Trim Extraction System Upgrade for Sheard Packaging

Client Overview:

Sheard Packaging is one of the UK’s largest independent corrugated packaging manufacturers, known for delivering high-volume, high-quality solutions to some of the country’s biggest brands. With a strong focus on operational performance, Sheard partnered with us to upgrade their existing trim extraction system — aiming to increase capacity, improve reliability, and prepare for future growth.

The Challenge:

Over time, Sheard’s original trim extraction system had been expanded and modified to keep up with rising demand. However, the layout had become inefficient — particularly the placement of external fans, which were difficult to access for maintenance and inspection. This limited uptime, increased labour requirements, and constrained their ability to scale.

Our Solution:

We delivered a comprehensive upgrade that significantly enhanced performance, streamlined operations, and reduced ongoing maintenance demands.

Key features of our solution included:

• High-Efficiency Trim Removal: A centralised extraction system takes production waste efficiently from multiple Göpfert Evolution, Emba and Asahi box-making machines and removes it to the baler room with improved flow, reducing manual handling and system blockages.
• Dual Baling System: We retained the existing baler and integrated a new unit, enabling Sheard to handle higher volumes, with less potential downtime, while reducing waste bulk and cutting transport costs.
• Optimised System Layout: External fans were rationalised and relocated to a more accessible position, dramatically improving maintenance access and minimising downtime.
• Energy Efficiency & Longevity: Conveying speeds were fine-tuned to optimise airflow, cut energy consumption, and reduce mechanical wear, along with the installation of a latest generation baler as the primary unit, significantly reducing energy consumption in the baling process — delivering ongoing cost savings.
• Centralised Smart Controls: A bespoke control panel now centralises system management, giving the client a clear dashboard, along with remote access to view system operation and faults, making start-up, shutdown, and troubleshooting faster and easier for operators.
• Future-Proof Design: The system is engineered with built-in flexibility to support future machinery and capacity upgrades without significant reinvestment.

The Outcome:

• Increased Capacity: The upgraded system now supports higher production volumes without bottlenecks or system strain.
• Reduced Operating Costs: Improved efficiency and energy use translate into real savings, while enhanced baling cuts transport and disposal costs.
• Minimal Downtime: Easier maintenance access and smarter controls result in faster servicing and improved uptime.
• Long-Term Flexibility: Designed to scale with Sheard’s growth, the system supports future expansion plans with minimal disruption.

Client Feedback:

“The team at Impact really understood our needs, delivering a system that supports long-term growth while improving performance and maintenance. The install was smooth and professional, with no disruption to production.” — Howard Elwin, Project Manager, Sheard Packaging

Impact’s Perspective:

“This project shows how collaborative engineering can drive both immediate performance improvements and long-term operational efficiency. The system is already helping Sheard’s teams work more efficiently and plan for the future.” — Darren Bayman, Sales Manager, Impact Air Systems

This project demonstrates how thoughtful engineering and future-ready system design can unlock real business value — improving productivity, reducing operational costs, and setting the stage for growth. For fast-paced manufacturing environments like Sheard Packaging, our tailored trim extraction solutions deliver measurable results from day one.