AES Delivers Scrap, Dust Collection Upgrade At TAVO Packaging When folding carton manufacturers invest in faster con- verting equipment and increased production capacity, scrap and dust-handling systems are often pushed be- yond their original design limits. If those systems are not addressed proactively, they can quickly become a bottle- neck that limits throughput, affects plant conditions, and drives up operating costs. That was the situation facing TAVO Packaging, a cus- tom folding carton manufacturer located in Fairless Hills, Pennsylvania. Serving large-volume customers across food service, refrigerated and frozen foods, bakery prod- ucts, and quick-serve restaurant markets, TAVO is known for consistent quality, responsiveness, and reliability.
As part of a facility-wide expansion, TAVO needed to ensure its infrastructure could support higher production volumes without compromising efficiency, safety, or long- term scalability. Central to that effort was a comprehensive upgrade to the facility’s scrap and dust collection system. Challenges Of An Outdated Scrap System As new high-speed converting equipment was added to the manufacturing floor, TAVO’s existing scrap system began to show its limits. Several key challenges were identified: • Outdated rooftop cyclones created an unattractive ex- terior appearance and no longer aligned with the facil- ity’s modernization efforts • An undersized scrap collection system restricted bal- ing flexibility, limiting production to only two grades of scrap paper bales • Cyclones exhausting to atmosphere generated a nega- tive air pressure environment inside the plant, resulting in energy inefficiencies and lost conditioned air • A centrally located baling room increased internal scrap travel distances, adding unnecessary material handling steps and reducing overall efficiency While TAVO’s operation continued to perform, it was clear that the scrap and dust collection system needed to evolve with the rest of the facility to support future growth. The AirShark™ separators played a critical role by increasing conveyance volume and efficiency while improving both interi- or plant conditions and exterior facility aesthetics.
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Len Prazych at 518-366-9017 lprazych@nvpublications.com
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18 March 9, 2026
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