Bernal Rotary Dies

What Bernal Rotary Dies does

Bernal Rotary Dies, operating legally as Komori Chambon USA Corporation, designs and manufactures precision rotary die-cutting and web converting systems for high-speed continuous manufacturing. The company serves enterprise manufacturers across folding carton packaging, beverage carriers, battery and energy storage components, consumer products, tobacco packaging, liquid packaging, food processing, medical devices, automotive, aerospace, and industrial manufacturing. Its core technology centers on two proprietary rotary die platforms: RP Rotary Dies with shearing blade technology that eliminates metal-to-metal contact and extends die life, and Crush Cut Rotary Dies pioneered by Bernal in the late 1960s using Electrical Discharge Machining (EDM) to produce a wedge-type cutting edge with .001" accuracy. The product portfolio extends from individual dies (3" to 40" diameter, supporting 10 to 500+ million revolutions) to complete converting systems spanning 1" to 110" web widths at speeds up to 1,500 fpm, including folding carton systems delivering .005" registration accuracy and 10-minute changeovers.

The company operates a custom-engineered, build-to-order business model, selling one-time capital equipment licenses directly to enterprise customers through a dedicated field sales organization (VP of Sales and Services, National Account Manager, Senior Business Development Manager, Spare Parts Sales Coordinator). Revenue streams comprise custom converting systems, rotary dies, die cutting modules and cassettes, spare parts and aftermarket support, and engineering/R&D services including R&D Proof of Principle that frequently yields patentable designs. Pricing is quote-based with no public tiers, reflecting the engineered-to-order nature of the product. Bernal assumes full system responsibility from concept development through installation and commissioning, supported by in-house advanced machining (CAD/CAM, CNC, CMM, EDM), microprocessor-controlled drives, PLCs, production data acquisition, and integrated visual inspection with real-time quality control. System efficiencies are stated at up to 99%.

Bernal was founded as Bernal Rotary Systems in 1972 (the firmographic founding year), having pioneered solid-hardened rotary dies using EDM in the late 1960s. The company was acquired by Komori Chambon Group—a global printing and converting technology manufacturer founded in 1923—forming the Bernal Komori Chambon Group (BKCG). Bernal operates from a single facility in Rochester Hills, Michigan, with 51–100 employees, and serves Fortune 500 clients with installations worldwide.

Name

Bernal Rotary Dies

Legal name

Komori Chambon USA Corporation

Website

https://bernalrotarydies.com

Company type

Private

Founded year

1923

Operating status

Operating

Headcount range

51–100 employees

Short description

Bernal Rotary Dies designs and manufactures precision rotary die-cutting and web converting systems for high-speed manufacturing, serving Fortune 500 enterprises across packaging, battery, food processing, medical, and aerospace as a Komori Chambon Group subsidiary.

Ownership category

akta.pro rank

Product category

Industrial Rotary Die-Cutting and Converting Equipment

NAICS

Other General Purpose Machinery Manufacturing (3339)

SIC

Printing Trades Machinery & Equipment (3555), Special Industry Machinery, Nec (3559)

akta.pro industry

PRIMARYIMALAKAH

Folding Carton & Paperboard Packaging Printing

Industrials, Manufacturing & Construction/Packaging & Containers/Labels, Sleeves & Packaging Printing

Keywords

• Rotary die cutting
• Converting systems
• Folding carton machinery
• Web converting equipment
• Precision die tooling

Headquarters

HQ city

Rochester Hills

HQ country

United States

HQ region

North America

Offices2 records

Markets served

GTM type

B2B

Offering type

Hardware or Manufacturing

Cost components

Personnel, Operations, Technology or R&D, Supply Chain, Marketing or Sales, Infrastructure

Revenue model

1. Custom Rotary Converting Systems and Machinery: Design, manufacture, and sale of custom purpose-built converting systems, special machine systems, and custom web fed systems. Systems accommodate web widths from 1 to 110 inches, operating at speeds from 10 to 1500 fpm. Full system responsibility from design through installation and commissioning.
2. Rotary Dies (RP and Crush Cut): Sale of precision rotary dies including RP dies with shearing blade technology and crush cut dies. Die specifications range from 3" to 40" diameter, supporting 10 to 500+ million revolutions. Custom engineered options available.
3. Die Cutting Modules and Cassettes: Precision-engineered die cutting modules and cassettes available in standard and custom designs. Single-slot, dual-slot, and custom module configurations. Includes bearing housings and spare parts.
4. Spare Parts and Aftermarket Support: Ongoing spare parts supply and replacement components for installed equipment. Dedicated parts coordinator and extensive spare parts inventory.
5. Engineering and R&D Services: Custom engineering solutions from concept through machine fabrication, testing, and installation. Proof of principle and prototype development services. Factory and site acceptance testing services.

