Trim and Dust Extraction Upgrade

Case Study

Project Overview

As part of a significant machinery upgrade, integratedAIR was approached by a major packaging manufacturer that had recently planned the installation of a new EMBA 175 Ultima inline converting machine. This high-end equipment presented new demands on the plant’s existing waste extraction infrastructure, calling for an equally advanced and efficient trim and dust extraction solution. integratedair was called in to assess the site and deliver a comprehensive system upgrade tailored to the increased air volume, corrugated scrap and dust management requirements brought on by the new machinery.

System Overhaul

A primary requirement was to accommodate the additional extraction demands introduced by the new machinery, which increased the system’s airflow requirement from approximately 30,000 m³/h to 55,000 m³/h. Before any new installation could begin, integratedAIR's engineers conducted a thorough strip-out of existing components that would be redundant with the upgraded system. This included the safe removal of the existing filter unit, air separator, rotary valve, and transition pieces.

old waste extraction system — Old waste extraction system

Smart Internal Ducting and Collection

The project was split into 2 phases.

Phase 1

With the old system cleared and the space prepared, external equipment was erected around the compactor to minimise downtime. The client was able to continue running the existing EMBA while awaiting delivery of the new EMBA. Internally, ducting was routed, ready for connecting to the new machine.

Phase 2

The final connections were completed, followed by a full commissioning of the system, working closely with all parties to ensure the switchover was completed on time.

High-Efficiency Dust Management

To meet the increased extraction demands introduced by the new EMBA machine, integratedAIR replaced the existing filter unit with a high-efficiency BlueClean VT Reverse Jet Tubular Bag Filter. This advanced system features reverse jet pulse cleaning technology, which uses compressed air to dislodge collected dust from the filter sleeves. The continuous cleaning process ensures minimal maintenance and consistently maintains air quality below COSHH limits of 10mg/m³. To further support the increased airflow and maintain system balance, a centrifugal fan was added to the system. This fan helps regulate pressure across the system and ensures stable, efficient dust removal during high-demand operation.

Following the successful installation of a smaller dust extraction unit at the same site, which has already delivered positive results, we’ve continued to engage closely with our client. Through ongoing conversations, we became aware of upcoming upgrades to their equipment. This open dialogue between our engineering team and the client has been key to understanding their evolving requirements and ensuring the project progresses smoothly for all parties involved.

Steve Margison, Sales Manager

This project was a great example of how collaboration, careful planning, and problem-solving under pressure can deliver exceptional results. Despite unexpected challenges, we kept a clear focus on safety, quality, and deadlines, and the team’s dedication meant we achieved a finish we can all be proud of.

Joshua Hargreaves, Project Manager

Project Outcome

integratedAIR’s waste and dust extraction system enhancements contribute to an efficient waste extraction system, engineered to support the high output of the new inline converting machine. With the expert integration of the new systems with the existing infrastructure, combined with advanced trim and dust extraction technologies, integratedAIR has helped future-proof the plant’s operations while maintaining air quality and productivity.

Do you need a waste and dust extraction solution for your facility?

Get in touch with integratedAIR Systems today to find out how we can support your next upgrade or expansion.

Get in touch

Call:
+44 (0) 161 488 4992

Email:
sales@integratedair.co.uk