AES helped TAVO Packaging upgrade its scrap and dust collection system as part of a facility-wide expansion, giving the company the capacity to support two new Bobst high-speed die cutters, improve plant cleanliness and safety, streamline bale handling, and enhance the exterior appearance of the facility.
Overview
TAVO Packaging is a custom folding carton manufacturer located in Fairless Hills, Pennsylvania. The company specializes in carton solutions for large-volume customers, with a focus on quick-serve restaurant, food service, refrigerated and frozen foods, and bakery product packaging.
As TAVO expanded its manufacturing capacity, the facility’s existing scrap and dust collection system needed major improvements. The old system relied on outdated roof-mounted cyclones, limited scrap handling capacity, and created negative air pressure inside the building. AES was selected to provide a modern scrap and dust handling system built around higher production volume, cleaner operations, better energy efficiency, and improved material flow.
What problem did AES solve?
TAVO needed to increase scrap conveyance capacity while eliminating the problems created by outdated rooftop cyclones, negative building pressure, limited bale grade separation, and an inefficient baling room location.
AES outfitted the facility with an upgraded scrap baling and dust collection system that included under-roof AirShark™ separators, a new dust collector, improved system placement near the loading docks, and a new baling room designed to streamline scrap paper bale transport.
Scope of Work
- Scrap and Dust Collection System Upgrade
- Scrap Conveyance System
- AES AirShark™ Separators
- Dust Collector
- New Baling Room Layout
- Manufacturing Capacity Upgrade
- Scrap Baling System Improvements
- System Location Near Loading Docks
- Facility Expansion Support
- System Start-Up, Commissioning & Training
- 40 HP Hogger
The Challenge
TAVO Packaging was known for its reliability, responsiveness, high-quality products, and strong packaging capabilities, but the facility needed upgrades to support increased production capacity and continue meeting customer demand.
The existing scrap collection system was undersized, the old cyclones on the roof hurt the building’s appearance, and the system created negative air pressure inside the plant. The baling room was also located in the center of the building, which meant scrap paper bales had to travel farther than necessary before storage and transport.
The main challenges we had to address:
- Outdated roof-mounted cyclones created an unattractive exterior appearance.
- The undersized scrap collection system limited production capabilities.
- The system could only support two grades of scrap paper bales.
- Cyclones exhausting to air created negative pressure inside the building.
- Negative air pressure contributed to inefficient energy use.
- The central baling room location made bale transport less efficient.
AES needed to provide a complete upgrade that improved scrap conveyance capacity, eliminated negative pressure issues, supported added production from two new Bobst high-speed die cutters, improved plant cleanliness, streamlined bale handling, and enhanced the facility’s appearance.
The AES Solution
AES outfitted TAVO’s facility with a modern scrap and dust handling system as part of a facility-wide expansion and manufacturing capacity upgrade. With two new Bobst high-speed die cutters added to the manufacturing floor, the AES scrap conveyance system enabled TAVO to keep up with the increased levels of scrap generated by the new machines.
The upgraded system included under-roof AES AirShark™ separators, which increased scrap conveyance volume and efficiency while improving facility aesthetics. AES also installed a new dust collector to eliminate negative air pressure inside the plant, improve cleanliness, and support more efficient operation.
AES System Components
The scrap and dust collection system upgrade included:
- AES AirShark™ separators
- Under-roof separator installation
- New dust collector
- Scrap conveyance system
- Scrap baling system improvements
- New baling room
- Loading dock-adjacent system location
- Support for two Bobst high-speed die cutters
- Improved bale transport layout
- Custom integrated scrap and dust collection layout
The completed system gave TAVO Packaging the scrap conveyance capacity needed to support increased production while improving plant cleanliness, safety, energy efficiency, and exterior appearance.
By combining under-roof AirShark™ separation, dust collection, improved system placement, and a new baling room layout, AES helped TAVO streamline scrap handling and support a more efficient folding carton production environment.
The Results
With the upgraded scrap baling and dust collection system in place, TAVO Packaging increased product throughput, improved plant cleanliness and safety, and enhanced the exterior aesthetics of the facility.
The completed system also eliminated negative pressure issues, improved scrap handling efficiency, streamlined bale transport, and gave TAVO the capacity needed to support higher production volumes from its new die-cutting equipment.
Download the Full Case Study
Download the complete TAVO Packaging case study to see how AES upgraded a folding carton facility with under-roof AirShark™ separators, dust collection, improved scrap conveyance, a new baling room, and system placement designed for more efficient bale handling.
A Scrap and Dust Collection Upgrade Built for Higher Packaging Throughput
This project shows how a properly engineered scrap and dust collection system can support more than waste handling. For TAVO Packaging, AES helped increase production capacity, improve plant cleanliness and safety, eliminate negative pressure issues, and streamline scrap bale movement near the loading docks.
For folding carton manufacturers, packaging plants, food packaging producers, and other facilities handling high volumes of trim, scrap, paper dust, and production byproducts, AES designs custom systems around equipment layout, material grades, building airflow, bale handling, and long-term operating goals.
Frequently Asked Questions
A scrap and dust collection system upgrade improves how a facility captures, conveys, separates, collects, and bales production scrap and dust generated during manufacturing.
TAVO needed to support increased manufacturing capacity, including two new Bobst high-speed die cutters. Its existing system was undersized, created negative building pressure, relied on outdated rooftop cyclones, and had an inefficient baling room location.
The system included under-roof AES AirShark™ separators, a new dust collector, scrap conveyance improvements, scrap baling system upgrades, a new baling room, and a layout positioned near the existing loading docks.
The new dust collector eliminated negative air pressure inside the plant, helping reduce inefficient energy use caused by the old cyclone exhaust setup.
Yes. AES designs and installs custom scrap and dust collection upgrades for folding carton manufacturers, packaging plants, converters, printers, and other production facilities handling paper scrap, trim, and dust.
