When discussing sustainability, many will note that the production of labels is inherently wasteful by design. Following the diecutting of labels from the larger roll, the material left – often referred to as “trim” – represents label matrix waste. Therefore, removing this waste is a critical converting process. Not only is this process wasteful, it can slow down production lines. In order to optimize the efficiency of the converting process, suppliers have engineered cutting-edge equipment to handle label matrix waste removal.

Effective trim and matrix removal are fundamental to the converting process, too. Narrow web converting applications generate byproducts during web slitting and diecutting. Once the web is diecut or trimmed, its byproducts become the weakest part of the web. 

According to Mike Balderas, VP of sales and marketing, BloApCo (Blower Application Company), matrix fragility often defines press variables: material types and thicknesses, web speed, production runs, etc. “Matrix removal equipment, particularly inline cutters and air-conveyed systems, is far superior to any other removal process,” says Balderas. “Air-conveyed systems pick up byproducts right from the web, feeding them at the same speed or higher.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.”

While converters can perform this process manually, it is far more effective to utilize the latest in automation. “Modern matrix removal systems are designed to keep production moving without compromise,” states Tom Embley, president and CEO, Precision AirConvey (PAC). “Precision AirConvey equipment enables converters to consistently run presses at their maximum rated speeds, minimize unplanned downtime, and avoid manual rewind/matrix roll handling. This equipment also reduces setup time and increases throughput, especially when paired with turret rewinders and splicers. Converters can increase their machine hour rate while also cutting waste transportation frequency and fuel usage by compacting matrix waste.”

“The primary benefit of automated matrix removal is sustained productivity,” adds Kevin McCloskey, president, Trim Waste Management (TWM). “When matrix is wound manually, press speed is often limited by how stable that waste roll remains as it grows. As rolls get larger, tension inconsistencies increase and operators are forced to slow down or stop entirely to change rolls.” 

Automated systems eliminate that constraint, adds McCloskey. Matrix is removed continuously, tension remains stable, and presses can run closer to their designed production speeds for longer periods of time. That becomes critical on higher-volume runs, where stopping a press just to remove a waste roll introduces lost time. The operator then has to re-register the job and material is wasted.

Matrix removal equipment must also keep pace with other technologies and demands. Higher press speeds and wider webs have necessitated better matrix removal solutions. According to PAC, other factors include the growing adoption of RFID, as well as increasingly challenging adhesives and substrates. 

Customization is not just reserved for presses, either. For example, PAC builds its equipment to meet the unique needs of label converters.

“We meet these demands through our X-Factor: a highly experienced engineering team that custom-designs every system to the specific press, layout, and production goals, thus ensuring maximum efficiency and long-term performance,” says Embley.

While utilizing this equipment seems advantageous, it’s also important to note the downside of forgoing the newest technological advancements when it comes to matrix. 

“Converters without automated removal often compensate by running wider web stock than necessary to stabilize the matrix,” remarks McCloskey. “That added edge trim improves roll integrity, but it also means more material consumption and more waste. Over time, that adds up in both costs and inefficiencies.”

“Not having continuous removal equipment means traditional rewinding removal systems,” adds Balderas. “Despite being a popular alternative for trim and matrix rewinding, these devices incur higher long-term costs and significant operational challenges.”

PAC finds the absence of this equipment wholly inefficient, too. The lack of new technologies can lead to increased operator fatigue and injury risk from manual waste roll handling. Tension challenges on rewind rolls can also translate to  slower press speeds. A manual process generates additional labor costs tied to waste collection and monitoring, as well. 

Another consideration is operations. Converters must account for a loss of floor space due to waste storage and forklift traffic. Frequent starts and stops will stress gearing on a press, requiring maintenance, too. With the workforce a continuing challenge, operators focused on waste monitoring spend less time addressing product quality.

Safety is critical, as well. “One often overlooked factor is safety and ergonomics,” says McCloskey. “Manual removal of matrix rolls requires operators to lean into the press and lift awkward loads. Automated systems remove that risk entirely, which becomes more important in an industry like ours where  the average age of press operators is high.”

Getting started is not a daunting task, either. It’s also one with a relatively fast ROI. “A matrix waste system is a proven investment in productivity,” says Embley.

For PAC, the typical ROI is under one year. In order to tailor the solutions to the converter’s needs, a quick 30-minute conversation helps determine whether the investment is right for each operation. Centralized systems improve uptime across the full converting floor, and installations are planned for minimal disruption. In fact, most facilities continue running during installation. PAC also offers financing and tiered system options to ensure solutions are available for a wide range of budgets.

According to TWM’s McCloskey, converters are not requesting the reinvention of the wheel. They’re simply seeking products that offer reliability, uptime, and systems that simply work without constant attention. The priority is getting waste off the press cleanly and consistently so production can continue uninterrupted. “What we see most often is demand driven by automation elsewhere in the pressroom,” says McCloskey. “When converters invest in butt splicers, dual rewinds, or higher-speed presses, manual matrix handling becomes the bottleneck. At that point, automated removal is no longer optional – it’s required in order to get the full benefit of those upstream investments.

