Close Menu
Crusader Flex with operator

Delta Crusader® FLEX Converter

The ultimate in process flexibility. Fully loaded and ready to go.

Machine comes complete and ready to perform a variety of processes. Simply load your specification and tooling

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. With a fresh update in 2020 that has improved flexibility, ergonomics, and usability, along with all the great features of the original model.

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.

Headshot for Jeff Snedeker

Top of the line flexibility.

Rotary Modules and Accessories

  • 9 Die Modules
  • 4 Hydrajack Truck Bridge Assemblies
  • 5 Nip Rollers
  • 9 Pneumatic Hook Ups with Touchscreen Controls
  • 5 Pneumatic Bridge Press Assemblies with Touchscreen Controls
  • Point to Point Registration
  • P-Cam
  • 4 Die Homing Sensors
  • 4 T-Slot Registration Sensors
  • 1 Web Support for Sheeter
  • 1 Dual/ Single Bullnose Assembly

Unwind/ Rewind Modules (3″ core) and Accessories

  • 2 Fixed Unwind Modules with Steering
  • 4 Fixed Unwind/ Rewind Modules without Steering
  • 6 Moveable Unwind/ Rewind Modules without Steering


  • 1 VFD Drive for vacuum Blower
  • 8 Idler Rollers, T- Slot Moveable 2″ dia.
  • 2 Splice Tables
  • Bases for T-Slot Modules

Flexible. Expandable. Reliable.

The Crusader® Flex Offers Several Additions:

Full servo motor control, simple operator interface, hundreds converting modules, rigid welded frame, best service in the industry.

Crusader® FLEX Converting System At A Glance

  • 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

The Crusader gives you so many options to do so many things. It’s like a dream.

Headshot for Nathan Holm

Crusader Options

We have 100s 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 machine for diagnositic parts

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.

Examples of Transdermal pouch and carton products made by web converting

Sealing, Pouching, Packaging

High-speed, repeatable flatbed pouching with continuous motion.

Unwind and Rewind Options


Servo controlled unwind and rewinds, closed loop tension, and unlimited expansion capabilities.

Image of Die Cutting and Spreading Conveyor

Part Handling

Conveyors, stackers, reject gates, waste removal and cartoner integration.


Flexographic printers, lot/date code printing and finishing modules for inline/nearline digital press integration.

Photo of Delta ModTech Robot


Robotics, pick and place, feeders, extruders, coaters, dryers, ERP/IoT system integration and more.


If you need it, we’ve probably already designed it and built it. Just ask!

Crusader® Flex Standard Technical Specifications

Max Web Width:330 mm (13 in)
Max Speed- Full Rotary:Up to 91 m/min (300 ft/min)* Higher speeds available upon request
Control System:Delta ModTech INTELLI-MOD® control system
Drive System:Individual Servomotor Control
Cabinet Construction:Welded Steel Frame, Aluminum Front Plate 10′ long

*Process Dependent

Product Development

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.

validation on a converting and pouching machine

FDA Validation, Documentation & Training

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.

Delta ModTech Service Team

Machine Support

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.

Ryan Herman

From curious questions to preparing a quote, we’re ready to help.

Whether we’re answering some introductory questions or if you’re in need of a quote, just fill in the form or call us at 1-800-279-3358 and we can get you the answers you need.