Here you can find frequently asked questions and answers about web cleaning, sheet cleaning, and removal of contamination in manufacturing processes.
Furthermore, you’ll find answers about the effects of dust elimination on production, quality, working conditions, and energy use.
Do you have a specific question that isn’t mentioned? Please get in touch with us: weโll gladly help.
1. Contamination and cleaning fundamentals
Web and sheet cleaning is the removal of dust, fibres and other loose contamination from moving substrates before it can interfere with production or product quality.
Contamination can originate from:
- the substrate itself, such as paper, board, tissue or nonwoven material
- production processes such as slitting, scoring, cutting, trimming or die-cutting
- dust and particles in the production environment that are attracted to a statically charged moving web or sheet
Effective cleaning removes this contamination before it reaches critical downstream processes such as printing, coating, laminating or converting. This helps reduce contamination-related defects, waste, cleaning stops and exposure to airborne particles.
Explore contamination sources and cleaning solutions for your application and production process.ยป
Several methods are used to remove dust, fibres and loose particles from moving webs and sheets. They can broadly be divided into two categories:
- Non-contact cleaning removes contamination without touching the substrate, using engineered airflows, extraction and, where required, active ionisation.
- Contact cleaning uses mechanical contact with the substrate, for example adhesive polymer rollers, rotating or stationary brushes, or cleaning systems that use a liquid or moist cleaning medium.
Some production lines use a combination of methods, such as non-contact pre-cleaning before a contact cleaning system.
The most suitable method depends on factors including the substrate, contamination type, web speed, surface sensitivity, required cleaning performance, available space and acceptable maintenance or consumable use.
Learn more about choosing an effective cleaning method for your production process ยป
Web or sheet cleaning is necessary when dust, fibres and loose particles interfere with product quality, production efficiency, equipment performance or working conditions.
Typical indications include contamination-related defects during printing, coating or laminating; disruption of sensitive processes such as digital printing; and unacceptable contamination risks in food, pharmaceutical or other hygiene-critical production environments.
Cleaning should also be considered when contamination causes:
- frequent cleaning stops
- reduced line speed or loss of productive time
- increased rejects, rework and material waste
- excessive use of compressed air or other inefficient cleaning methods
- unnecessary energy consumption
- premature wear or contamination of downstream equipment
- dust exposure or additional housekeeping requirements
The need for web cleaning, and the most suitable cleaning method, depend on the substrate, production process, contamination type and the consequences of allowing that contamination to continue through the line.
Learn more about indications for web cleaning in your production process ยป
Yes. Properly engineered and correctly applied non-contact web cleaning can effectively remove loose and electrostatically influenced dust, fibres, and particles without touching the substrate.
โNon-contactโ only describes the absence of mechanical contact; it does not by itself determine cleaning performance. The result depends on how contamination is mobilized, captured, and extracted, and on how well the cleaning system is matched to the substrate, contamination, and production conditions.
Performance should therefore be assessed under actual operating conditions using measurable cleaning and production results.
Learn more about the engineering principles behind Weducon non-contact web cleaning technology.
Web-cleaning performance can be evaluated through direct contamination measurements and through its effect on the production process.
Direct methods include comparing contamination levels before and after cleaning, examining collected contamination samples and their composition and, where appropriate, using particle counters. The composition of the removed contamination is as important as the total quantity. Very fine dust may have less impact on print quality, while fibres โ especially brush fibres โ can cause serious print defects even in relatively small quantities.
The amount of contamination collected by the filter system provides additional evidence when measured over comparable production periods, materials and production volumes. It should always be assessed together with the composition of the collected contamination and the results observed in production.
Operational indicators include longer intervals between wash-ups, fewer contamination-related defects and rejects, reduced manual cleaning, more stable print quality and increased production uptime. The most suitable measurement method depends on the substrate, contamination type and purpose of the installation.
At Model Group, improved contamination removal eliminated additional plate-washing stops, created approximately eight extra production hours per month and prevented further customer claims related to dust-induced print defects.
Effective web cleaning reduces the amount of dust, fibres and loose particles entering critical downstream processes. Depending on the application, this can contribute to:
- fewer contamination-related defects and rejects
- more stable product quality and printing performance
- longer intervals between wash-ups and manual cleaning stops
- reduced maintenance requirements
- improved production uptime and throughput
- less material waste and unnecessary resource use
In printing, this can help prevent defects such as hickeys and bullโs-eyes. In coating and laminating processes, effective cleaning reduces the risk of particles becoming trapped in or beneath the applied layer.
