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
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