Case Description:
Earlier this year, a US-based manufacturing company reached out to Joraco Press Company requesting a quote for a "Clean Room application to replace hydraulic clicker press." The RFQ also stated that they are "looking to purchase ASAP if the product is right." Based on our previous experience with Clean Room specifications and Die Cutting applications, Joraco was able to quickly formulate a product proposal to their project engineer that resulted in an overview meeting via Zoom, and subsequent detailed Estimate from our Sales team. A Purchase Order soon followed allowing us to finalize the design and start production.
The project was straight-forward, but there were several details that needed review before a press type could be selected, as well as the design of the tooling and fixturing. The value-added benefit that Joraco provided is in-house engineering and design; a Project Engineer was assigned the project and worked directly with the client's engineers to communicate all the guidelines and specifications we needed.
Off-the-Shelf vs. Customized Solution*
Naturally, most potential buyers would look for an "Off-the-Shelf" (OTS) solution first because that almost always means "less expensive." There are numerous products on the market that utilize Steel Rule Dies (SRDs) to die cut paper, plastic, fabric, and leather. In fact, most of the presses in the garment industry are hydraulic "clicker" style presses that are well-suited for using a high mix of SRDs in various sizes and shapes. But in our client's case, needing the clean room requirements dropped the number of OTS options to only a few. Additionally, the client wanted to avoid the size and expense of a hydraulic solution that they have currently due to maintenance issues and potential contamination hazards. 
Joraco Press Company was able to offer a best case scenario for the client:
- We could design a custom solution utilizing existing press designs that required only air pressure to operate.
- We could easily convert that press to a Clean Room Level III package including all stainless steel construction.
- We could design, fabricate, and assemble the complete solution in house in our USA facility, which allowed us to match the lead time for other options, and more importantly, provide a customized machine for the same price or less than OTS options.
Machine Configuration
The client was able to send us their SRDs and sample material in advance, so we conducted testing to make sure we chose the best press series and configuration. We needed to accommodate dies that were up to 400mm wide and material as thin as printer paper. This presented several complications involving the size of the die set that was needed. The main issue being that in order to die cut such thin material evenly over a large area, the precision and parallelism between the top and bottom die plates had to be exact. Our engineers called for a 4-post die set with extra large 1.5" guides and bushings.
We chose the TOGGLE-AIRE® Series Model 3530 benchtop pneumatic toggle press to handle the actuation. Toggle presses are inherently precise in regard to ram depth in the shut position because the linkages provide mechanical limitation and adjustment that is repeatable within 0.001". The press is capable of providing up to 16 tons of force if needed (and depending on the SRD and material thickness, all of that could be needed), but since there will be many variations in the material and dies, we made sure there was enough headspace available.
Lastly, the size of the SRDs and the material involved, the client required a simple slide tray in from of the die set to prepare the work. We utilized a 3D printer to fabricate simple guides and a backstop out of ABS plastic to help the operator guide the SRDs if needed.
Testing and Delivery
Another value-add Joraco Press Company offers is Factory Acceptance Testing (FAT) here in the same facility where we engineer, fabricate, machine, and assemble our presses and solutions. Not only were we able to test some final samples using the actual SRD's and material we had on hand before the client's arrival, but we also have the ability to make any last minute changes or adjustments during the FAT to ensure it passes all quality checks. When the project engineer arrived, they were able to breeze through their checklists quickly and successfully. 
Our client left our facility confident that the machine works to the specifications, as well as first hand knowledge of how to set the machine up when it arrives in a few days time via FedEx Freight. The client will have some internal procedures for fixturing the machine in the clean room environment, but unlike any other option on the market, it will only require a single air line to operate and start producing cuts immediately. No electricity, no hydraulic fluids and set up, and no research and calibration prior to operation.
Customized Solutions* from Joraco Press Company
Joraco Press Company and Automated Industrial Machine, Inc have decades of experience designing and building custom press machines for every industry. Our US based manufacturing facility has engineering, machining, and assembly operations all under one roof! We are flexible and equipped to customize any of our standard products, as well as design custom products from the ground up.
Nearly 70% of our presses are shipped with some form of customization, whether it is the addition of Packages, Options, or Accessories, or it is a complete multi-head automated assembly system. Our value-added approach to Manufacture-to-Order machine building puts us ahead of our competition in cost, customization, and delivery.
* We should differentiate "Custom Solution" from "Customized Solution" because Joraco Press Company has a range of standard presses, packages, options, and accessories that we use as a base for customization. We are able to provide clients with a custom machine for their specific project and application, but still provide the backend parts and service support operators need to keep their machine running for decades. Our small, but vertically integrated operation is paired perfectly with over 75 years of legacy products, designs, and knowledge to assure our machines are less susceptible to obsolescence.