When folding carton manufacturers invest in faster converting equipment and increased production capacity, scrap and dust-handling systems are often pushed beyond their original design limits. If those systems are not addressed proactively, they can quickly become a bottleneck that limits throughput, affects plant conditions, and drives up operating costs.
That was the situation facing TAVO Packaging, a custom folding carton manufacturer located in Fairless Hills, Pennsylvania. Serving large-volume customers across food service, refrigerated and frozen foods, bakery products, and quick-serve restaurant markets, TAVO is known for consistent quality, responsiveness, and reliability.
As part of a facility-wide expansion, TAVO needed to ensure its infrastructure could support higher production volumes without compromising efficiency, safety, or long-term scalability. Central to that effort was a comprehensive upgrade to the facility’s scrap and dust collection system.
The Operational Challenges of an Outdated Scrap System
As new high-speed converting equipment was added to the manufacturing floor, TAVO’s existing scrap system began to show its limits.
Several key challenges were identified:
- Outdated rooftop cyclones created an unattractive exterior appearance and no longer aligned with the facility’s modernization efforts
- An undersized scrap collection system restricted baling flexibility, limiting production to only two grades of scrap paper bales
- Cyclones exhausting to atmosphere generated a negative air pressure environment inside the plant, resulting in energy inefficiencies and lost conditioned air
- A centrally located baling room increased internal scrap travel distances, adding unnecessary material handling steps and reducing overall efficiency
While TAVO’s operation continued to perform, it was clear that the scrap and dust collection system needed to evolve alongside the rest of the facility to support future growth.
A Strategic Approach to Scrap & Dust Handling
AES partnered with TAVO to design and install a custom-engineered scrap and dust handling system aligned with the company’s expansion goals and day-to-day operating realities.
Rather than simply replacing individual components, AES took a system-level approach, focusing on material flow, equipment placement, and long-term performance.
Key elements of the solution included:
- Relocating the scrap system adjacent to the loading docks, significantly reducing internal scrap movement and improving overall material flow
- Installing a new dust collector to eliminate negative pressure issues, improve plant cleanliness, and reduce energy loss
- Constructing a new baling room near the docks, streamlining bale handling, staging, and transport for storage and shipment
- Integrating AES AirShark™ rotary separators beneath the roof, delivering high air-handling capacity in a compact footprint while eliminating the need for large, unsightly rooftop cyclones
The AirShark™ separators played a critical role by increasing conveyance volume and efficiency while improving both interior plant conditions and exterior facility aesthetics.
Supporting Higher Throughput Without Compromising Efficiency
With the upgraded system in place, TAVO gained a scrap and dust-handling solution designed to keep pace with increased production demands driven by new high-speed die cutters on the manufacturing floor.
The integrated system now supports:
- Higher scrap volumes without restricting production
- Cleaner, safer plant conditions
- Improved energy efficiency through the elimination of negative pressure
- Reduced material handling and simplified scrap flow
- A more modern exterior appearance aligned with facility upgrades
Just as important, the system was engineered with scalability in mind, allowing TAVO to continue growing without outgrowing its scrap infrastructure.
Beyond Scrap Handling
The project’s impact went beyond scrap collection alone. By addressing scrap and dust handling as part of a broader facility expansion, TAVO improved overall operational efficiency while positioning the plant for long-term success.
The results included:
- Increased product throughput
- Improved plant cleanliness and safety
- Reduced energy inefficiencies
- Streamlined bale handling and logistics
- A future-ready scrap system designed to support continued growth
Designing Scrap Systems to Support Your Entire Operation
At AES, we design, build, and maintain integrated scrap systems that do more than move material from point A to point B. We engineer solutions that support productivity, safety, and profitability across the entire manufacturing operation.
As a single source for conveyance needs, we work as a partner in process improvement, helping facilities design scrap and dust handling systems that align with current demands and future expansion plans.
If your scrap system is limiting capacity, efficiency, or growth, we’re ready to help.
View the full TAVO Packaging case study or contact AES to discuss your scrap and dust collection needs.