Enhancing Trim Handling and Recycling Efficiency for Global Label and Packaging Producer

The Challenge: Reducing Foil Trim Waste and Improving Production Conditions

CCL Label Dornbirn, a global leader in label and packaging solutions, faced a critical challenge in managing foil trim waste from its slitting machines. With eight machines producing significant amounts of trim, the company required an efficient and sustainable foil trim handling solution that would enable material separation for recycling while maintaining a clean production environment.

The existing system in the old plant had served the company for many years, but with evolving sustainability goals and efficiency demands, it needed an advanced solution to improve trim handling, reduce waste, and improve air quality in the production area. The new system needed to integrate cutting, pneumatic conveying, dedusting, and trim handling to improve operational efficiency while reducing environmental impact.

The Facts: Foil Material Specifications and Trim Handling Requirements

Material Specifications:

• Material processed: Flexible packaging foil with a thickness between 25–90 µm.
• Cutting speeds: Up to 700 m/min.

System Requirements:

• Required functions: Cutting, pneumatic conveying, dedusting, and foil trim handling.
• Key challenges: Material separation for recycling, waste reduction, and improved air quality.

The Solution: Streamlining Foil Trim Extraction and Recycling

The fully integrated pneumatic conveying and foil trim handling system is tailored to CCL Label Dornbirn’s production requirements. The solution combines cutting, material separation, air filtration, and automated trim transport to support efficient waste handling across eight slitting machines.

The system consists of the following primary equipment:

• MCB-160 cutters process foil trim for efficient pneumatic conveying.
• KU10000 separators separate the conveyed trim from the transport air, supporting controlled material collection.
• Filter systems and a blower remove dust from the conveying air before returning filtered air to the production area.

The system transports foil trim from the eight slitting machines through a pneumatic conveying system into a container compactor.

Key Features

• Material Separation: Operators can direct foil trim into two separate recycling streams, supporting more effective recovery of production waste.
• Air Management: Trim passes through a blower into the KU10000 separator and filtration system. Dust is removed before filtered air is returned to the production area, helping maintain a cleaner working environment.
• Energy Optimization: Electro-pneumatic flaps and frequency converters adjust blower speed based on real-time demand, reducing unnecessary energy consumption during production.

Advantages & Benefits: Improved Recycling, Cleaner Production Environment, and Energy Efficiency

Since installing the pneumatic foil trim handling system, CCL Label Dornbirn has achieved improvements in waste management, recycling efficiency, and production conditions.

Improved Recycling

Effective material separation allows foil trim waste to be directed into two recycling streams, supporting material recovery and reducing mixed waste.

Cleaner Production

The integrated filtration system removes dust from the conveying air before returning it to the production area, helping maintain a cleaner working environment.

Energy Efficiency

Frequency converters and electro-pneumatic flaps adjust fan speed according to production demand, helping reduce energy consumption.

Lower Maintenance

Advanced filtration helps minimize equipment wear and maintenance requirements, supporting reliable operation and reduced downtime.

Sustainable Waste Handling

Automated foil trim extraction and material separation support more efficient waste handling and the company’s sustainability goals.