The actual benefits depend on the substrate, the position of the cleaner and the contamination problem it is intended to solve.
Learn more about the advantages of web cleaning for your particular production processยป
The best position to install a web or sheet cleaner depends on the source of the contamination and the objective of the cleaning process.
As a general principle, contamination should be removed as close as practical to either:
- the point where it is generated
- the critical process step it could disrupt
- the point before different layers or surfaces come together
For example, a cleaner intended to reduce dust emissions and prevent contamination from spreading through the line, or pressed into the substrate, is best positioned close to the source. To further improve print quality, cleaning immediately before the first printing unit is often used to remove contamination that’s generated during stacking or transport.
In coating, laminating or reel-to-reel processes, the cleaner may be installed shortly before the coating, lamination or rewinding stage to prevent particles from becoming trapped between layers or being wound into the finished reel.
The final position must also take account of web stability, static charge, available space, machine access, airflow requirements and the risk of contamination being generated again after cleaning.
Contact Weducon for advice on the most effective cleaning position in your production line.
2. Weducon cleaning technology
No. A boundary layer is a near-surface airflow created as a moving web entrains surrounding air. It is not a physical barrier that prevents non-contact cleaning. It does, however, mean that airflow close to the web must be deliberately controlled.
In a Weducon cleaner, the incoming web-generated airflow is guided into the cleaning zone before it is deliberately disrupted and replaced by controlled cleaning airflow. Aerodynamic forces can then mobilize contamination close to the surface, while extraction immediately captures the released particles.
Learn more about how Weduconโs web cleaning technology works.
Operating noise depends on the cleaner width, required airflow, filter/fan configuration and installation environment.
Non-contact cleaning requires sufficient airflow and extraction capacity, but Weducon systems are designed to limit unnecessary turbulence and noise. The specially designed pressure and vacuum slots improve aerodynamic efficiency, prevent particle build-up and can reduce operating noise by up to 10 dB compared with earlier or conventional designs.
The final sound level is assessed for each configuration and installation. Where required, system layout, ducting, fan selection and positioning can be optimised further to support safe and comfortable working conditions.
Learn how Weducon combines effective cleaning with reduced noise and energy use.
Operational efficiency depends on more than the cleaner head alone. To reduce energy use and maintenance, Weducon combines aerodynamic pressure and vacuum chambers with frequency-controlled airflow and a matching self-cleaning filter/fan unit.
The airflow is adjusted to the required cleaning performance, avoiding unnecessary resistance and energy loss, while the extracted contamination is separated from the air before purified air is returned to the cleaner. This reduces energy use, operating noise, filter maintenance and consumable requirements.
Depending on the configuration and the system being replaced, this approach can reduce energy use by 20โ30% compared with earlier or conventional systems.
Weducon actively neutralizes static charge within the controlled cleaning zone. This reduces the electrostatic component of particle adhesion at the point where the cleaning airflow can immediately mobilize and extract contamination.
This does not mean that the substrate will remain permanently free of static charge after leaving the cleaner. Subsequent friction, contact with rollers, material separation, or other process conditions can generate a new static charge further downstream.
The purpose of Weducon ionization is therefore to control static charge where it directly affects cleaning performance.
Read more about static charge in converting processes and in the complete description of Weducon Cleaning Technology.
Production processes, materials, and requirements continue to change. Higher recycled content can change contamination loads, while lean production increases the focus on stable output with less waste, energy use, maintenance, and unnecessary production stops. Noise exposure, dust containment, and efficient system integration are also increasingly important.
Weducon therefore continues to develop airflow efficiency, filtration, controls, noise reduction, and system integration in response to these production requirements.
Developments such as the EU Packaging and Packaging Waste Regulation (PPWR) and the broader move towards circular production further increase the importance of material efficiency and preventing avoidable production loss.
Read more about PPWR, production loss, and saleable output and reducing production waste in packaging and printing.
Simple vacuum extraction primarily relies on air being drawn towards an extraction opening. Active non-contact cleaning also creates controlled airflow close to the substrate to mobilize contamination before it is extracted.