“From an operational standpoint, there is virtually no learning curve,” adds McCloskey. “Operators don’t need to adjust settings or manage complex controls. The system runs continuously once activated. From a planning standpoint, converters should evaluate matrix characteristics, press layout, and how waste will be handled after removal. That includes decisions around compacting, baling, or transporting waste offsite.”

Equipment evolution

In recent years, matrix removal equipment has seen consistent innovation. Production needs and market conditions have served as key drivers of technological growth, specifically around automation.

“There have been significant changes in performance, features, and cost,” says BloApCo’s Balderas. “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.”

PAC has utilized enhanced non-stick coating technologies for increasingly aggressive materials. Meanwhile, scalable solutions now fit smaller shops through large multi-press operations. This leads to proven and installed solutions from one to more than 40 presses.

Modern matrix removal equipment emphasizes automation due to skilled labor shortages. But while automation has driven substantial innovation in this market, the equipment remains quite similar.

“The core technology itself hasn’t changed dramatically – and that’s not a weakness,” says TWM’s McCloskey. “Pneumatic conveyance, cutting, and airflow management have proven reliable over decades of use. What has evolved is how widely the technology is applied. Automated matrix removal was once associated primarily with larger or wider presses running long jobs. Today, it’s increasingly relevant across narrower web widths, as those presses run faster and handle higher application volumes. As converters push for more uptime and stopless production, automation across the production floor has raised expectations for every supporting piece of auxiliary equipment, including waste removal.”

Sustainability factor

Given that the design of labels is inherently wasteful, sustainability has become paramount throughout the manufacturing supply chain. Using air-conveyed matrix and trim removal systems allows converters to push boundaries on operational efficiency, notes BloApCo’s Balderas. These systems reduce unscheduled downtime and save labor and material. Plus, 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,” states Balderas. “In 2023, 70.5% of converters said so, and in the 2024 survey, 64.3% confirmed it.”

More PAC customers are being asked to demonstrate how their production waste is managed as part of their end users’ sustainability and accountability programs. “Matrix systems play a direct role in helping facilities meet these environmental goals,” explains PAC’s Embley. “They enable narrower stock usage, reducing raw material consumption. The typical annual savings on raw materials is 2-3% annually. And this equipment reduces waste volume destined for the landfill.”

Automation and sustainability go hand in hand here. “First, automation allows converters to reduce unnecessary edge trim,” explains TWM’s McCloskey. “When matrix stability no longer depends on winding a large roll, converters can run narrower web stock without sacrificing performance. That directly reduces material usage and waste generation. Second, automated systems make it easier to capture matrix cleanly for downstream handling. Waste can be conveyed directly into compactors or balers, which is often a requirement for recycling or energy-recovery programs. Manual handling makes that process inconsistent and labor-intensive. Lastly, reducing press stops and rework also reduces waste. Fewer restarts mean less off-register material and fewer discarded labels. Sustainability, in this case, comes from running the press more efficiently, not just from what happens after the waste is generated.”

Sustainability has emerged as a key trend. TLMI has established a subcommittee to address the challenges associated with matrix waste. PAC’s Marco Acevedo chairs TLMI’s Matrix Sustainability Committee, where he contributes to advancing landfill-alternative solutions.

System selection

All BloApCo equipment is made at the company’s Wisconsin location, protecting the 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.

“The core principle of inline cutting and blowing away waste remains unchanged from BloApCo’s patented design from decades ago,” remarks BloApCo’s Balderas. “We still support trim cutters and fans installed in the mid-60s.”

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 main components of BloApCo’s matrix removal systems are the inline trim cutter, material handling fans, and ducting,” says Balderas. “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.”

PAC has continued to expand its powerful solutions that fit real-world converting environments. These environments range from the smallest converting shops to the biggest players in the field. PAC’s products include Enhanced EcoPAC, a compact footprint baler with improved performance. The company has also developed advanced coating options for matrix reclamation with aggressive adhesives. Improved sound attenuation for a quieter, safer facility has been engineered, as well. Finally, TrimPAC 80 is a cost-effective, pre-engineered single-press system.

Meanwhile, TWM stays attuned to the demand of the market with its newest product development. McCloskey says, “TWM meets that demand by focusing on system performance and service. We design systems that are straightforward to operate and require minimal adjustment. Once installed, operators turn them on, feed the waste, and walk away. Properly maintained cutters are essential to system reliability. Dull or misaligned blades lead to longer waste pieces, airflow disruption, and eventually clogs that take presses off-line. Our refurbished cutter service offers fast turnaround and significant cost savings compared to replacement or OEM refurbishment while restoring cutters to original performance tolerances.”