How a Corrugated Cardboard Manufacturer Increased Production Efficiency to Over 95 Percent by Eliminating Cutting Waste
Learn how a packaging manufacturer solved production downtime and reduced energy consumption through optimized airflow control
“By replacing compressed air with a controlled airflow solution, we were able to eliminate waste buildup and restore production performance above 95 percent.”
About the company and their role in corrugated cardboard production
The company operates in the corrugated cardboard industry, transforming large sheets into finished packaging products. Their production relies on high-speed cutting processes where precision and continuity are critical.
Why cutting waste accumulation created production inefficiencies and machine downtime
After investing in a new cutting machine, the company experienced lower-than-expected production performance.
The main issue was clear:
Cutting waste accumulated between cardboard sheets
This caused frequent machine interruptions
Production output dropped below expected levels
What should have been a productivity upgrade became a bottleneck.
How an initial compressed air solution increased energy consumption without solving the root problem
To address this, the maintenance team implemented a compressed air solution.
While this approach was easy to install, it created new challenges:
High compressed air consumption
Increased energy costs
Limited effectiveness in fully removing waste
The problem was partially addressed, but not solved in a sustainable way
How Optimus Instruments introduced a more efficient airflow solution for waste removal
To improve the process, the company partnered with Optimus Instruments.
The goal was to eliminate waste buildup while reducing energy consumption and stabilizing production.
Optimus demonstrated a solution based on Paxton centrifugal blowers combined with air knives and nozzles.
Key elements of the solution included:
High airflow up to 2400 cubic meters per hour
Controlled air velocity for effective waste removal
Optimized airflow direction at the point of impact
Adjustable flow using a motor control system
Pressure monitoring for consistent performance
The system was designed to match the width and requirements of the cardboard production line.
How controlled airflow eliminated waste buildup and improved machine reliability
By replacing compressed air with controlled airflow, the process changed significantly.
Cutting waste was effectively removed from the line
Machine interruptions were eliminated
Airflow could be adjusted based on production needs
This resulted in a stable and continuous production process.
What results were achieved after implementing the optimized airflow solution
After implementation, the company achieved clear and measurable improvements:
Production efficiency increased to over 95 percent
Machine downtime was significantly reduced
Energy consumption decreased compared to compressed air
Maintenance costs remained low
The return on investment was achieved in less than three years
Why replacing compressed air with controlled airflow improves efficiency and reduces costs
This case highlights an important insight.
Compressed air is often used as a quick solution, but it is not always the most efficient or controllable option.
By switching to a controlled airflow system, the company was able to:
Reduce energy usage
Improve process reliability
Increase production output
Final thoughts on improving production performance through smarter airflow control
Improving production is not always about new machines.
In many cases, it is about improving how existing processes are supported and controlled.
Looking to reduce downtime and improve efficiency in your production process
If you are dealing with production inefficiencies or high energy consumption, Optimus Instruments helps you analyze your process and implement the right airflow solutions to improve performance.