Metal Can Scrap Removal System Capacity Expansion

Can Manufacturing Plant – Australia

Client Overview

A leading aluminium can manufacturing facility in Australia operating high-speed bodymaker and trim lines required an upgraded metal scrap removal system to support increasing production demand and improve operational reliability.

Running multiple lines at high output, the plant processes significant volumes of aluminium trim and offcut scrap daily. Efficient, uninterrupted scrap extraction is critical to maintaining line performance, ensuring safe working conditions, and maximising material recovery.

The Challenge

As production volumes increased, the existing scrap handling system began to present operational limitations, including:

• Scrap build-up around trim presses and conveyors
• Risk of blockages affecting line stability
• Inconsistent airflow across multiple extraction points
• Excessive housekeeping requirements
• Reduced aluminium recovery efficiency

In high-speed can manufacturing environments, even minor scrap accumulation can lead to unplanned downtime, safety concerns, and material loss. The facility required a robust, high-capacity metal scrap removal system capable of operating continuously under demanding production conditions.

The Solution

Impact Air Systems designed and installed a fully engineered, high-efficiency pneumatic metal scrap removal system tailored specifically to the plant’s layout and production speeds.

The upgraded system includes:

• High-velocity metal scrap removal from bodymakers to ensure consistent trim extraction and prevent blockages
• Cupping hood metal scrap extraction for efficient capture of aluminium waste at source
• A Hyper Oil four-stage oil mist filtration system on bodymakers to significantly reduce airborne oil particles
• Two-stage ink mist filtration and dedicated printer ink fume extraction to improve air quality in decoration areas
• Optimised oven exhaust stack systems to support safe and compliant discharge
• Centralised scrap conveying and controlled collection to enhance material handling efficiency

The system was carefully integrated into the live production environment to minimise disruption and ensure seamless commissioning.

Measurable Results

Following installation and optimisation, the facility reported significant operational improvements:

• Improved scrap removal consistency across all lines
• Reduction in scrap-related line stoppages
• Enhanced aluminium recovery for reprocessing
• Cleaner production areas with reduced manual intervention
• Lower housekeeping time and associated labour costs
• Greater production stability at high line speeds

By improving airflow control and scrap conveyance reliability, the plant strengthened both operational resilience and material efficiency.

Operational & Commercial Benefits

The new metal scrap removal system has delivered tangible benefits to the Australian facility, including:

• Increased uptime and reduced unplanned production interruptions
• Higher aluminium recovery rates, supporting raw material efficiency
• Improved workplace safety and housekeeping standards
• Reduced risk of scrap accumulation and fire hazards
• Long-term reliability under continuous, high-speed operation

In high-volume can manufacturing, stable scrap extraction is not just a housekeeping function — it is a critical component of line performance and margin protection.

Supporting High-Speed Can Production

This project demonstrates how a purpose-engineered scrap extraction system can enhance reliability, safety, and material recovery in modern aluminium can plants.

By combining specialist industry experience with tailored engineering design, Impact Air Systems continues to support can manufacturers worldwide in maximising efficiency, protecting equipment, and converting production waste into measurable value.

Need a Scrap or Fume Extraction System for Your Facility?

Contact our specialists at +44 (0)116 244 8855 or sales@impactairsystems.com.