Marbach consolidates its full-rubber cutting die to prevent inner layer bursting in recycled corrugated board

Processing corrugated board with high recycled fiber content presents an unavoidable mechanical challenge during the die-cutting phase: surface tension tends to fracture the inner layers. To mitigate this operational waste, the German manufacturer Marbach continues to drive the adoption of its marbacover|2.0 technology, a cutting die specifically designed to stabilize substrates with lower structural quality.

The architecture of this tool stands out for its full rubber coverage. As detailed by Ralf Nuyken, Industry Manager at Marbach, this configuration ensures that the corrugated board is compressed evenly over its entire surface during the die-cutting impact. By distributing the pressure, the localized stresses that cause the inner layers to burst are drastically reduced, achieving a clean cut with only a slight loss of caliper (material thickness).

In the industrial context of 2026, where circular economy regulations force converters to work with lower basis weights and shorter fibers, the mechanical stress tolerance of the boards has decreased. The bursting of inner liners not only affects the aesthetics of the final packaging but also compromises its box compression test (BCT) performance and causes jams in high-speed folding and gluing lines.

The marbacover|2.0 system addresses this operational bottleneck by being compatible with almost all current corrugated board qualities and operating seamlessly alongside standard creasing systems. The standardization of this type of specialized tooling reflects a clear trend in the converting sector: preparation machinery and tooling must compensate for the mechanical deficiencies of sustainable materials to maintain the profitability and speed of packaging lines.