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Newly updated crusader

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

  • Guaranteed to meet your performance specifications
  • Reduced risk with proven solutions
  • Application support for new products
  • Best service in the industry

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

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Flexible. Expandable. Reliable.

One design. Small to large. Now or in the future. Full servo motor control, simple operator interface, hundreds converting modules, rigid welded frame, best service in the industry.

Crusader Converting System Features 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

Crusader Flex full image

Introducing the ultimate in process flexibility.

Delta Crusader® FLEX-Machine comes complete and ready to perform a variety of processes. Fully loaded with options for the manufactures that want to be confident in handling any project. Simply load your specifications and tooling.  

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.

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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!

Delta Crusader® Standard Technical Specifications

Max Web Width:254 mm (10 in), 330 mm (13 in), 406 mm (16 in), 508 mm (20 in), 609 mm (24 in)
Max Speed:Up to 91 m/min (300 ft/min)* (Higher speeds available upon request)
Unwind/Rewind Mandrel Diameter:76 mm (3 in) standard, other sizes available
Control System:Delta ModTech INTELLI-MOD® HMI
Drive System:Individual Servomotor Control
Cabinet Construction:Welded Steel Frame, Aluminum Front Plate

*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.

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.