NSF Ultra Die Cutting

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Exceptional fast set up, high productivity, accuracy and high-quality output make the NSF Ultra one of the most profitable machine purchases you can make for your business.


Typical THERM-O-TYPE die cutting equipment and foil stamping applications include; packaging, announcements/invitations, pocket folders, business cards, greeting cards, as well as enhancing a wide range of digitally printed, small or large quantity, products.


Flat foil stamping can be produced at speeds up to 5,000 impressions per hour using magnesium, copper or brass dies, using NSF Ultra die cutting equipment.

Standard height dies can be mounted on a “honeycomb” style chase using toggles. 

Using a chase with a tapped hole pattern, standard height dies can be mounted using Bunter Posts or by screwing the die directly to the chase, after the dies have been drilled and countersunk.

Blind and Foil Embossing can be produced at speeds up to 5,000 impressions per hour using standard single and multi-level embossing dies and counters on THERM-O-TYPE die cutting equipment. 

Standard height dies can be mounted on a “honeycomb” style chase using toggles.

Using a chase with a tapped hole pattern, standard height dies can be mounted using Bunter Posts or by screwing the die directly to the chase, after the dies have been drilled and countersunk.

Perforating and scoring can be produced at speeds up to 5,000 impressions per hour on NSF Ultra die cutting machines. Standard perforating (including micro perforating) and scoring rule can be used mounted in die board or secured using letterpress furniture and quoins in the “letterpress chase”.

High Speed Foil Fusing can be produced at speeds up to 4,000 impressions per hour. The HSFF process fuses foil to text and graphics that have been printed with toner (or ElectroInk on certain stocks). HSFF does not require a metal foil stamping die.

Foil stamping equipment producing holograms. A holographic registration system is available as an option. The holographic registration option is not required when applying holographic “wallpaper” patterns. This option is required when applying registered holographic images.

THERM-O-TYPE NSF Ultra die cutting equipment can kiss and die cut at speeds up to 5,000 impressions per hour using steel rule dies. Die cutting dies can include scoring, perforating (including micro perforating) and hole punching. A “letterpress chase”, furniture and quoin/s are used to secure steel rule dies in the press. A inline waste stripping attachment is available.


Probably the most impressive feature of the NSF Ultra is it’s productivity.

While NSF Ultra die cutting machines can run up to 5,000 impressions per hour, this is just one aspect of productivity.

Good engineering, ergonomics and automation are essential for achieving fast set up and to minimise set up delays and operator workload.

The ability to adjust paper registration and foil draw settings through the touch screen, having a large capacity feeder with pre-load feature, the ability to step and repeat imprint positions, the ability to quickly load and thread foil rolls and many other NSF Ultra features, combined with high throughput speed, ensures maximum productivity in your plant.

NSF Ultra equipment for die cutting is highly automated with the machine controlled through a full colour touch screen interfaced to a Windows computer core.  

Stored paper registration (including step and repeat up to eight positions), foil draw, die temperature, jam set up and machine speed settings can be retrieved and loaded by the operator, significantly reducing set up time and potential errors when running repeat orders/formats.

Up to 500 programs can be stored and retrieved using the touch screen control.

THERM-O-TYPE die cutting equipment features a wide range of ergonomic and automation features designed to simplify operation and reduce operator workload. 

These features include; easy chase and makeready plate access and support, hinged foil support shafts, automatic press set up feature, automatic paper jam detect set up, machine set up information stored and retrieved for up to 500 jobs, remote press controls at the delivery end of the press, automatic foil speed adjustment based on machine speed and foil draw length, computer controller central lubrication, compressed air supply and lubrication level are automatically monitored and interlock through the touch screen.

The feeder on NSF Ultra has been optimised to run small, variable quantity orders and large quantity orders.

When running large quantity orders, the NSF Ultra feeder can hold a 32″ high pile of stock and the feeder can be pre-loaded while the press is running to minimised down time.

The combination of high capacity feeder and pre-loading significantly increases productivity, while reducing operator workload.

When running small quantity orders, the operator can select how far they want the paper lift tray to lower, then press a single button to lower the paper tray to the desired level automatically.

Again, this feature increases productivity while reducing operator workload.

NSF Ultra die cutting equipment can step and repeat up to eight imprint or die cut positions down the length of the sheet. This feature is ideal for producing small quantity orders. Using a smaller (less expensive) die, which requires less makeready, customers can produce small quantity foil stamped and die cut orders inexpensively and efficiently.

TDC (top dead center) represents the most closed position of the impression mechanism. BDC (bottom dead center) represents the most open position of the impression mechanism. Using the TDC and BDC touch screen controls, operators can quickly and accurately set the initial impression pressure at the start of each job. This helps to eliminate the potential for smashing dies due to improper impression adjustment during set up. TDC/BDC controls are also used when mounting an embossing counter or when making a cast counter on the press.

Customers can batch count on the NSF Ultra. To use this feature, the operator sets a batch quantity and a number of skip feed cycles in the touch screen control. Once programmed, NSF Ultra die cutting equipment will run the desired batch quantity then skip feed the selected number of cycles to create a gap between batches on the delivery conveyor.

Optical sensors at the feeder, headstop and delivery monitor paper movement through the press. If a paper jam condition occurs, the press will automatically stop in the bottom dead centre/off impression position.

A double sheet sensor is interlocked to the NSF Ultra controls. If a double feed occurs, the press will stop automatically and the touch screen will display an error message.

If a skip feed occurs, the NSF Elite will automatically drop off impression to ensure that foil isn’t imprinted on the makeready. When the next sheet enters the impression area, the press will automatically go back on impression. The NSF Elite will not stop, or imprint on the makeready, if there is a skip feed.

The standard NSF Ultra foil system includes dual foil support shafts, dual programmable foil draws, and four waste foil rewinds shafts.

Foil draw is controlled through the touch screen and multiple foil draw lengths can be programmed to minimise foil waste. Up to 7.2″ diameter foil rolls can be used and foil draw length can be adjusted while the machine is running.

NSF Ultra die cutting equipment features a computer controlled pneumatic centralised lubrication system. Lubrication cycles are activated as required using speed, impression pressure and run/idle time information collected and processed by the computer.

The computer monitors the lubrication system and will stop the press and alert the operator to a low oil condition.

NSF Ultra die cutter incorporates several important mechanical and electrical safety features. A dedicated 24-volt safety circuit with emergency stops switches; fail-to-safe relay and reset button have been installed. All controls and switches mounted to the control panel operate at 24-volts or less.

A inline die cut waste stripping attachment can be added to THERM-O-TYPE Die Cutting Equipment. Manually stripping die cut sheets is too time consuming and expensive for most applications. Using the NSF Ultra optional waste stripping attachment, most die cut products can be automatically stripped at speeds up to 5,000 impressions per hour.

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