High-Speed Rewinding Trim Handling Solution – France

In high-speed paper rewinding operations, trim handling systems play a critical role in ensuring production stability and maintaining finished roll quality. When trim extraction cannot keep up with the machine speed, production interruptions, slowdowns, and efficiency losses become unavoidable.

In France, a leading machine manufacturer serving the papermill industry required a reliable and efficient trim handling solution for its new high-speed rewinding machine line. To meet updated technical specifications and ensure stable performance under demanding conditions, the company partnered with Kongskilde to implement an advanced pneumatic system.

Project Requirements

The upgraded rewinding machine demanded a modern trim handling solution capable of operating at high speeds while adapting to varying trim widths. Key requirements included:

  • Reliable operation across different trim widths

  • Stable performance during machine start-up

  • Continuous trim extraction at speeds up to 1,500 m/min

  • Efficient handling of silicone-coated greaseproof paper

  • Seamless integration with existing equipment and control cabinets

Technical Facts

  • Material: Greaseproof paper with silicone coating on both sides

  • Trim dimensions: 2 x 15 mm

  • Trim width range: 50–150 mm (each side 25–150 mm)

  • Base weight: 32 – 70 gsm

  • Maximum reel width: 3,800 mm

  • Operating speed: 500 – 1,500 m/min

  • Maximum capacity: 840 kg/h (cut 2 x 100 mm at 1,000 m/min)

  • Edge size / winder speed: 25–50 mm x 1,500 m/min, 150 mm x 500 m/min

The Implemented Solution

Kongskilde provided a high-performance chopper fan system designed to convey edge trim using a single blower. Compared to conventional solutions requiring two blowers, this approach delivers improved efficiency while significantly reducing energy consumption.

The installed system includes:

  • Chopper Fan

  • Cooling Fan

  • Butterfly Valve

  • Dampers on nozzle piping to regulate airflow according to operating speed

This configuration ensures continuous and stable trim extraction for greaseproof paper at rewinding speeds of up to 1,500 m/min.

Control and Integration

The trim handling system was fully integrated into the existing control cabinet to ensure synchronized operation with the rewinding line. Key features include:

  • The chopper fan is controlled by a frequency converter to maintain consistent performance.

  • The cooling fan operates simultaneously to prevent overheating.

  • The butterfly valve is regulated by a single-phase servomotor (24V DC/AC) and a 4–20 mA regulation card for precise control.

Additionally, the installation includes 60 meters of ductwork with a diameter of 300 mm, connected directly to the mill’s existing cyclone system. This integration ensures efficient trim evacuation and compatibility with the existing recycling process (cyclone and pulper).

Energy Savings and Operational Benefits

One of the most significant advantages of this solution is reduced installed power demand. The new system operates with only 37 kW, compared to the previous requirement of 2 x 37 kW, resulting in a substantial reduction in energy consumption.

Thanks to frequency inverter control, power usage can be adjusted precisely according to suction demand, lowering operating costs and supporting a more sustainable production process.

Key Advantages

  • Continuous and stable trim extraction, improving production uptime

  • Reliable performance at high rewinding speeds

  • Efficient handling of demanding materials such as silicone-coated greaseproof paper

  • Seamless integration with existing machinery and control infrastructure

  • Lower energy consumption and reduced operating costs

  • A future-ready system capable of supporting further production upgrades