Using the right industrial blade can make all the difference in the efficiency, accuracy, and performance of your manufacturing equipment. Custom industrial blades are engineered with the precise blade geometry for your use case, whether it’s in food processing or packaging. They’re also designed with the ideal material for your application.
When you use an industrial blade that’s tailored for a specific job and machine, it generally lasts longer, leading to fewer replacements and less downtime due to equipment failure. However, custom industrial blades are more expensive and take longer to acquire, so they may not always be the best option. Learn about the differences between custom and off-the-shelf blades and how your operational needs impact which one you should choose.
When your blade is designed for the correct cutting speed of your equipment and thickness for your finish, it streamlines your entire operation and reduces stress on your equipment. Your machines can cut through materials more easily, so there’s less friction and heat buildup, two factors that increase wear and tear. They can run faster and support higher daily output.
Mismatched blades, including those that are the wrong hardness or have the wrong edge profile for your circumstances, can slow down your operations and force your machines to work harder. You may experience subpar results and increased expenses related to redundant work and wasted materials.
Off-the-shelf blades are designed to generic specifications for various uses. While this makes sense from a sales standpoint, it doesn’t offer you optimal performance for your specific job. In food processing, hygiene is a top priority, and the environment is often wet and acidic. Custom industrial knives made from food-safe materials, such as stainless steel alloys or anti-corrosive coatings, help you to meet strict safety standards and reduce food adherence, speeding up production. Custom blade geometry can make it easier to cut soft items that off-the-shelf blades would crush or tear, particularly as the blade wears down. Blades that make more precise cuts result in less waste and faster production runs.
In plastics processing, outfitting your machines with blades designed with the exact heat sensitivity, cutting edge, and flex characteristics for the job reduces edge defects and other flaws. You can speed up your line without sacrificing quality.
The initial price for custom-designed blades shouldn’t be your only consideration. Although they do cost more up front, much of that cost is defrayed by the long-term value in terms of increased performance and production. The lifecycle value of custom blades, which are designed for durability and function, is often much higher. With higher-grade materials and precision manufacturing, your custom blades typically have a significantly longer lifespan. You can save on blade replacements and work stoppages (a byproduct of less efficient blades).
Investing in your industrial blades allows you to select materials that will perform optimally in your environment and applications. With off-the-shelf blades, you’re stuck with options that work adequately but not ideally. The two factors that have the biggest impact on your industrial blade performance are the type of metal and the blade geometry.
By matching the right steel to your cutting applications and manufacturing process, you can avoid safety hazards and premature wear on your industrial cutting blades. Stainless steel knives, for instance, provide the most suitable option when corrosion resistance and extremely sanitary conditions are paramount, such as in food preparation. Grades such as 420 or 440A stainless hold up well even during repeated exposure to cleaning chemicals and maintain a sharp edge in high-volume environments.
If your raw materials are abrasive or dense, a high-carbon option, such as D2 tool steel, may be better. This type of steel performs well under high-pressure applications, such as heavy plastics and rubber processing.
You can also choose to add coatings to your custom blades. In industrial applications where you’re cutting through sticky items, coatings such as Teflon (PTFE) reduce friction and resist buildup that can slow down production and lead to more frequent maintenance-related downtime.
Blade geometry is the other major advantage of customizing your industrial knives. Edge angles impact both sharpness and lifespan. Steeper angles result in sharper, smoother cuts. However, blunter angles often hold up better under high-force applications.
Single bevels work best when you need directional, precise cuts, while double bevels handle heavy-duty tasks with ease. You can also choose industrial blades with compound bevels for more complex tasks. The right combination of angles, bevels, and thickness will improve your cut quality, cycle time, and product consistency.
Working with a trusted partner like Hyde Industrial Blade Solutions for your custom knife fabrication allows you to refine your blade specs to your exact needs. A company with in-house experts in blade materials and design can work with you to determine the right blade for optimizing your machinery and manufacturing line.
When choosing a blade manufacturing partner, their proximity and production time can also increase your efficiency and lower your costs. Working with a partner domestically means you won’t have long, unproductive waits for your initial orders or replacement blades. As we’ve seen in the past few years, working with foreign manufacturers often means extensive, unexpected supply chain disruptions that can interrupt your operational continuity. Local partners also frequently have better support teams in the event you do experience a problem.
There are several considerations when it comes to custom vs. standard industrial blades. If your manufacturing process involves any of the following, you’ll benefit from custom blades:
There are some use cases where standard blades are the better option. If you’re running a low-volume operation that doesn’t demand a high degree of precision, it may not be worth the investment in custom blades.
Hyde Industrial Blade Solutions has over 150 years of experience in manufacturing custom industrial blades. We’ll work with you to develop the perfect blade for your needs. Contact us for a free quote through our website or by calling us at 508-765-4759.