The Challenge: Improving Waste Handling Efficiency in Flexible Film Packaging Production
This Polish factory specializes in manufacturing flexible packaging films for food, pharmaceutical, and industrial applications. As production speeds increased, their existing scrap-handling methods created bottlenecks that slowed operations and compromised workplace cleanliness.
The facility faced several key challenges:
- Manual scrap removal slowed output and required unnecessary labor.
- Transport delays disrupted workflow, especially during rewinding and cutting of flexible films packaging.
- Poor airflow and energy inefficiencies created air-quality issues and unnecessary operating costs.
- Compliance requirements demanded effective dust control and improved indoor air quality.
To maintain productivity and ensure safe, efficient handling of film waste, the manufacturer needed a fully automated scrap extraction system tailored for flexible film packaging production.
The Facts: Material, System Requirements & Production Parameters
- Material: Plastic and aluminium scraps from rewinding/cutting lines
- Production speed: Up to 400 m/min
- Film thickness: 100 μ
- Trim size: Up to 500 mm skeleton
- Transport distance: 95 m horizontal / 12 m vertical
- Variable waste widths:
- Rewinding machine scraps: up to 50 mm
- Cutting machine scraps: up to 500 mm
The system needed to support differing widths, high conveying speeds, and consistent scrap removal across multiple flexible packaging films and formats.
The Solution: Automated Pneumatic Film Scrap Extraction & Shredding
Kongskilde engineered a custom pneumatic waste extraction system designed to improve efficiency for flexible film packaging production. The solution automates scrap collection, shredding, and transport while eliminating dust and optimizing energy usage.
How the System Works
- MultiCutters mounted at production machines shred film scraps and prepare them for transport.
- BTK blowers generate the airflow needed to vacuum scraps directly from the source.
- OK piping and FK piping transports shredded material to large press containers.
- A KU static separator removes shredded waste from the conveying airstream.
- A DS filter cleans the air, capturing particles before recirculation.
- MTD blowers return purified air into the hall, eliminating negative pressure.
- A main blower equipped with a frequency converter automatically adjusts speed based on machine load—reducing energy consumption.
Key Operational Strengths
- Handles multiple waste widths and film types seamlessly
- Supports high-speed lines producing flexible packaging films
- Eliminates dust and ensures continuous film scrap removal
- Protects employee health by maintaining clean and balanced air pressure
Advantages & Benefits: Cleaner Air, Higher Efficiency, Lower Energy Costs
Continuous, Efficient Waste Removal
The pneumatic system ensures uninterrupted removal of film scraps, minimizing downtime and stabilizing production flow. Rewinding and cutting lines maintain peak performance without manual intervention.
Cleaner Air and a Healthier Work Environment
- Dust and particles are separated from the conveying airflow
- Only clean, filtered air is recirculated into the hall
- Eliminates negative pressure zones
- Supports compliance with workplace safety and hygiene standards
This significantly improves working conditions for employees handling flexible film packaging materials.
Reduced Energy Consumption
The frequency-controlled blower optimizes energy use by adjusting power based on the number of machines operating. This leads to:
- Lower operational costs
- Reduced environmental impact
- Stable airflow and consistent scrap removal performance
The Kongskilde MultiCutter shreds film scraps directly at the source, enabling smooth, uninterrupted transport through the system.
The KU Static Separator directs bulk materials into a stationary compactor, baler, or container, while the conveying air is efficiently expelled, enabling clean, efficient waste collection.
The BTK Blower is designed for continuous transport of materials, like shredded film scraps, through a closed loop conveying system.
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Explore Kongskilde Solutions for Flexible Packaging
Kongskilde provides complete systems for flexible packaging waste extraction, shredding, conveying, and collection—helping manufacturers remove film scraps automatically from converting lines, reduce downtime and dust, and keep production running efficiently.
Optimize Your Flexible Film Packaging Waste Handling
Looking to automate scrap removal, improve air quality, and enhance the efficiency of your flexible packaging film production? Don’t hesitate to ask how we can help.