In a Weducon system, fan-generated cleaning airflow, ionization, and extraction work together within the cleaner. The extraction airflow exceeds the supplied clean airflow, helping to capture released contamination and contain it within the system.
Suction capacity alone therefore does not determine how effectively particles are removed from the substrate.
3. System selection, integration and operation
A suitable web cleaning method should achieve the required cleaning result under actual production conditions and maintain that result at an acceptable total operating cost.
This means looking beyond purchase price. Relevant factors include the substrate and contamination, production speed, installation position, energy use, consumables, maintenance, operator intervention, and production downtime.
Contact cleaning can be the right choice where contamination adheres strongly to a suitable substrate. Contact and non-contact methods can also complement each other. For example, non-contact pre-cleaning can reduce the contamination load reaching a contact cleaner, reducing consumable use and maintenance requirements.
The most useful comparison is therefore the cleaning result achieved under actual production conditions and the total cost and effort required to maintain that result over time.
See our label and narrow-web contamination control page for an example of this application-based approach.
Weducon provides web and sheet cleaning solutions for different positions within a production line. The appropriate position depends on where contamination is generated, whether later process steps create new contamination and which parts of the production process need protection.
In corrugated-board production, for example, a web cleaner can be installed directly after the slitter/scorer and before the pull-roll section. This removes contamination close to an important source and helps prevent dust from spreading through the corrugator and production environment.
Additional sheet cleaners can be installed after one or more cut-off levels. These remove contamination generated during subsequent cutting and handling before the sheets continue to stacking, converting or printing. For more information on these applications, visit corrucleaner.com
Where several cleaning positions are required, Weducon can combine the cleaners, filter/fan units and controls into one integrated system. The different positions then complement each other: upstream cleaning limits the spread of contamination, while downstream cleaning removes particles generated later in the process.
At Adara Packaging, adding sheet cleaning after the cut-off to an existing web-cleaning installation resulted in 40% less dust at the printing machine and 46% fewer production stops for printing-plate cleaning.ย See how complementary web and sheet cleaning positions improved results at Adara Packaging.
The required installation space for a Weducon cleaning system depends on the cleaner series, substrate width, system configuration and available machine layout.
Weduconโs HE series includes web and sheet cleaning systems for a wide range of widths and production environments. Depending on the cleaner type, the cleaner head typically requires approximately 225 or 340 mm of free web or sheet path.
For label and narrow-web applications, the compact HEM series is designed for integration where available space is limited. The exact dimensions depend on the cleaner width, mounting arrangement and selected filter/fan configuration.
In some applications, the cleaning system can be incorporated entirely within the available machine space. For selected Celmacch flexo presses, a single-sided Weducon HE-70 sheet cleaner is available as a factory-integrated OEM option in the press infeed. The cleaner uses dedicated mounting provisions without invasive modifications to the flexo press or any increase in its footprint.
The matching filter/fan unit does not always need to be positioned directly beside the cleaner. Where the installation permits, it can be located elsewhere and connected through appropriately dimensioned ducting. Smooth, laser-welded ducting helps limit pressure loss, airflow resistance and unnecessary energy use.
Because Weducon systems are configured for the production line, mounting frames, ducting routes and component positions can be adapted to the available space while maintaining accessibility, safety and cleaning performance.
Send us your line layout and application details to discuss a suitable cleaning configuration.
No. Weducon cleaning systems are designed to operate without interfering with normal production.
The non-contact cleaning principle removes dust, fibres and loose particles without touching the substrate. This avoids marking, scratching or damaging sensitive surfaces and coatings.
The active ionisers operate at 24 V DC and neutralise electrostatic charge within the cleaner rather than charging the substrate. The substrate leaves the cleaning zone neutralised, although static charge can build up again later in the process.
Contamination is immediately extracted and captured in the matched filter/fan unit. Effective filtration prevents removed particles from being returned to the production environment.
Because the cleaner does not create mechanical contact or drag, it does not influence substrate tension or normal web transport when correctly integrated and adjusted.
Learn more about Weduconโs non-contact cleaning principle.
No specialised technical knowledge is required for normal operation of a Weducon web or sheet cleaning system.
After installation and commissioning, Weduconโs installation specialist trains the relevant operators and maintenance personnel. The instruction covers normal operation, system checks, basic maintenance and the correct restart procedure after a production-line shutdown.
