Blog / Trim and Dust Extraction
Upgrade
12th October 2025
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 Systems 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.
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.
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.
External upgrades were made to the system with the
installation of a new air separator. Incoming material now flows through
heavy-duty trim specification ductwork into this unit, where heavier trim waste
is separated by a perforated air screen and directed into a new rotary valve
before being compacted.
As material enters the Air Separator, heavier particles are
deflected by the screen and directed through a controlled discharge path that
leads to the waste compactor, while lighter dust continues through to the
filtration stage. To prevent the risk of reverse airflow or pressure imbalances
in the system, three non-return inlets were fitted at the air separator. These
inlets are designed to allow air and material to enter in one direction only,
which prevents the re-entrainment of waste.
A motor-driven rotary valve transfers waste collected by the
air separator into the compactor, regulating material flow and protecting
downstream equipment from overload or blockages. To minimise turbulence during
this transfer, transition chutes were installed between components.
Custom-fabricated support structures were also added to hold all the new
external elements in place securely.
To ensure full system integration and safe operation,
integratedAIR’s electrician carried out essential electrical upgrades within
the factory. These included configuring signal feeds from the new EMBA machine
to interface with the extraction system, supplying power to the newly installed
55kW centrifugal fan, and integrating high-level sensors from the client’s
compactor to prevent overfilling or jamming. Our commissioning engineers
collaborated closely with the client’s team to verify system performance and
ensure efficient, trouble-free operation.
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. 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.
