The primary cause of this issue is the absence or insufficiency of structural bridges, commonly known as Nicks, in the die-line design. These bridges are responsible for maintaining the physical connection between the die-cut cartons and the main sheet until the final stage. Without these vital connections, centrifugal forces and intense vibrations at high speeds—such as 7,000 sheets per hour—cause premature separation of parts, leading to sheet disintegration and production stops.

To resolve this, nick width and frequency must be optimized based on the board weight and machine speed. Implementing modern grinding techniques instead of manual tools provides superior sheet stability. This ensures that subsequent processes, such as Stripping and Blanking, are performed seamlessly. By scientifically calculating the bridge strength, production managers can minimize downtime and ensure that the integrity of the layout remains intact throughout the entire mechanical workflow.