The Crusader® Rotary Converter
The Top Choice for the most Successful Contract Converters in the world.
Over 30 years ago we designed the Crusader Converter from the ground up to be the most flexible and precise roll to roll die cutting machine on the market.
This first-of-its-kind machine continues to be the industry leading narrow web die cutting platform for contract converting.
- Guaranteed to meet your performance specifications
- Reduced risk with proven solutions
- Application support for new products
- Best service in the industry
Forward and Backward Compatible
One Design. Small to Large. Now or in the Future.
Flexible. Expandable. Reliable.
Full servo motor control, simple operator interface, hundreds converting modules,
rigid welded frame, best service in the industry.
Crusader Converting System
at-a-glance
FEATURES:
- Each cutting, nipping, sealing, printing and winding station is servo controlled.
- Advanced controls and closed loop registration provide the tightest tolerances available.
- Expandable modular platform
- Delta ModTech’s Intelli-MOD™ control system
- Intuitive HMI touchscreen interface with Product Recipe recall
- Quick change tooling
- Rigid welded steel frame
- Minimal maintenance
- Worldwide service with online support
“At Boyd, advanced manufacturing technologies increase our ability to provide our customers higher quality products with tighter tolerances. Our servo driven Crusader presses utilize both rotary and flex die technology to convert multiple layers of material and control island placement inline, ensuring part repeatability.”
Jeff Snedeker, Engineering Manager
Crusader Options
We have 100’s of predesigned ModTech modules that fit seamlessly on the Crusader Converter.
Closed Loop Registration
MOD-Track® Inspection System – part conformance, verification and closed loop registration
control. Simple on-screen setup.
Laser Die Cutting
EDGE® Laser Technology – Intricate cuts, ablation, kiss cutting, drilling, slug removal.
Part Placement
Save precious materials with our game changing Island Placement modules.
Sealing, Pouching, Packaging
High-speed, repeatable flatbed pouching with continuous motion.
Winding
Servo controlled unwind and rewinds, closed loop tension, and unlimited expansion capabilities.
Part Handling
Conveyors, stackers, reject gates, waste removal and cartoner integration.
Printing
Flexographic printers, lot/date code printing and finishing modules for inline/nearline digital press integration.
Integration
Robotics, pick and place, feeders, extruders, coaters, dryers, ERP/IoT system integration and more.
Crusader® Standard Technical Specifications
Max Web Width: 10” (254 mm), 13” (330 mm), 16”(406 mm), 18” (457 mm), 20”(508 mm), 24” (609 mm)
Max Speed: Up to 500 ft/min (152 m/min)*
Registered Cut Tolerance: +/- 0.002 inch (50 microns)*
Unwind/Rewind Mandrel Diameter: 3″ (76 mm) standard, other sizes available
Control System: Delta ModTech INTELLI-MOD™ control system
Drive System: Individual Servomotor Control
User Controls: Touchscreen HMI Pendant Arm
Footprint: 8′ x 6′ x 7.65′ (Crusader® Base Platform)
Cabinet Construction: Welded Steel Frame, Aluminum Front Plate
* Process dependent
Product Development
Delta's Proof of Principle Service
If your product or materials are still in the development phase, our in-house R&D facilities allow you to work the bugs out of your products and allow us to prove we have a solution to manufacture your parts.
Visit our Product Development page or Contact us to learn more.
FDA Validation, Documentation & Training
Delta is a Total Solution Provider
As a manufacturer, you look to the machine builder as the expert on the equipment. This shouldn’t stop with the ability to supply useful specifications, test procedures, custom instructional material and advanced training. Our validation practices are modeled after GAMP and allow the flexibility to work with you and your project needs.
Visit our Validation and Training pages to learn more.
Machine Support
Passionate Service
Excellent service. You don’t know how important it is until you need it. We have you covered.
We invest in the resources to keep your machines up and running. From process changes, to spare parts, to total system retrofits, we are here to serve you. Online process support, upgrades, and
troubleshooting are just a phone call away.
Visit our Machine Support page to learn more.
From curious questions to preparing a quote,
we’re ready to help
You’ve read a lot about us, so now can we hear about you?
Whether we’re answering some introductory questions or if you’re in need
of a quote, just fill in the form below or call us at 1-800-279-3358 and we can get you the answers you need.
From the Delta ModTech Blog
Choosing Right: Laser Die Cutting Vs. Rotary Die Cutting
Precision vs. durability? Cost vs. quick run capabilities? In the laser die cutting vs. rotary die cutting smackdown, there are a variety of reasons to choose one over the other – and a whole lot of grey area in between. Let’s take a closer look at what’s right for your die cutting machine.
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How to Make Your Rotary Die Live a Long, Profitable Life
Do you ever wonder why it always seems like the lifespan of your rotary die comes up 5,000 feet short? It’s always an issue for converters, so we tapped the experts at RotoMetrics for some insights on how to help your rotary die live a long, profitable life.
Read more
How to Get Shifts to Perform Consistently With Knowledge Sharing
Why are there such differing manufacturing performance levels between shifts? While some of the differences can be attributed to personnel, a big reason is a company’s inability to effectively transfer knowledge between shifts. An organizational expert provides us with six methods to consider to improve the situation.
Read more