Installing matrix removal equipment in a label manufacturing facility offers significant benefits to converters. With an emphasis on speed, efficiency, and sustainability, these products can provide significant benefits.

Converters generate a large amount of byproducts during web slitting and diecutting. Once the web is diecut or trimmed, its byproducts become the weakest part of the web. As such, matrix fragility often defines the whole press variables: material types and thicknesses, web speed, production runs, and more. Therefore, effective trim and matrix removal are fundamental to the converting process. 

BloApCo (Blower Application Company, Inc.) has engineered continuous removal systems to keep presses running faster and eliminate downtime. The result: saving time, labor, and materials. The company’s systems offer a host of benefits.

“Matrix removal equipment, particularly inline cutters and air-conveyed systems, is far superior to any other removal process,” explains Mike Balderas, VP of sales and marketing, BloApCo. “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,” adds Balderas.

Advanced features

BloApCo has developed products that offer a wide range of advanced features to benefit label converters. The new BloApCo removal equipment provides machine-health monitoring for intelligent monitoring of knife sharpness and bearing life. Plus, the company has designed V-belt drive construction in fans and cutters to optimize functionality and durability. This has been optimized for the given application. Meanwhile, HCHC, Neor, or Carbide edge knives have been developed for enhanced performance and extended sharpness life. 

“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.,” says Balderas. “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.”

There is a downside to not taking advantage of the newest features of modern matrix removal systems, too. “Not having continuous removal equipment means traditional rewinding removal systems,” remarks Balderas. “Despite being a popular alternative for trim and matrix rewinding, these devices incur higher long-term costs and significant operational challenges. For example, 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.”

Meeting demand

Today’s label converters frequently seek cost and performance in these products. In the case of BloApCo, the ROI is quite reasonable, notes Balderas.

“BloApCo matrix removal equipment is easily scalable,” he says. “Depending on the application, it can start at less than $30,000 for a complete bagclone system and grow to a fully integrated waste management system. Either way, efficiency gains and cost savings result in fast and attractive ROI. The ROI bridge shows the typical ROI for a standalone BloApCo Bagclone system. The standard operational cost assumptions are a $500/hour downtime rate, maintenance costs for rewinders, and an average roll swap time of  approximately five minutes, plus web breaking twice per week.”

These systems are suitable for converters of all sizes, as well. “There is a misconception that continuous matrix and trim removal systems are viable only for large systems,” comments Balderas.

Sustainable benefits

Matrix removal systems also serve as key sustainability differentiators. Using air-conveyed matrix and trim removal systems allows converters to push boundaries on operational efficiency. Plus, reducing unscheduled downtime saves labor and material. Meanwhile, using thinner substrates and liners helps reduce material waste.

“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,” says Balderas. “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,” he adds. “Trim and matrix removal is critical to their operations, efficiency, and profitability. It helps enormously with sustainability and EPR efforts.”