Go-to-market motion1 record

Distribution channels2 records

Marketing channels3 records

Core offering

Bernal designs and manufactures precision rotary dies (RP Rotary Dies with proprietary shearing blade technology and Crush Cut Rotary Dies with EDM-machined wedge-type cutting edges) and custom rotary converting systems for high-speed continuous web processing. Systems support web widths from 1 to 110 inches and speeds from 10 to 1,500 fpm, with full single-source responsibility from concept and engineering through fabrication, installation, and commissioning. Core customers are enterprise industrial manufacturers in folding carton, beverage packaging, battery components, medical, automotive, aerospace, consumer goods, and food processing.

Product overview

Bernal Komori Chambon Group offers a portfolio of precision rotary die-cutting solutions and custom converting systems. The core product line centers on rotary dies (RP Rotary Dies and Crush Cut Rotary Dies) paired with Die Cutting Modules that provide the mechanical environment for optimal die performance. These are complemented by complete Rotary Converting Systems and Folding Carton Systems that integrate dies and modules into full production lines. Additional offerings include Food Processing Systems for food-grade applications, Purpose-Built Machines for specialized custom applications, and Engineering and R&D services for concept-to-installation support. The portfolio is unified around precision web-fed converting technology supporting industries including packaging, medical, automotive, aerospace, consumer goods, food products, batteries, and tobacco.

Differentiator

Problem solved

Functional benefit

Brands

• RP Rotary Dies: Revolutionary shearing blade technology for extended die life and exceptional cut quality in folding carton applications
• Crush Cut Rotary Dies
• Die Cutting Modules & Cassettes

Products and services

• Rotary Converting Systems Custom-engineered converting systems for high-speed continuous web processing, designed and built to customer specifications and integrated into printing and packaging production lines. Targeted at enterprise industrial manufacturers in folding carton, beverage packaging, battery components, medical, automotive, aerospace, consumer goods, and food processing.
• RP Rotary Dies Precision rotary dies featuring proprietary shearing blade technology with Crossover Technology for precise cut adjustments, designed for extended die life and consistent cut quality at high speeds in folding carton and packaging applications. Targeted at folding carton manufacturers and packaging converters.
• Crush Cut Rotary Dies Solid-hardened rotary dies engineered for clean cuts at high speeds, manufactured from hardened steel with an EDM-produced wedge-type cutting edge. Targeted at packaging converters and industrial manufacturers requiring tight cutting tolerances and resharpenable tooling.
• Die Cutting Modules Precision die cutting modules and cassettes with integrated pin stripping, quick changeover capability, and robust construction. Targeted at folding carton converters and other web-fed manufacturers operating with various die types at speeds up to 1,500 fpm.
• Food Processing System Custom food-grade sheeting, cutting, and modular processing systems for snack foods, liquid packaging, drink pouches, breakfast cereals, coffee packaging, and potato, rice, or corn dough products. Targeted at food processing manufacturers requiring sanitary design and high-speed continuous operation.
• Folding Carton Systems High-speed folding carton cutting systems designed for inline integration with flexographic, gravure, or offset printing presses. Targeted at folding carton manufacturers needing high-speed precision cutting and rapid changeovers.
• Purpose-Built Machines Custom machinery engineered for specialized high-precision processes that combine cutting, folding, and packaging functions outside of standard product lines. Targeted at industrial manufacturers with unique converting or assembly requirements, including medical device producers.
• Engineering Services Custom engineering solutions spanning concept development, machine design, electrical design, fabrication, factory acceptance testing, installation, and site acceptance testing for rotary die-cutting and converting applications. Targeted at industrial manufacturers commissioning new converting systems or product lines.
• R&D Proof of Principle Research and development services that take unique die-cutting, converting, and assembly challenges through engineering, prototyping, build, and testing, often producing patentable designs. Targeted at manufacturers with novel converting or assembly requirements.