Day-to-day operation is straightforward. Once the system has been correctly set up, operators mainly need to check its status, empty the dust container when required and verify that the system is running after maintenance or a shutdown.
No further specialised skills are normally needed. More extensive technical work and scheduled preventive maintenance can be carried out by trained maintenance personnel or Weducon service specialists.
Weducon cleaning systems are designed for low-maintenance operation with limited consumable use.
Routine maintenance mainly consists of:
- emptying the dust container at intervals determined by the contamination load
- inspecting the cleaner, ducting and filter/fan unit
- checking the ionisers and system status
- scheduled preventive maintenance
As part of the production-line restart procedure, operators should verify that the cleaning system has been switched back on after maintenance or a shutdown.
The matching filter/fan unit is self-cleaning, which helps maintain airflow and reduces the need for frequent filter replacement. Depending on the selected filter system, consumable requirements can be very limited.
Maintenance frequency and cost depend on the system configuration, operating hours, contamination type and the amount of material removed. Weducon therefore determines the appropriate maintenance plan for each installation.
Learn how Weducon combines low-maintenance filtration with stable cleaning performance ยป
Weduconยฎ supplies the HE and HEM series web & sheet cleaning systems in the majority of Europe, directly to end-users as well as O.E.M.โs.
Together with our partners, large areas of the world are covered.
Please contact us to discuss the possibilities and see how we can solve your problem today.
Weducon retrofit installations are engineered to minimise or avoid modifications to existing production equipment.
Wherever possible, we use existing mounting points, independent support structures and separate controls. Weduconโs Automatic Impulse Generator (AIG), for example, allows the cleaning system to operate independently of the machine PLC when direct control integration is not preferred.
If modifications or control connections are required, these are identified during the engineering phase and agreed with the customer and, where appropriate, the original equipment manufacturer. This helps protect the integrity of the existing machine and avoid unnecessary impact on applicable warranty conditions.
Weducon has extensive experience integrating cleaning systems into existing production lines as well as into OEM-installed equipment.
Installations of Weducon web cleaners in existing equipment show that if modifications are needed, they can always be carried out without modifying your converting equipment.
Other examples are BHS integrated web cleaning installations (Corrucleaner@) at Adara Packaging and DSSmith in Finland.
A further example is Weduconโs BHS-W Conversion Kit, developed to replace existing BHS-W cleaning units with modern double-sided Corrucleanerยฎ technology. The retrofit uses the existing machine environment as its starting point, limiting the need for major modifications while bringing older corrugators closer to the cleaning principle used in current BHS installations.
A typical Weducon retrofit installation can often be completed within 18โ22 hours and planned around a scheduled maintenance stop or weekend.
Weducon prepares the installation while production is still running. This includes engineering, measurements, prefabrication and coordination of the mechanical, electrical and pneumatic work.
Once the line is stopped, the installation generally proceeds in stages:
- mechanical installation of the cleaner and related components
- connection of the filter/fan unit, ducting and controls
- commissioning, functional testing and operator instruction
With careful preparation, production can normally resume at the agreed time without requiring an additional unscheduled shutdown. The exact installation time depends on the system configuration, available space, machine accessibility and the extent of integration with the existing line controls.
A Corrucleanerยฎ retrofit in an operational BHS corrugator, for example, was installed, commissioned and ready for production within one weekend.
See how a Weducon cleaning system was retrofitted within a planned production stop.
Discuss installation planning for your production line with Weducon.
4. Paper & board production - contamination control
In paper and cardboard production, Weducon web cleaning systems are integrated at points where fibres, dust, and microparticles are generated, such as after slitting or cutting, or before winding and stacking. The system’s configuration and positioning are determined by the web width, line speed, material properties, and contamination characteristics, ensuring effective dust extraction without disrupting production processes.
Static charge increases particle adhesion by attracting fibres and dust to the web surface and edges, as illustrated in our knowledge article on static control. This interaction not only amplifies contamination build-up but also reduces the effectiveness of passive removal methods, making controlled ionisation an important factor in effective web cleaning.
Contamination at the edges is more difficult to control because fibers and cutting residues are generated there and are less affected by surface airflow patterns. Because the open edges are no longer covered by coating, fillers and binders break loose, releasing the long fibers as well.
This debris tends to accumulate, migrate further down the production line, and can be easily transferred during stacking, printing, or converting.
