Pregis engineers paper cushion conveyance system using air ducts for improved worker ergonomics

10 Mar 2022 --- Pregis is unveiling a “first-of-its-kind” paper cushioning conveyance system using air ducts. The protective packaging manufacturer says the system allows paper cushions created by its Easypack Packmaster Pro machines to be conveyed via air blowers or aluminum ducting to conveniently located overhead delivery hoppers.

The Packmaster Pro delivers a range of lightweight, robust paper cushions on-demand that are easily molded around any product. The new delivery system significantly improves worker ergonomics and packing speed while reducing equipment capital expenditures.

“Typically, paper packaging machines are dedicated to either one or two packing stations. By conveying the paper void fill cushions to an overhead hopper, which feeds up to six packaging stations, the need to take up valuable floor space with multiple machines is eliminated,” explains Paul van Dijk, senior product manager paper systems at Pregis Europe.

“Additionally, packers who are using the new conveyance system tell us that it is more ergonomic for them. Finding people to staff open positions is problematic in many countries. This [issue] makes creating a work environment that supports packer satisfaction more important than ever.”

Proprietary engineering
Proprietary engineering has gone into the air duct conveyance system design to enable efficient operation. Unlike other delivery systems, which use conveyor belts or structural poles, the Pregis conveyor-less approach is more cost-effective, uses less energy, frees up floor space and is low maintenance, the supplier says.

The air ducts move fan-folded paper, which has been created from a roll with nearly five kilometers of paper (depending on paper weight). This system significantly reduces roll changes per shift, adding to efficiency.

“For more than a decade, Pregis has a significant track record in providing overhead delivery systems for inflatable materials. We have taken much of the knowledge gained with those applications and applied it to our 100% recycled paper solutions,” adds van Dijk.

“Further, the way we have engineered the paper conveyance ducting will allow it to work side-by-side with an air pillow system overhead system, for those operations that require both packing solutions at each pack station to accommodate a variable mix of items.”

Last year, US-based packaging manufacturer Pregis joined forces with German chemical and consumer goods company Henkel to develop environmentally sustainable protective packaging solutions.

Edited by Joshua Poole