Efficient matrix and trim removal is fundamental to the converting process

Matrix removal equipment, particularly inline cutters and air-conveyed systems, is far superior to any other removal process.

Air-conveyed systems pick up byproducts right from the web, feeding them at the same speed (or higher) as the web. Through an air-convey system, inline cutters chop the material, and material handling fans blow the waste to a collection area, either standalone or centralized.

BloApCo matrix removal equipment lets converters run at full web speed while minimizing breakage risks, allowing thinner materials, a thinner matrix, lighter trim, maximizing material use, and reducing waste.

BloApCo’s continuous removal systems keep presses running faster and eliminate downtime to change, saving time, labor, and materials.

The new BloApCo removal equipment offers advanced features:

• Machine-health monitoring for intelligent monitoring of knife sharpness and bearing life.
• V-belt drive construction in fans and cutters optimizes functionality and durability, designed for the given application.
• HCHC, Neor, or Carbide edge knives for superior performance and extended sharpness life.

The main components of BloApCo’s matrix removal systems are the inline trim cutter, material handling fans and pneumatic conveying duct systems. Depending on the size and scope of the air convey system, other ancillary items might be needed, such as oil mist units to prevent adhesive build-ups, diverters, noise reducers, filter bags or containers, a baler, etc. Therefore, systems can be standalone for single removal points (BloApCo Bagclone) or integrated into a multiple-removal system. Either way, the simplicity of the BloApCo system makes any solution affordable, convenient, and effective.

BloApCo removal systems have been trusted by tag and label converters for decades, known for their unrivaled durability and endurance, superior performance, and lowest cost of ownership.

Conversely, the alternative to continuous removal equipment is traditional rewinding removal systems. Despite being a common option for trim and matrix rewinding, these devices incur higher long-term costs and significant operational challenges:

• PROBLEM: Rewinders accumulate waste, resulting in frequent trim and matrix roll changes, increasing downtime, labor costs, and material waste. Operators often operate cranes or lifting equipment to remove heavy rolls from overhead rewinders, with unnecessary risk of severe injury or death.
• SOLUTION: BloApCo removal equipment continuously picks up all trim and matrix.
• PROBLEM: Higher maintenance costs of trim and matrix rewinders (air shafts, tension control systems, breaks, drives, etc.).
• SOLUTION: BloApCo removal equipment has the lowest TCO (Total Cost of Ownership) and requires minimal maintenance.
• PROBLEM: Downtime caused by frequent web breakage.
• SOLUTION: BloApCo removal equipment uses air velocity and differential pressure to air-convey the material into the collection system, avoiding web breakage.
• PROBLEM: Limited web speed due to matrix fragility when rewinding. Most die-cutting designs demand thicker materials or more robust matrices to prevent web breakage.
• SOLUTION: BloApCo removal equipment can be adjusted to meet and exceed the web speed.

In addition to helping converters reduce costs and increase efficiency (making them financially sustainable), BloApCo removal systems are a comprehensive waste management solution.

As mentioned, using air-conveyed matrix and trim removal systems allows converters to push boundaries on operational efficiency: reducing unscheduled downtime saves labor and material, using thinner substrates and liners helps reduce material waste, and optimizing matrix patterns maximizes label material use. All these benefits can also improve the converter’s EPR.

TLMI matrix survey results indicate that the leading obstacle converters encounter when processing and diverting their matrix byproduct from landfill is the freight cost to transport waste. In 2023, 70.5% of converters said so, and in the 2024 survey, 64.3% confirmed it.

BloApCo matrix removal equipment helps with waste separation and handling, facilitating its management and disposal. Systems can be easily scaled to reduce hauling costs.

BloApCo has been the reference provider of waste management equipment since 1933, playing a leading role in the value chain and helping customers succeed in their sustainability efforts.

4. How has matrix removal equipment evolved in recent years?

There have been significant changes in performance, features, and cost.

From a performance standpoint, BloApCo uses energy-efficient motors, V-belt drive assemblies that extend the knives’ sharpness, nonstick and oil-mist units for demanding adhesive applications, and vibration and temperature sensors to monitor the equipment’s health, to name a few.

From a cost standpoint, the equipment and overall system integrability have become more affordable for converters of any size. All BloApCo equipment is made at our Wisconsin location, protecting our supply chain from tariff exposure. The use of lean manufacturing and modern techniques throughout the entire value chain reduces costs without compromising equipment quality, endurance, or durability.

If it ain’t broke, don’t fix it. The core principle of inline cutting and blowing away waste remains unchanged from the BloApCo’s patented design from decades ago. We still support trim cutters and fans installed in the mid-60s!