BEAMstack™- robot for automated counting, separating, packaging
SMARTembosser™ – patented embossing system for rim-embossing
PRElaser™ – Laser system for additional functions as perforation
REELsplicer™ – In-register reel changing and splicing system
WEBslitter™ – production enhancement system
PRINTinspect™ – 100 % print inspection system
WEBinspect™ – 100 % web surface inspection system
Frequently Asked Questions (FAQ) About Die-Cutting Challenges and Solutions
Effective Solutions to Common Problems and Issues.
I have problems with lid curling in die-cutting. How do I stop it?
1Solution: BERHALTER Swiss Die-Cutting’s advanced anti-curling technology
By reducing foil deflection, BERHALTER Swiss Die-Cutting machines minimize material distortion, effectively preventing lid curling and ensuring high-quality output. Lid curling is a frequent issue in standard die-cutting machines across global industries, often caused by excessive foil deflection. BERHALTER Swiss Die-Cutting machines are engineered to prevent this by minimizing material distortion and ensuring optimal processing.
I have foil, film, or material misalignment issues. How does pre-centering ensure precise positioning?
1Solution: BERHALTER Swiss Die-Cutting’s pre-centering system
Fully automatic roll pre-centering ensures precise alignment of the roll/reel and material right from the start, preventing initial misalignment and ensuring accurate print-to-die registration from the very beginning of the process.
I struggle with foil, film, or material drifting. How does web guiding stabilize alignment?
1Solution: BERHALTER Swiss Die-Cutting’s web guiding system
Fully automatic foil/web guiding system ensures precise material alignment throughout the die-cutting process, preventing foil from running off track, compensating for deviations, and ensuring smooth, controlled foil movement for optimal print-to-die registration.
I experience unstable foil, film, or material tension. How does tension control improve stability?
1Solution: BERHALTER Swiss Die-Cutting’s tension control system
Fully automatic tension control further ensures precise material/foil alignment, preventing material shifts and ensuring consistent and stable die-cutting performance. Roll/material/foil alignment ensures consistent tracking and registration, eliminating common misalignment challenges in conventional die-cutting processes. Many die-cutting machines worldwide struggle with foil misalignment, leading to registration inconsistencies due to inadequate web guiding and tension control. BERHALTER Swiss Die-Cutting’s advanced pre-centering and web guiding systems ensure precise alignment, eliminating such risks and optimizing production efficiency.
I can’t achieve consistent foil flatness. What’s the solution?
1Solution: BERHALTER Swiss Die-Cutting’s automated break and redressing device
BERHALTER Swiss Die-Cutting’s fully automated, servo-controlled break and redressing unit ensures optimal foil flatness, eliminating inconsistencies common in standard die-cutting machines. Across various industries, maintaining consistent foil flatness in die-cutting can be difficult, leading to reduced precision and material handling issues. BERHALTER Swiss Die-Cutting’s technology eliminates these issues by ensuring superior material handling and precise flattening control.Our die-cutting solutions provide superior handling and precision, ensuring consistently flat material throughout the process.
I need stable foil tension for better die-cutting results. What should I use?
1Solution: BERHALTER Swiss Die-Cutting dancer unit
Maintaining stable foil tension is critical for consistent die-cutting results. The BERHALTER Swiss Die-Cutting dancer unit is specifically designed to prevent fluctuations, ensuring precise material handling and uniform flatness throughout the process. With continuous, stable contact, the BERHALTER Swiss Die-Cutting dancer unit maintains optimal tension control, preventing material fluctuations and ensuring precise, high-quality die-cutting.
I have a problem with foil slipping, causing print-to-die registration issues. How can I prevent this?
1Solution: BERHALTER Swiss Die-Cutting’s patented adjustable feeding roller pressure control
BERHALTER Swiss Die-Cutting’s innovative adjustable feeding roller pressure ensures precise control over foil movement, effectively eliminating slippage problems and maintaining perfect print-to-die registration. Foil slipping is a common challenge in standard die-cutting machines worldwide, often caused by insufficient roller pressure control in conventional systems. BERHALTER Swiss Die-Cutting eliminates this issue with its advanced roller pressure control, ensuring smooth and precise foil movement. BERHALTER Swiss Die-Cutting’s technology is designed to prevent such issues by ensuring precise foil movement and maintaining perfect print-to-die registration.
