Trim Extraction System for Book Production Reduces Downtime and Recovers Warm Air – Poland

The Challenge: Clean, Continuous Trim Extraction in Book Production

In high-speed book production, continuous trim and dust extraction is essential to maintain efficiency and product quality.

This facility operated five production lines generating a constant stream of paper trim from three-side trimmers, along with fine, “woolly” paper dust from cutter machines. However, their existing extraction system, built around aging and worn fans, could no longer keep up with production demands.

As a result:

• Trim and dust accumulated around machines and in containers.
• Operators were frequently interrupted to clear material buildup.
• Unplanned stoppages became increasingly common.
• The production area appeared untidy, especially during customer visits.
• The system lacked capacity to support future expansion.

The company needed a reliable paper trim extraction system capable of supporting all lines while improving cleanliness, uptime, and operational efficiency.

The Facts: Material, System Requirements & Production Parameters

• Material: Paper book trim
• Width of trim: Up to 30 mm
• Length of trim: Up to 430 mm
• Trim thickness: Up to 80 mm; paper up to
• 400 g/m²
• Machines served: 5 lines, 1 suction point per machine
• System routing: 60 m height, 3.5 m width,
• 5 angle joints
• Production speed: Up to 9,000 cuts/hour

The Solution: Centralized Trim and Dust Extraction

Kongskilde designed and installed a centralized pneumatic trim extraction system tailored to the facility’s layout and production requirements.

Key System Components

• KU 20000 separator for efficient trim separation with minimal air loss.
• DS 28 cartridge filter to capture paper dust and fines.
• MTK 55 main blower supported by an MCD 50 auxiliary blower for stable airflow.
• Compact, frame-mounted system allowing space optimization and truck access.

How the System Works

• Paper trim is pneumatically conveyed from all five lines to the separator.
• Dust is filtered and discharged via a rotary valve into a press for enclosed handling.
• Waste is automatically diverted between containers when one becomes full.
• Ducting and airflow are engineered for gentle conveying across 60 meters, reducing wear and blockages.

This integrated solution ensures continuous, efficient material handling with minimal operator intervention

Advantages and Benefits: Cleaner Production, Higher Uptime, and Lower Heating Costs

The new trim extraction system delivered immediate operational improvements across the facility.

Cleaner Production Environment

Trim and dust are captured directly at the source, keeping machines and floors clean while improving overall working conditions.

Increased Uptime

Automatic waste handling and container changeover eliminate manual interruptions and reduce unplanned downtime.

Improved Operational Efficiency

Centralized waste collection simplifies logistics and keeps the production floor clear for better workflow.

Lower Operating Costs

Reduced labor for manual cleaning and more efficient waste handling lower day-to-day operational expenses.

Energy Savings

Filtered, warm air is returned to the production hall, helping reduce heating costs during colder months.