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AeroDieCut Case Study with Morisaki; Die Board Supplier in Japan
Who is Morisaki?
Morisaki Inc. is a leading Japanese company specialising in the production of high-quality die boards. From industrial die boards, to vacuum-forming dies and dies for corrugated cardboard, Morisaki’s diverse portfolio spans a wide range of materials and applications. Their expertise extends to the production of prototypes, small batches, and custom die boards, tailored to meet the unique needs of their clients.
Morisaki's customer-centric approach is a key differentiator. With a deep understanding of their customers' challenges, they leverage decades of experience to offer tailored solutions. Drawing from both past successes and setbacks, the company is adept at crafting the best possible solutions for each customer, making them a go-to partner for the packaging and die-cutting industries.
In addition to die board production, Morisaki also manufactures signboards and shop fixtures, while offering additional products such as blades and materials—providing a one-stop service for all their customers' needs.
What they do and use AeroDieCut for
- Small Batch Production:
They use AeroDieCut for producing small lots, often fewer than 1,000 pieces, for products that traditional packaging manufacturers cannot accommodate. - Corporate giveaways:
The machine is used for producing promotional items, such as corporate giveaways and gifts. - Sample Production:
AeroDieCut plays a critical role in producing samples for distribution, giving clients a clear view of the final product before full-scale production. - Test Die-Cutting:
It is also used in the prototyping phase to test various die-cutting parameters (such as perforation pitch, creasing width/depth, and ease of assembly and tear-off, etc.) before the production of wooden die boards.
How Did They Discover AeroDieCut
Morisaki first encountered AeroDieCut at a printing equipment exhibition in Kyushu, Japan. They were immediately impressed by its ability to address a long-standing challenge in the industry: small-batch die-cutting. “We are receiving an increasing number of inquiries for small batches, and AeroDieCut machine seemed like the perfect solution to meet those needs,” says Mr. Junichi Morisaki, a representative from Morisaki. The machine's ability to handle small runs efficiently was a key selling point, particularly as demand for low-volume, customized packaging continues to rise.
AeroDieCut stands out from conventional die-cutting machines due to its innovative processing method in terms of pressing and feeding, which reduces uneven cutting quality in the finished products. Its simplicity and ease of use were also major factors in their decision to install the machine. “AeroDieCut is as simple to operate as an on-demand printer,” he explains. “It’s a game-changer for us, enabling us to expand our capabilities and offer new services to our customers.”
The Impact on Their Operations
Before installing AeroDieCut, Morisaki struggled to handle more than 100 sheets at a time with their cutting plotter. With AeroDieCut now in place, they’ve been able to scale production to handle over 100 sheets in a single batch. This upgrade has streamlined their die board manufacturing process and created new efficiencies, particularly for small batch runs.
“As a supplier of die boards, we can quickly produce wooden die boards for the AeroDieCut, which has streamlined our production systems,” says Mr. Yoshida, technical manager from Morisaki’s Planning and Design Department. “AeroDieCut has not only enhanced our operational efficiency but has also helped us better meet the needs of our customers in the packaging industry, which values flexibility and agility.”
The Outlook for Japan’s Manufacturing Industry
Looking forward, Morisaki sees several growth opportunities for Japan’s manufacturing sector, particularly in packaging and printing. Technological advancements, digitalization, and increasing environmental awareness are driving forces that will continue to shape the industry. However, challenges such as labour shortages, skills mismatches, and global competition remain ongoing concerns.
“We are confident that adopting new technologies like AeroDieCut, along with sustainability initiatives, will be key to the growth and competitiveness of the industry,” Mr. Yoshida explains. “As the demand for smaller lot sizes and more customized products continues to rise, we see this as both a challenge and an opportunity to add value to the packaging industry.”
Despite the common belief that small-lot production is unprofitable, Mr. Junichi Morisaki sees it differently. “Our mission is to turn this challenge into added value,” they say. “By fulfilling the unique needs of the market, we can create new demand and help the industry thrive in this evolving landscape.”
Are you facing any challenges with creating die boards? If you have any projects you’d like to try or questions you need help with, please don’t hesitate to reach out to us. Our team, along with our trusted die supplier Morisaki, will work closely with you to explore new possibilities and find the best solutions for your needs.
Morisaki also shares their packaging design expertise with the international market through their website- What a Box, offering innovative designs that may inspire your next project. Do not forget to visit their website.