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SmartGap Die

Full Payback for EDI® SmartGap™ Die from Nordson Can Occur in ‘a Matter of Months’

CHIPPEWA FALLS, WI, U.S.A., October 16, 2018: Nordson Corporation has developed a digital tool for comparing the cost inputs of standard sheet dies with removable lower lips and those of the EDI® SmartGap™ mechanism for rapidly changing sheet thickness.

The tool, called the SmartGap Payback Analysis, enables sheet manufacturers to calculate the payback time for switching to SmartGap technology. It can be accessed online at

SmartGap technology enables manufacturers to make changes in thickness with unprecedented speed, extend the range of thicknesses that they can produce, and achieve these improvements while enhancing sheet quality. The system uses a single-point adjustment mechanism that changes the lip gap while simultaneously modifying the length of the lip land to provide the most appropriate conditions for the newly adjusted thickness as the sheet exits the die. By mechanically linking the adjustment of these two key process variables, the SmartGap system ensures a proper set-up of the die and takes substantial time and guesswork out of the process for achieving desired sheet properties.

Users of the SmartGap Payback Analysis enter two types of information: 1) the one-time costs of equipment investment for a standard sheet die with removable lower lip and for a new SmartGap system; and 2) process data including die length, output rate, number of die gap and die lip changes, number of working days, raw material cost, approximate product selling price, and burden cost of sheet line per hour.

Using these inputs, the tool calculates the daily output values of the two systems, including downtime, missed production output, downtime cost, missed product gross profit, and total downtime cost; compares the time required for changing die lips versus that needed for changing the die gap in the SmartGap system; and estimates the how long it would take for a complete return on an investment in the SmartGap system.

Payback typically occurs in a matter of months, according to Sam G. Iuliano, senior technical manager for Nordson’s EDI brand.

“The SmartGap system eliminates the extended shutdowns for changes in lip components that have often been necessary when transitioning to new job runs, reducing to a matter of a few minutes changeovers that used to take two hours or more,” said Mr. Iuliano. “Also overcome are previous limitations on thickness range caused by the complexities of die modification; the SmartGap system readily encompasses die gap adjustments over a range of 0.400 in. (10.2 mm), enabling processors to efficiently run with multiple product changes per day. At the same time, the SmartGap system enhances product quality and consistency, in part by keeping the lip faces and lip lands parallel while carrying out changes in thickness.”


Nordson Corporation engineers, manufactures and markets differentiated products and systems used for the precision dispensing of adhesives, coatings, sealants, biomaterials, polymers, plastics and other materials, fluid management, test and inspection, UV curing and plasma surface treatment, all supported by application expertise and direct global sales and service. Nordson serves a wide variety of consumer non-durable, durable and technology end markets including packaging, nonwovens, electronics, medical, appliances, energy, transportation, construction, and general product assembly and finishing. Founded in 1954 and headquartered in Westlake, Ohio, the company has operations and support offices in more than 30 countries. Visit Nordson on the web at, @Nordson_Corp, or

Nordson Polymer Processing Systems provides customers with engineered components to melt, homogenize, filter, meter, and give shape to plastic and fluid coating materials. Nordson Corporation leverages the collective plastics industry experience from a series of strategic acquisitions to offer a uniquely broad portfolio of industry-leading technologies. Nordson delivers a full range of precision melt stream products — from screws and barrels for extrusion and injection molding — to filtration systems, pumps, and valves — to the extrusion dies and pelletizing systems to meet the constantly evolving needs of the polymer industry.

Nordson Corporation provides customers with local technical sales, service and remanufacturing capabilities through sales organizations and regional manufacturing facilities in over 30 countries. To learn more visit us at or