Complete Paper Converting Systems for Trim Removal, Vacuum Transfer and Dust Collection
Paper converting systems from Engineered Recycling Systems capture, move and process the waste a converting plant produces every minute it runs. ERS designs, builds and installs complete systems for corrugated plants, folding carton operations, sheet plants, commercial printers and paper mills across North America. One ERS system handles the entire path the waste takes: trim removal at the machine, vacuum transfer through the plant, scrap collection and baling at the back end, and dust collection to keep the air clean along the way.
That whole-system approach is what separates ERS from suppliers who sell a single component. A blower on its own will not keep a corrugator running. Ductwork alone will not stop a jam at the slitter. What keeps a converting plant productive is a properly engineered system in which the capture hoods, the piping, the fan, the separator, the baler and the filtration are all sized for the same production rate and all work against the same static pressure. ERS engineers the system as one machine, then stands behind it.
Trim Removal at the Machine
Trim removal is where the system starts. Every converting line makes edge trim, slitter waste, start-up sheets and misruns, and all of it has to leave the machine the moment it is made. If it does not, it wraps a roll, jams a stacker or lands on the floor for someone to pick up by hand. ERS builds capture hoods that mount directly to the machine and pull trim away at the point it is created, sized to the width and speed of the line rather than to a catalog number.
We work on corrugators, flexo folder gluers, rotary die cutters, flat bed die cutters, sheeters, slitters, folding carton presses and web presses. Each machine presents a different problem. A corrugator makes long continuous edge trim at high speed. A rotary die cutter makes short scrap in bursts. A sheeter makes a narrow, fast ribbon. The hood, the throat size and the air volume are chosen for the machine in front of us, which is why ERS surveys the plant before quoting rather than after.
Vacuum Transfer Through the Plant
Once the trim is captured it has to travel, sometimes several hundred feet, sometimes through two buildings, usually overhead and out of the way of forklifts and maintenance access. Vacuum transfer is the part of the system most often undersized, and an undersized transfer line is the most common cause of plugged pipe in a converting plant.
ERS sizes the piping and the fan together. We calculate the material load, the conveying velocity required to keep that material airborne, and the total static pressure the system will see with every branch open. The layout is routed around the plant as it actually is, not as the drawings say it is, and the ductwork is built from heavy gauge material with long radius elbows at the wear points. The result is a transfer line that carries the full production rate of every machine tied into it, on the worst day of the year, without dropping material in a horizontal run.
Scrap Collection, Baling and Storage
At the end of the line the waste has to be turned into something that can be sold. ERS supplies the back end of the system as part of the same package: cyclone separators, receiving bins, feed conveyors and balers sized to the volume the plant actually produces. The separator drops the material out of the air stream, the conveyor feeds the baler at a steady rate, and the baler produces mill-ready bales that a broker will pay for.
Getting this end right pays for itself. Loose scrap in a trailer is worth a fraction of what a dense, consistent bale is worth, and a baler that keeps stalling because it is being fed in surges costs more in downtime than the difference in price. ERS matches baler capacity to the real production rate, and designs the surge capacity ahead of it so that the baler runs steadily instead of chasing the line.
Dust Collection
Converting produces paper dust along with the trim, and ERS includes filtration in the system so that the air returned to the plant is clean and the material handled stays where it belongs.
Matrix Removal
Some die cutting operations also need the matrix stripped and carried away, and ERS handles that as part of the same system where the application calls for it.
Industries We Serve
ERS paper converting systems run in corrugated box plants, sheet plants, folding carton operations, commercial print shops, tissue converting facilities and paper mills. The waste is different in each of them, but the requirement is the same: get it away from the machine immediately, move it reliably, and turn it into a product that leaves the building at the best price available.
Engineering, Installation and Service
ERS is an engineering company before it is a supplier. Every project starts with a plant survey, where we measure the machines, walk the intended routing and talk to the people who run the line about what actually goes wrong today. From there we produce a system design, a layout drawing and a quotation that covers the complete installed system rather than a list of parts.
We install the system ourselves and commission it with the plant running, and we support it afterward with parts, service and system modifications as production changes. Converting plants add machines, move lines and increase speeds, and an ERS system is designed with the capacity and the access to grow with them.
Talk to ERS About Your Plant
If trim is jamming your machines, if your transfer line plugs, if your baler cannot keep up, or if you are installing a new line and want the waste handling engineered properly from the start, ERS can help. Call +1 770-954-8780 or email info@engineeredrecycling.com and we will arrange a plant survey.