Quantifiable outcome

• System efficiencies up to 99%
• +5 more outcomes

Segments9 records

Ideal customer profiles4 records

Technology focussed No

API detail

Has API

No

API docs

API detail

Core technology

AI maturity

App detail

Feature5 records

Partnerships

One partnership is on record.

• Komori Chambon GroupcoreStrategic or Co-development PartnerKomori Chambon Group acquired Bernal, creating the Bernal Komori Chambon Group (BKCG). The acquisition enhances precision solutions through expanded global resources, state-of-the-art engineering, and commitment to continuous improvement. Komori Chambon Group, founded in 1923, is one of the leading manufacturers in the printing press industry with over a century of experience in printing and converting technologies. The acquisition provides cutting-edge solutions for prototyping through large-scale production.

Scale indicators8 records

Recent moves4 records

Expansion highlights5 records

Direct peers

• Mark Andy: Mark Andy is a leading manufacturer of narrow- and mid-web flexographic printing presses and inline converting equipment for labels and packaging. Direct competitor to Bernal in web-fed converting, particularly for folding carton and label converters requiring integrated printing and die-cutting lines.
• Comexi: Comexi manufactures flexographic, offset, and gravure printing presses plus converting equipment (slitting, laminating, die-cutting) for flexible packaging and folding carton converters. Direct peer offering integrated converting lines targeting the same Fortune 500 packaging manufacturers served by Bernal.
• PCMC (Paper Converting Machine Company): PCMC, now part of Barry-Wehmiller, designs and manufactures custom web-fed converting equipment for hygiene, packaging, and tissue markets. Highly comparable to Bernal's rotary converting systems business, with overlapping customers in packaging and similar custom-engineered capital equipment delivery model.
• C.U.E., Inc. (Cincinnati Union Equity): C.U.E. provides engineered converting equipment and web handling systems for paper, film, foil, and packaging applications. Direct competitor to Bernal in custom purpose-built converting systems with similar Fortune 500 industrial customer base.
• Atlas Converting Equipment: Atlas Converting Equipment designs and manufactures slitting, rewinding, and web-handling machinery for film, paper, and converting applications. Direct peer with comparable custom capital equipment sales motion to converters in overlapping end-markets.
• RotoMetrics: RotoMetrics is the most direct peer to Bernal, manufacturing precision rotary tooling (solid and flexible dies) and supporting converting equipment for the folding carton, label, and packaging industries. Both companies serve the same converters with rotary die-cutting consumables and engineered solutions, making product, customer, and technology alignment nearly identical.
• Karl Heinz (KHK): Karl Heinz is a German manufacturer of precision rotary dies, anvils, and converting equipment for the packaging industry. Direct peer offering similar engineered rotary tooling to folding carton and packaging converters, especially in the European market where Bernal currently has limited direct presence.

Broad incumbents

• SPGPrints: SPGPrints manufactures rotary screen printing, digital inkjet, and laser imaging equipment for textiles, graphics, and packaging applications. Broad incumbent with overlapping converting/printing equipment portfolios targeting similar industrial converters.
• BHS (Bühler Group): BHS, part of the diversified Bühler Group, supplies web converting, coating, and finishing equipment for paper, film, and foil across multiple industrial segments. Broader incumbent with overlapping converting capabilities, though not specialized in the rotary die-cutting niche that Bernal owns.

Emerging players

• Preco Laser Systems: Preco designs and manufactures laser-based converting and die-cutting systems for labels, packaging, and industrial applications. Emerging player with adjacent technology that competes against Bernal's mechanical rotary die-cutting in certain packaging segments, particularly short-run and digital finishing workflows.

Market position

Strengths5 records

Weaknesses5 records

Competitive moat5 records

Key risks6 records

Key highlights7 records

Customer concentration

• Xx.com/bernalrotarydie
• Facebookfacebook.com/bernaldies
• LinkedInlinkedin.com/company/bernal-rotary-dies

Revenue estimate

Valuation estimate

Number of profiles

Profiles6 records

Funding overview

Funding rounds

Investors

Funding detail is available on the Subscription and Enterprise plan.Contact sales →

M&A

Investments

M&A and investment is available on the Subscription and Enterprise plan.Contact sales →

Frequently asked questions about Bernal Rotary Dies