In folding carton manufacturing, scrap handling systems play a critical role in maintaining production efficiency. As die cutters operate at higher speeds and facilities add new equipment lines, scrap removal infrastructure must keep pace. Without the right systems in place, scrap can create operational slowdowns, increase labor demands, and limit overall throughput.
Seaboard Folding Box recognized this challenge as it prepared to move into a new facility in Westminster, Massachusetts. A long-established provider of custom folding cartons for the food, pharmaceutical, and consumer products markets, the company needed a scrap handling solution capable of supporting its expanding production capabilities.
To meet these demands, Seaboard partnered with AES to design and install a fully automated scrap removal system engineered to handle the trimmings generated by multiple high-speed die cutters while improving efficiency, reducing manual handling, and supporting future growth.
The Challenges of Scaling Scrap Handling for a Growing Operation
Seaboard’s previous scrap system had become increasingly difficult to manage as production demands grew, and the company identified several operational challenges that needed to be addressed in the new facility.
Inefficient System Design
The existing scrap system was both overloaded and labor-intensive, making it difficult for the operation to keep pace with rising production. A new system would need to handle higher scrap volumes while also reducing the manual labor required to manage scrap removal.
Costly Heating & Cooling Losses
Energy efficiency was another major concern. The old facility experienced significant heat loss, which drove up energy costs and made it difficult to maintain stable conditions within the plant. Because the new building would feature a fully conditioned production floor, improving HVAC efficiency became a critical requirement.
Insufficient System Capacity & Scrap Grade Segregation
The previous scrap system was undersized and lacked the capacity needed to support additional equipment lines. At the same time, bale quality needed improvement, and the company needed better resources to separate scrap by grade to maximize recycling value.
Together, these challenges made it clear that Seaboard needed a modern, automated scrap removal solution capable of supporting both current production demands and future growth.
A Turnkey Automated Scrap Removal System From AES
Seaboard turned to AES to design a comprehensive system that would address these challenges while delivering the speed, reliability, and scalability needed for long-term success.
We provided a turnkey equipment and installation package, managing the project from initial engineering through commissioning. The project scope included:
- System design and engineering
- Equipment selection and integration
- Fabrication and installation of twin cyclone collectors
- Die cutter ducting and associated sheet metal fabrication
- Divert valves, fans, and support structures
- A fresh air intake system
- System start-up, commissioning, and training
This integrated approach ensured that every component of the system works together seamlessly while supporting the facility’s operational goals.
Key System Enhancements That Improved Plant Performance
The automated scrap removal system introduced several important upgrades that improved both operational efficiency and long-term cost performance.
Improved System Efficiency & Built-In Redundancy
With the new automated system in place, Seaboard’s high-speed die cutters can operate at full capacity. Automation reduces manual scrap handling while improving the consistency and reliability of scrap removal.
Built-in system redundancy also reduces the risk of downtime, and the infrastructure now has sufficient capacity to support additional machines as the company continues to expand.
Fresh Air Make-Up System
AES also installed a fresh air make-up system, significantly improving the plant’s HVAC efficiency.
This solution eliminated the need for an expensive dust filtration system while delivering both upfront and ongoing cost savings. By improving airflow and maintaining balanced air pressure within the building, the system also helps maintain a more stable and comfortable production environment.
Energy-Efficient Motor Controls
Energy-efficient motor controls were integrated throughout the system to reduce electrical consumption and improve operational efficiency.
These upgrades generated measurable monthly energy savings and helped Seaboard qualify for a sizable rebate from its utility provider, National Grid, further improving the project’s return on investment.
Scrap Grade Segregation Capabilities
The system also allows efficient separation of scrap by grade. This capability enables Seaboard to maximize the value of recyclable materials and improve bale quality, supporting the company’s recycling revenue stream.
Results: Greater Efficiency, Energy Savings & Capacity for Future Growth
With the new automated scrap removal system and fresh air make-up system fully operational, Seaboard achieved several important performance improvements.
The project delivered:
- Improved operational efficiency across the converting floor
- Reduced labor requirements through automated scrap removal
- Lower energy costs and improved HVAC efficiency
- A sizable utility rebate tied to energy-efficient equipment
- Built-in system redundancy and excess capacity for future expansion
- Improved bale quality and scrap grade separation
By eliminating system bottlenecks and improving facility infrastructure, Seaboard boosted overall operational efficiency and increased product throughput.
Turning Scrap Handling Into an Operational Advantage
Scrap removal is often treated as a secondary system within a manufacturing operation, but the right infrastructure can have a meaningful impact on productivity, energy use, and overall plant performance.
By implementing an automated scrap removal system tailored to its production environment, Seaboard Folding Box created a more efficient workflow, reduced operational costs, and prepared the facility for future equipment additions.
AES partners with manufacturers to engineer scrap handling systems that support modern production environments, integrating equipment, airflow, and automation into a cohesive solution that keeps operations running smoothly.
If you’re evaluating upgrades to your scrap handling infrastructure, contact AES to start planning a solution tailored to your operation.
And explore the full case study to learn more about the Seaboard Folding Box project.