Creasing Matrix
Xpert Creasing Matrix products are the culmination of years of expertise and innovation, perfected in the art of creasing cardboard
What is Creasing Matrix? Here’s a brief guide…
Creasing matrix is a widely used consumable system designed for forming precise creases in cardboard during the production of packaging, point-of-sale displays, cartons, and boxes.
Developed to simplify and speed up die-cutter setup, the creasing matrix system ensures that the creasing base aligns perfectly with the creasing rule. This self-aligning feature delivers consistently accurate creases on both solid and corrugated board.
Before the introduction of creasing matrix, alignment was done manually – a time-consuming and labour-intensive process. Today, creasing matrix is an essential tool in modern print finishing, where efficiency, precision, and quick turnaround times are critical.
By ensuring accurate placement on the first setup, it minimises downtime on die-cutting machines and supports cost-effective, high-speed production.
Advanced Creasing Matrix solutions for efficient die-cutting
The self-locating design of a creasing matrix ensures perfect alignment between the creasing rule on the die cutting plate and the matrix base on the creasing plate. This precise registration allows for more complex and detailed packaging designs to be achieved efficiently on die-cutting machines. Creasing and die-cutting typically occur simultaneously using the same die cutting plate, eliminating the need for multiple passes through the press and significantly reducing production time.
Various creasing matrix profiles are available to accommodate intricate design requirements, such as creating creases close to die-cut edges or near window cut-outs in the board. For corrugated cardboard, specialised options like double creasing matrix or chamfered base profiles help minimise surface damage – particularly on heavily inked or printed materials.
In addition, reverse creasing matrix can be used to protect printed surfaces by placing the crease on the reverse side of the board. This technique not only preserves the visual quality of the printed side but also enables features like concertina folds to be produced in a single pass through the press.
How Is Creasing Matrix Set Up on a Die Cutting Template?
To set up creasing matrix on a die cutting template, each matrix strip is trimmed to match the length of the corresponding crease rule in the die pattern. These strips are then applied directly over the crease rules on the die cutting plate, with the matrix locator gripping the rule using its plastic shoulders, and the adhesive side of the base profile facing upwards. For best results – especially at fold intersections, each end of the creasing matrix should be chamfered at a 45-degree angle during trimming. This ensures clean, precise folds in corners where crease lines meet.
Once all creasing matrix strips are correctly positioned on the crease rules, the adhesive backing on each matrix base is removed. The die cutting plate is then installed in the press, aligned with the creasing base plate. When the two plates are pressed together, the matrix bases adhere firmly to the creasing base plate, automatically self-aligning to ensure perfect registration between the crease rules and matrix channels. After successful transfer and alignment, the rule alignment locators can be removed from the matrix bases, completing the setup.
Plastic Counter – Film Base
Colour Coded and labelled for easy use
Polyester base eliminates the need to adjust rule heights
Easily applied locator ensures accurate positioning
Smooth curved shoulder profile allows faster press speed
Finger lift tape speeds up time to make-ready
Selecting the correct Matrix
The following guidelines are intended as a general reference for selecting the correct size of creasing matrix. However, it’s important to consider the specific type of board you’ll be working with. Boards made from virgin fibre are typically easier to crease, as their longer fibres reduce the risk of cracking. In contrast, recycled boards contain shorter fibres and are more prone to cracking during the creasing process. Additional factors such as surface coatings and the board’s moisture content can also affect performance and should be taken into account. Once you’ve identified the most suitable matrix type for your material, the next step is selecting the appropriate size for optimal results.
There are four variables to check:
1. Crease Rule Thickness
This depends mainly on the board to be creased, and in most cases it has already been decided on by your die maker after you told him what you were cutting. You will need to know the crease thickness (conversions below). As a general rule with carton board, if the board is under 0.510mm you need to use 2pt crease. 0.510mm to 1.0mm use 3pt crease rule. For corrugated board you would normally use 3pt and above.
Crease Conversion
- 1.5pt = 0.535mm
- 2pt = 0.71mm
- 3pt = 1.07mm
- 4pt = 1.42mm
- 6pt = 2.14mm
2. Crease Rule Height
As a general rule, the height of the crease rule is determined by subtracting the board thickness from the height of the cutting rule. Your die maker will usually guide you on this based on the material you’re cutting. When working with corrugated board, it’s important to use the crushed thickness rather than the uncompressed measurement. For thicker substrates, improved delamination can often be achieved by applying slight compression during the creasing process.
So, for example…
Cutting rule = 23.8mm high
Board thickness = 0.40mm thick = Crease rule height of 23.4mm high
3. Matrix Shoulder Depth
As a general guideline, the shoulder height should match the thickness of the board. When working with corrugated board, be sure to use the crushed thickness for accurate results.
So, for example…
Board thickness of 0.40mm = Matrix shoulder depth = 0.40mm
4. Matrix Channel Width
Refer to the diagrams below for guidance. For folding carton work, calculate the channel width (B) by multiplying the board thickness (C) by 1.75, then adding the crease rule thickness (D). This applies to creasing against the grain. For creases with the grain, use the next smaller channel width.
For corrugated board, calculate the channel width (B) by doubling the crushed board thickness (A) and adding the crease rule width (D).
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For questions and enquiries regarding the creasing matrix, please contact us directly