AES helped UN1F1ED Global Packaging improve scrap handling and dust control with a turnkey scrap removal and baling system that collects material from six production points and conveys it through an integrated pneumatic system to an AirShark™ separator and automatic baler.
Overview
UN1F1ED Global Packaging provides innovative, high-quality packaging solutions from its facility in Sutton, Massachusetts. The company needed a reliable way to collect scrap from multiple production areas while also supporting cleaner operations through dust control.
AES was selected to provide a turnkey scrap removal and baling system with dust control. The system collects scrap from six points of generation, including die cutters, folders, gluers, and other production equipment, then moves the material through pneumatic conveyance ducting for separation and baling.
What problem did AES solve?
UN1F1ED needed a system that could collect scrap from several production machines, reduce manual handling, support dust control, and deliver scrap material efficiently to an automatic baler.
AES provided a complete integrated system with a new 40 HP hogger, pneumatic air conveyance ducting, material handling fans, structural steel supports, a 60,000 CFM AirShark™ rotary material separator, electrical controls, installation, startup, commissioning, and training.
Scope of Work
- Project Design & Engineering
- AirShark™ Model AS-60 Rotary Material Separator
- Pneumatic Air Conveyance Ducting
- Material Handling Fans
- Structural Steel Supports
- Electrical Control Package
- Rigging & Installation
- System Start-Up, Commissioning & Training
- 40 HP Hogger
The Challenge
UN1F1ED Global Packaging needed a more efficient way to collect scrap and manage dust from multiple areas of its packaging production operation. Scrap was being generated at several points throughout the facility, including die cutters, folders, gluers, and other production equipment.
Because the system had to support six points of generation, AES needed to create an integrated layout that could collect material consistently, convey it through ductwork, separate the scrap from the air stream, and feed it into an automatic baler.
The main challenges we had to address:
- Scrap was being generated from six different production points.
- Die cutters, folders, gluers, and other equipment needed reliable scrap collection.
- Scrap material had to be conveyed efficiently through an air system.
- Dust control needed to be included as part of the overall scrap handling process.
- A new shredder had to be integrated into the scrap removal system.
- The system needed to feed separated material into an automatic baler.
AES needed to provide a complete turnkey system that combined project design, engineering, shredding, air conveyance, material separation, baling integration, structural supports, controls, installation, startup, commissioning, and training into one coordinated solution.
The AES Solution
AES designed and installed a turnkey scrap removal and baling system with dust control for UN1F1ED Global Packaging’s Sutton, Massachusetts facility. The system collects scrap from six points of generation and moves the material through pneumatic conveyance ducting.
AES also provided a new 40 HP hogger integrated into the scrap system. From there, scrap material is filtered through a 60,000 CFM AirShark™ Model AS-60 rotary material separator before dropping into an automatic baler for efficient handling.
AES System Components
The scrap and dust removal system included:
- 40 HP hogger
- AirShark™ Model AS-60 rotary material separator
- 60,000 CFM material separation capacity
- Pneumatic air conveyance ducting
- Material handling fans
- Structural steel supports
- Electrical control package
- Automatic baler integration
- Rigging and installation
- Custom integrated scrap and dust removal layout
The completed system gave UN1F1ED Global Packaging a more efficient way to collect scrap from multiple production machines while supporting dust control and automated baling.
By combining shredding, pneumatic conveyance, AirShark™ separation, baler integration, structural supports, controls, installation, commissioning, and training, AES delivered a turnkey system built around the facility’s real production needs.
The Results
With the new scrap and dust removal system in place, UN1F1ED Global Packaging gained an integrated way to collect scrap from six production points and convey material efficiently to an automatic baler.
The completed system helped improve scrap handling, support dust control, reduce manual handling, and create a cleaner, more efficient production environment for packaging operations.
Download the Full Case Study
Download the complete UN1F1ED Global Packaging case study to see how AES designed and installed a turnkey scrap and dust removal system with a 40 HP hogger, pneumatic conveyance, AirShark™ separation, structural supports, electrical controls, installation, commissioning, and training.
A Turnkey Scrap and Dust Removal System Built for Packaging Production
This project shows how a properly engineered scrap and dust removal system can support cleaner, more efficient packaging production. For UN1F1ED Global Packaging, AES helped connect multiple scrap generation points into one coordinated system that conveys, separates, and delivers material to an automatic baler.
For packaging manufacturers, folding carton plants, converting facilities, and other operations handling trim, scrap, and dust, AES designs custom systems around the real production environment, equipment layout, material flow, collection points, and long-term operating goals.
Frequently Asked Questions
A scrap and dust removal system collects production scrap and airborne dust from manufacturing equipment, then conveys the material through ductwork to separation, collection, baling, or processing equipment.
UN1F1ED needed to collect scrap from six points of generation, including die cutters, folders, gluers, and other production equipment, while also supporting dust control and efficient baling.
The system included a 40 HP hogger, AirShark™ Model AS-60 rotary material separator, pneumatic air conveyance ducting, material handling fans, structural steel supports, electrical controls, automatic baler integration, installation, commissioning, and training.
The AirShark™ separator filters scrap material from the pneumatic conveyance air stream before the material drops into the automatic baler.
Yes. AES designs and installs custom scrap removal, dust control, pneumatic conveyance, material separation, baling integration, controls, and turnkey installation systems for packaging plants, converters, printers, and other production facilities.
