The Challenge: Eliminating Clogging, Downtime, and Dust Across Eight Tea Packing Lines
This Polish tea producer operates eight high-speed packing lines, each generating continuous paper trim and fine dust. As production demands increased, the limitations of the existing waste handling setup became a direct operational liability.
Each machine relied on its own local exhaust unit with small-diameter pipes. These systems were prone to clogging, causing dust to accumulate around the lines and forcing regular manual cleaning stops. Operators had to monitor individual exhausts, empty waste containers, and restart machines after each blockage, adding unnecessary labor and reducing line efficiency. Loose trim and dust on the floor created safety hazards and disrupted internal logistics.
To protect operator safety and sustain maximum throughput across all eight tea packing lines, the facility required a single centralized trim extraction system capable of continuous, uninterrupted waste removal.
The Facts: Material Specifications and Production Parameters
Machines 1 and 2
- Material: Paper (tissue) and plastic film
- Piece dimensions: 120 x 120 mm
- Material weight: 21 g/m²
- Quantity: 150 pieces/min.
Machines 3 to 8
- Material: Paper
- Trim width: 12 mm
- Material weight: 21 g/m2
- Speed: 17.5 m/min
- Quantity: Continuous cutting and extraction
The centralized system needed to accommodate two distinct waste streams and varying output conditions across a single coordinated trim extraction network serving all eight food packaging machines.
The Solution: A Centralized Paper Trim and Dust Extraction System for Food Packaging Production
Kongskilde engineered and installed a centralized trim extraction system connecting all eight tea packing machines into one coordinated solution for continuous paper trim removal, dust control, and a cleaner production environment.
How the System Works
- The installation is divided into three extraction lines, each sized to match the specific requirements of its machine group.
- MultiAir blowers generate the conveying airflow needed to transport paper trim and dust from each food packaging machine.
- Pressure-monitored suction points stabilize system performance and reduce the risk of clogging in small-diameter pipe sections.
- Trim waste is conveyed through the network and discharged into large waste bins for centralized, easy handling.
- A KNFK bag filter separates dust from the conveying airstream and collects it in a controlled manner. Filtered air is recirculated back into the production hall, reducing heating costs.
- A central control panel manages all start/stop functions and alarm monitoring across all eight lines.
Key Operational Strengths
- Designed for small pipe diameters and high-pressure conveying conditions
- Handles two distinct waste streams within a single centralized network
- Scales across multiple machine groups through three individually sized extraction lines
- Maintains stable performance without manual monitoring or operator restarts
- Supports continuous, shift-long operation across all eight food packaging lines
Advantages & Benefits: Higher Uptime, Cleaner Air, and Lower Operating Costs
Cleaner Production Through Inline Waste Collection
Trim and dust are removed continuously at the source, eliminating the cleaning stops that previously interrupted production across all eight tea packing lines.
Higher Uptime and Full-Capacity Operation
With clogging-related stoppages eliminated, all eight food packaging lines maintain consistent throughput and run at full capacity throughout every shift.
Lower Heating Costs Through Air Recirculation
Filtered air from the KNFK bag filter is recirculated back into the production hall rather than expelled, reducing the energy needed to condition incoming fresh air.
Lower Labor Demand
Centralized collection removes the need for operators to monitor individual exhausts, empty local waste containers, or restart machines after blockages, reducing manual handling across the entire facility.
Improved Workplace Safety
Removing loose paper trim and dust from the production floor reduces slip and fire hazards, supporting a safer working environment across all food packaging lines.
More Usable Floor Space
Centralized waste collection replaces multiple individual containers and local exhaust units, freeing up floor space and making the production environment significantly easier to maintain.
Before centralized extraction, operators managed dust buildup and clogging manually across all eight tea packing lines.
Waste collected from the three extraction lines is discharged into large waste bins, while dust is handled separately through the KNFK bag filter for clean, controlled operation.
The MultiAir blower generates the conveying airflow that transports paper trim and dust from all eight tea packing machines to a central collection point.
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Explore Kongskilde Solutions for Food Packaging Production
Kongskilde provides complete trim extraction and dust control systems for food packaging manufacturers. From paper trim conveying and dust filtration to waste collection and air recirculation, every system is designed to keep packaging lines running cleanly and at full capacity.
Optimize Trim Extraction on Your Packaging Lines
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