Fibre length, stiffness and bonding influence how easily fibres detach during processing, while coatings affect surface adhesion and electrostatic behaviour. Cutting and trimming methods further determine particle size and release intensity, which directly impacts whether contamination remains airborne, adheres to the web, or migrates to edges.
Contamination becomes structurally embedded when fibres and dust are included upstream of winding, slitting, or stacking. At these stages, particles are compressed into the web or trapped between layers in rolls or stacks, making downstream removal ineffective and increasing the risk of surface dents, print defects and handling issues.
In high-speed paper and board lines, contamination is primarily driven by fibre release during formation, trimming and cutting, particularly in grades with higher recycled fibre content, where shorter fibres and fines are more easily released. Combined with airflow and static effects around the moving web, these particles are readily transported downstream and embedded into rolls or process components.
5. Printing contamination control
No. Effective cleaning at the press infeed is independent of the substrateโs origin. Even when sheets or webs are delivered pre-processed, contamination can still be introduced during transport and handling. Cleaning directly before printing addresses this risk.
In most cases, no. Integration depends on the press model, available space and safety requirements. Retrofit installations are commonly designed to fit into the existing line, with mounting and controls adapted to the press, so operator workflows remain largely unchanged.
No. Dust extraction and substrate cleaning address different issues. Extraction reduces airborne particles in the press environment, while substrate cleaning removes contamination from the substrate surface itself. In practice, extraction helps keep the press area cleaner, while substrate cleaning directly affects print quality. Many plants use both to achieve stable and predictable print quality.
Because the press infeed is the last controlled point before the substrate enters the printing process. Dust and fibres can be introduced at various stages, including transport, storage and handling, regardless of how or where the substrate was produced. Cleaning directly at the press infeed helps prevent contamination from entering the press, reducing print defects, unplanned wash-ups and manual cleaning during production. In web-fed and sheet-fed printing alike, this approach reduces the risk of recontamination between earlier process steps and printing.
Web cleaning is used for continuous substrates in web-fed processes such as offset, where the material runs uninterrupted through the press. Sheet cleaning is applied to individual sheets in sheet-fed presses, such as flexo and digital presses, where each sheet is cleaned before entering the press. The choice depends on substrate format, line speed and press layout.
6. Label & narrow-web contamination control
The system can be mounted using base or cantilever brackets and utilizes existing mounting locations. Electrical integration requires PLC integration and frequency-controlled fan operation. Installation is straightforward using standard industrial connectors.
No. The system uses long-life filter cartridges with sub-micron filtration and antistatic coating. No disposable HEPA cassettes are required, and the filter medium has a life expectancy of at least 60 months under normal operating conditions.
When ionization is placed in front of the cleaner, loose particles are released before the extraction system can capture them. This creates the risk of particles ending up in the air or on the floor.
With ionization in the center of the cleaner, the released particles are immediately removed. That’s why the HEM-70 integrates 24V DC active ionization in the center of the cleaner, within the blower air channel. Clean airflow carries ions directly toward the substrate, improving static neutralization, preventing residual contamination, and reducing ionizer maintenance.
The HEM-70 typically operates with up to 30% lower energy consumption than conventional non-contact cleaning systems. Its optimized airflow design and efficient AFC filter/fan unit provide stable cleaning performance with reduced operational load.
Yes. The system operates at up to 25% lower noise levels compared to conventional systems, contributing to a cleaner and more comfortable working environment in narrow web production facilities.
The COL270B-AL filter cartridges are ATEX certified and grounded throughout. The antistatic aluminium coating ensures high electrical conductivity (Rd < 10ยณ Ohm), effectively dissipating electrostatic charges and enhancing safety in explosion-sensitive production environments. The pneumatic cleaning valves are ATEX certified, and when a placement in an ATEX zone is needed, the motor specifications can be adapted. Only the control cabinet must be placed outside the zone.
The AFC filter/fan unit uses reverse-jet pulse cleaning to continuously regenerate the filter cartridges. Heavy contaminants are pre-separated and collected in a dust tray before reaching the filter media, preventing overload and ensuring constant airflow performance over long operating periods.
The HEM-70 achieves 99.9% filtration efficiency for particles in the 0.2โ2 ฮผm range. The AFC filter unit uses sub-micron filtration media (dust class M), ensuring minimal particle escape and preventing recontamination of the substrate.
