Ten years of digital zone levelling: efficiency in make-ready tasks. Marbach has been setting standards for efficient and reproducible die-cutting results for a decade.

We are celebrating our tenth anniversary of digital zone levelling. We laid the foundation for this technology with the introduction of DZL|plate for paperboard die-cutting machines at drupa 2016. Since 2025, DZL|foil has complemented the portfolio as digital zone levelling for corrugated board die-cutting machines. The goal was and is to specifically compensate for height differences in the die-cutting process and, for example, reduce knife setup times.

In addition to wear-related tolerances, it is also necessary to compensate for order-specific dynamic tolerances in the die-cutting area. These are technically unavoidable but result in increased setup effort for the machine operator for almost every job. The digital zone levelling specifically compensates for these tolerances and significantly reduces the recurring setup effort, individually tailored to each machine.

The basis of digital zone levelling for both the DZL|plate and DZL|foil variants is the determination of the machine height profile. For paperboard die-cutting machines, this profile is evaluated digitally and transferred directly to a new Vetronit plate. This creates a frame cover plate that is individually tailored to the machine, compensates for height differences, and significantly reduces setup effort. “The DZL|plate impresses with its ready-to-use application and the significant reduction in knife setup times, an advantage that is evident with every job,” explains Bernhard Reisser, Industry Manager for paperboard at Marbach.

For corrugated board die-cutting machines, the determined height profile is used for a different application: instead of a plate, an individually customized foil with the precisely matched height profile is produced. The foil is inserted into the cutting chase (cutting platen) and reliably compensates for unevenness, without replacing the protection plates. The result is consistent die-cutting quality with significantly reduced setup effort. "The DZL|foil is flexible, precise, and quick to use. Height tolerances can be reliably compensated, with virtually no additional mechanical intervention," adds the Industry Manager for the corrugated board at Marbach.

The digital zone levelling has stood for stable processes and reliable die-cutting quality for ten years. A solution that simplifies everyday production, increases efficiency, and proves itself in practice every day.