Converting Conversations | Episode 2 Recap: Score Slitting in Converting

Score slitting—also called crush cutting—is one of the most widely used methods for processing pressure-sensitive materials. In Episode 2 of Converting Conversations, we dive into how score slitting works, where it performs best, and what makes it different from other methods like shear or razor slitting.

If you handle tapes, foams, or nonwovens, this is one method you’ll want to master.

What Is Score Slitting?

Score slitting uses a round, unsharpened knife that presses material against a hardened anvil roll. Unlike razor or shear methods, score slitting relies on force and contact—not blade sharpness—to make the cut.

The key is balancing pressure. The blade must apply enough PSI to cut cleanly through the substrate without prematurely dulling or damaging the roll. Most setups use air holders (pneumatics) to fine-tune this contact.

Ideal Materials for Score Slitting

Score slitting is commonly used for:

• Adhesive tapes (transfer, double-coated, foam)

• Laminates with foils or scrims

• Nonwovens (spunbond, meltblown, spunlace)

• Some films and papers (when no other slitting type is installed)

For woven or fabric-based materials, score slitting may be paired with hot knife elements to seal frayed edges during the cut.

Blade and Roll Considerations

The Rockwell hardness of the anvil roll typically ranges from 63–65, ensuring long-term durability. Knives come in various angles (30°, 45°, 60°) and radii to match material types and cutting results.

Keeping the blade lubricated (wicking) is critical when cutting adhesives to prevent picking or buildup. Episode 2 showcases options like:

• Auto wicking systems

• Individual wick-fed holders

• Felt wicks for continuous lubrication

Automated Score Slitting

High-volume tape converters benefit from auto-positioning score slitting systems with 60–140+ knife holders. These allow quick changeovers between sizes (e.g., 1″, 1.5″) and reduce setup time in short-run production environments.

Systems can handle web widths from 62 to 72 inches, making them ideal for demanding, multi-cut applications.

When to Use Score Slitting

Choose score slitting when:

• Running pressure-sensitive materials with adhesives

• Cutting multiple lanes of tapes or laminates

• Edge sealing is needed for fabrics

• Shear/razor options aren’t ideal or available

Watch the Full Episode

Want to see the breakdown in action? Episode 2 of Converting Conversations explains how different razor configurations can improve cut quality, speed, and efficiency.