Replacing Cutter in Existing Conveying System – Belgium

The Challenge: Replacing a Cutter Without Disrupting an Existing Conveying Line

Retrofitting a single component into an aging pneumatic conveying system carries real risk when the surrounding blower and piping specifications are unknown, since any mismatch can increase backpressure, cut capacity, or force a costly system-wide upgrade. The customer needed a reliable cutter replacement that could slot directly into an older pneumatic conveying line.

With unknown blower specifications and fixed pipe diameters, the new unit had to operate without increasing backpressure or reducing capacity. A scalable solution was required that would protect uptime and avoid costly system changes.

Key Issues:

• Existing blower and pipe diameters were fixed and could not be modified
• No specification data existed on airflow performance
• The new cutter had to maintain or increase previous processing capacity
• Retrofit needed to happen without halting production

The Facts: Material Specifications and System Requirements

Material specifications:

• Extrusion-coated waste
• Trim and off-cuts from disposable overalls
• Light, non-woven fabric

System constraints:

• Blower and pipe diameters fixed at existing specifications
• No documented airflow or backpressure data available for the installed system
• New cutter required to match or exceed prior processing capacity

The Solution: Testing and Retrofitting the Right Cutter Size

Because no data existed for the installed blower or pipework, Kongskilde performed controlled tests at its Technology Centre to identify the correct cutter size for the application. Testing confirmed that while the MultiCutter MC 3000 could process the material, achieving the lowest possible backpressure required the larger MultiCutter MC 5000. The MC 5000 was retrofitted directly into the existing line, paired with the customer’s current blower and piping.

1. MultiCutter MC 5000 retrofitted into the existing conveying line Cutter sized to match existing blower capacity without modification Integrated directly into the customer’s existing piping.
2. Performance validated through testing at the Kongskilde Technology Centre before installation.

How the retrofit was validated:

1. Kongskilde reviewed the existing conveying line, where no blower or pipe specification data was available
2. Sample material was run through test cutters at the Kongskilde Technology Centre to measure backpressure and throughput
3. The MultiCutter MC 3000 was tested first and found capable of processing the material
4. The MultiCutter MC 5000 was tested next and identified as the unit achieving the lowest backpressure
5. The MC 5000 was installed into the existing line and paired with the current blower and piping

This testing-first approach let the customer upgrade a single component with confidence, without guessing at compatibility or risking unplanned downtime.

Advantages & Benefits: A Scalable, Low-Risk Retrofit

Improved System Scalability

The retrofit cutter was sized specifically for optimal backpressure, giving the customer headroom for future throughput needs.

Lower Upgrade Costs

Retaining the existing blower and piping avoided the cost of a full system replacement.

Faster System Integration

A modular cutter design allowed the new unit to integrate into the existing line without extended installation time.

Verified Performance Before Installation

Testing at the Kongskilde Technology Centre confirmed the correct cutter size before the unit was installed, reducing the risk of unplanned downtime.

Built-In Flexibility for Future Upgrades

The modularity of Kongskilde’s conveying components means additional elements can be swapped or upgraded later without redesigning the full system.