Trim transport systems on high-speed paper rewinding lines play a critical role in production continuity and reel quality. When trim removal is insufficient, line stops, speed reductions and losses in production efficiency can occur.
A leading manufacturer of paper-industry machinery in France needed a more efficient and reliable trim transport system for its new high-speed winding machine series. To meet the new technical requirements and ensure uninterrupted operation with demanding materials, it turned to Kongskilde’s advanced pneumatic solution.
Core Requirements of the Project
The high speeds targeted on the new winding line and the variable trim widths meant existing solutions fell short. The main features expected from the system were therefore:
- Smooth operation at different trim widths
- Stable performance during machine commissioning
- Continuous trim suction up to 1500 m/min
- Reliable removal on silicone-coated greaseproof paper
- Full compatibility with the existing line infrastructure and control systems
Technical Requirements
- Material: Double-sided silicone-coated greaseproof paper
- Trim width: 50–150 mm (25–150 mm on each side)
- Maximum reel width: 3800 mm
- Operating speed: 500–1500 m/min
- Maximum capacity: 840 kg/h (2 x 100 mm cut at 1000 m/min)
- Edge size / speed: 25–50 mm x 1500 m/min, 150 mm x 500 m/min
The Solution: A Single-Blower Chopper Fan System
The solution developed by Kongskilde specifically for the project was a chopper fan system operating with a single blower. By eliminating the dual-blower requirement common on the market, this system delivered both more efficient operation and reduced energy consumption.
The installed system consists of the following components:
- Chopper Fan
- Butterfly valve
- A damper system on the line to adjust the air flow
Thanks to this structure, trim removal is automatically optimised according to the machine’s operating speed, providing uninterrupted suction up to 1500 m/min.
The system was integrated into the factory’s existing control cabinet for full compatibility. The components are managed as follows:
- The chopper fan is controlled via a frequency converter for stable performance.
- The cooling fan runs in sync with the system to prevent overheating.
- The butterfly valve is precisely controlled with a 24V single-phase servomotor and a 4-20 mA regulation card.
In addition, the system was connected to the existing cyclone via a 60-metre, 300 mm diameter ducting line, and trim removal was seamlessly integrated into the existing recycling line (cyclone and pulper).
Energy Savings and Gains
One of the most important advantages of the new system is the significant reduction in installed power demand. While the solution runs on just 37 kW, the previous system required 2 x 37 kW. Operating costs were thus reduced and a more sustainable production infrastructure was created.
Thanks to the frequency inverter, energy consumption is adjusted to the suction demand, preventing the system from wasting power.
The main gains achieved with this project:
- Higher production continuity through continuous and stable trim removal
- Reliable performance at high speeds
- Smooth operation with demanding materials (silicone-coated greaseproof paper)
- Easy integration with the existing line infrastructure
- Low energy consumption and more efficient operating costs
- A modern system infrastructure suited to future capacity increases
