The Challenge: Upgrading Outdated Trim Handling System
The customer had several challenges they needed to address in their production:
- Wanted 6 new individual venturi systems to optimize efficiency from 6 extruders.
- Conserve floor space and discharge material at 2 opposite points of the factory where briquette machines were placed.
- Provide better air separation.
- Must be a more efficient system with enhanced safety features.
- Must completely mitigate stops and remove downtime.
The Facts: Material & System Requirements
- Material: Food packaging film
- Conveying distance: 10 – 25m and 5 bends
- Trim thickness/Speed relation:
- 10 – 25 micron at 60-110 m/min
- 30 – 50 micron at 45-60 m/min
- 50 – 90 micron at 25-50 m/min
- 90 – 180 micron at 12-25 m/min
The Solution: A Modern, Energy-Efficient Conveying System
Kongskilde engineered a custom pneumatic system that optimizes pick-up, conveying, and discharge from the 6 extruder machines.
- For each extruder, Kongskilde installed 2xØ60 or 3xØ60mm pick-up points, each with a steel flex hose of 1.2 meters.
- Both suction points joined into a common duct that will connect to an individual Venturi ITF 100 per machine.
- Upgraded to a high-pressure blower, the MultiAir FC2080T, equipped with a frequency inverter and soundproof design.
- Main equipment has been placed on the top floor of the client’s machines and each venturi system has been installed near the final section of the route, at approx. 1-2 meters before the static separator.
- KU Static Separators have been chosen as the common discharge equipment.
The Advantages & Benefits: Annual Savings & Reduced Maintenance
In the previous solution, the continuous trim sometimes was not properly discharged into the compactor and as a result of this, some quality rejects were provoked by jams on the rolls.
- ROI = 1.5
- Eliminated downtime (0% stops), saving €40,000 annually.
- Reduced energy consumption by 60%, saving €22,000 annually.
- Eliminated compressed air, saving €9,000 annually
- Reduced preventative and corrective maintenance costs by €9,000 – €12,000 annually.
- The smaller footprint of the MultiAir blower allows for optimized space management.
- Improved safety through reduction of noise pollution by 10% on the production floor.
- Breakdowns, corrective maintenance, and stops were eradicated.
Before Kongskilde’s Solution:
Before the system was installed, the continuous trim was not properly discharged into the compactor. As a result, some quality rejects were provoked by jams on the rolls.
After Kongskilde’s Solution:
After the system was installed, downtime and unnecessary stops were completely eradicated, resulting in significant annual savings.
Download the full case study:
Explore Kongskilde Solutions for Plastic 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 Plastic Packaging Waste Handling
Looking to automate scrap removal, improve air quality, and enhance the efficiency of your plastic packaging production? Don’t hesitate to ask how we can help.