Complete Trim, Dust and Pneumatic Conveying Upgrade at Corruseal, South Africa.

As demand for corrugated packaging continues to grow, manufacturers are under increasing pressure to maximise productivity while maintaining the highest standards of quality and reliability. Supporting systems such as pneumatic conveying, trim extraction and dust control play a vital role in ensuring production lines operate efficiently, removing waste quickly and reliably without interrupting the manufacturing process.

When leading South African packaging manufacturer Corruseal embarked on a major upgrade of its waste handling infrastructure, it selected Impact Air Systems to design, manufacture and install a bespoke pneumatic conveying, trim extraction and dust control system tailored to the requirements of its corrugated board production facility.

Supporting One of South Africa’s Leading Packaging Manufacturers

Corruseal manufactures corrugated board and cartons for many of South Africa’s leading FMCG, fresh produce, beverage, homecare and general trade brands. With manufacturing facilities located throughout the country, the company supplies packaging for both domestic and export markets, producing high-quality corrugated solutions that are rigorously tested to meet the demands of each application.

To support continued production efficiency, Corruseal required a complete upgrade to its trim extraction and waste conveying infrastructure, capable of serving multiple production areas while maintaining reliable performance across the entire plant.

Engineered Around the Production Process

Following a detailed review of the site’s operational requirements, Impact Air Systems designed a bespoke system to collect and pneumatically convey trim and production waste from several key areas of the facility.

The project included:

• Edge trim extraction from both sides of a Fosber Tri-Wall Corrugator, conveying material approximately 235 metres.
• Edge trim extraction from both sides of a Fosber Single-Wall Corrugator, conveying material approximately 225 metres.
• Pneumatic conveying from an additional sheet shredder, transporting material approximately 205 metres.
• Waste collection from ten die cutters and conversion lines, conveying material approximately 70 metres.
• Conveying from a sheet shredder (hogger) within the baler area over approximately 15 metres.

In total, the system conveys production waste over 750 metres, requiring careful consideration of airflow, conveying velocities and system balancing to ensure reliable performance across every connected process.

Designed for Reliable, Continuous Operation

In a modern corrugated board plant, waste handling systems are an essential part of the manufacturing process. Any interruption to trim removal can quickly affect production efficiency, leading to material build-up, increased maintenance and unplanned downtime.

With multiple production lines operating simultaneously, the new system was engineered to provide dependable extraction and conveying performance under varying production conditions. Every aspect of the installation, from extraction points and ductwork routing to fan selection and conveying design, was developed specifically for the site’s operational requirements.

By efficiently removing edge trim and production waste at source, the system helps maintain clean production areas, reduces manual handling and supports continuous manufacturing throughout the facility.

Customer Feedback

Commenting on the completed project, Thembinkosi Msimang, Group Technical Procurement, Corruseal, said:

“Impact Air Systems worked closely with us throughout the project, taking the time to understand our operational requirements and develop a solution tailored to our facility. From the initial design through to installation and commissioning, the team demonstrated a high level of professionalism, technical expertise and attention to detail. The new pneumatic conveying, trim extraction and dust control system has provided a reliable solution for handling production waste across multiple processing areas, and we’re very pleased with the quality of both the installation and the support provided throughout the project.”

Dave Lansdell, Managing Director at Impact Air Systems, added:

“Projects of this scale require far more than simply specifying fans and ductwork. Every production line generates different waste volumes and conveying demands, so it’s essential that the entire system is engineered around the customer’s process. For Corruseal, we designed a solution capable of transporting trim and production waste over more than 750 metres while maintaining reliable conveying performance across multiple production areas. The result is a robust, dependable system that will support efficient manufacturing for many years to come.”

Improving the Working Environment

Alongside pneumatic conveying, the project also incorporated dust extraction to capture airborne dust generated during the manufacturing process.

Effective dust control contributes to cleaner housekeeping, helps protect production equipment and creates a safer, more comfortable working environment for operators while supporting efficient plant operation.

Engineering Air Handling Solutions for the Global Packaging Industry

Every Impact Air Systems installation is engineered around the individual requirements of the customer. Machine layouts, production speeds, waste characteristics and conveying distances all influence system design, making every project unique.

With more than 35 years of experience supplying pneumatic conveying, trim extraction and dust control systems to paper and packaging manufacturers worldwide, Impact Air Systems continues to deliver bespoke engineering solutions that improve reliability, reduce maintenance requirements and help manufacturers keep production moving.