Converting Conversations | Episode 3 Recap: Shear Slitting in High-Speed Converting

When precision and clean edges matter most, shear slitting is the go-to method for converters across paper, film, foil, and laminate applications. In Episode 3 of Converting Conversations, we break down how shear slitting works, the difference between tangential and wrap setups, and why this method delivers superior cut quality for high-speed lines.

What Is Shear Slitting?

Shear slitting functions like a rotary scissor, where a male and female knife come together to cleanly slice material. This method excels in cutting:

• Paper and board stock

• Films (especially thicker gauges)

• Laminates and nonwovens

• Foil-based substrates

With speeds reaching up to 6,000 feet per minute, shear slitting is favored for high-output lines that demand tight edge control and minimal debris.

Key Setup Types: Tangential vs. Wrap Shear

Tangential shear slitting cuts across a flat web path, making it easier to automate knife positioning. It’s commonly used for its flexibility in handling mixed material types and varying widths without sacrificing control.

Wrap shear slitting adds a degree of web wrap around the shear shaft, increasing stability—especially important for thin films or narrow trim. This setup improves trim handling at high speeds using trim pickup tubes for cleaner waste management.

Material-Specific Blade Configurations

Choosing the right blade matters. Shear knives vary in angle, rim width, and grind style:

• Wide-rim knives handle thick films like thermoform by displacing material cleanly.

• Double hollow ground knives are used for foils to avoid edge roll.

• Standard blades are common for plain papers and general-purpose substrates.

Each blade configuration is selected based on how the material behaves under pressure and shear force.

Enhancing Efficiency with Automation

Shear slitting setups can be fully automated, including knife positioning, core placement, and even laser-assisted core alignment. These features reduce setup time, minimize waste, and allow operators to run precise cuts across a wide range of sizes.

Shear slitting is often combined with web cleaning systems like tacky rollers or vacuums to eliminate debris, especially for brittle coatings or adhesive-backed substrates.

Watch the Full Episode

Want to see the breakdown in action? Episode 3 of Converting Conversations explains how different razor configurations can improve cut quality, speed, and efficiency.