VPK Group boosts efficiency with Hunkeler shredder integration on BOBST MASTERLINE 2.1 flatbed die-cutter

At its Raamsdonksveer facility in the Netherlands, VPK Group produces corrugated packaging for a wide range of markets. The site operates several BOBST converting lines, including the MASTERLINE 2.1 flatbed die-cutter, installed in 2013. When recurring waste-handling issues began to affect the efficiency of the line, the maintenance team sought a more reliable and effective shredding solution.

“We had a standalone shredder in the past, but it was not effective,” explained Marc van Ham, Maintenance Manager at VPK Group Netherlands. “We had a lot of jam-ups in the waste transport system. When the die-cut waste wasn’t shredded into small pieces, it jammed and caused blockages on the belts running underneath the machines. That would stop the whole line and caused a lot of disruptive machine downtime.”

The business reports that each jam took up to an hour to clear, and could occur up to five times per week, causing significant lost production hours. The VPK Group team needed solution that would ensure smooth waste removal and protect production continuity.

BOBST and Hunkeler: a seamless integration
Following years of collaboration, Marc and the VPK team turned to their trusted partner for support. BOBST proposed integrating the Hunkeler HKZ700 shredder, a system developed through close collaboration between the two technology providers, directly with the MASTERLINE.

“Initially, we asked BOBST if they had any new developments to shred die-cut waste,” said Marc. “They proposed the Hunkeler solution, which they had already tested at another customer site. They showed us videos, we contacted that customer, and they were very satisfied.”

The installation was carried out by BOBST at the start of 2025 and included a full software upgrade to synchronize the shredder in-line with the die-cutter. From the installation to resolving early teething problems, the BOBST service team provided quick, effective support.

“The implementation was very good,” Marc confirmed.

“The installation was done by BOBST, including the software update. We had a few small issues when running at top speed, but BOBST reacted very fast, adjusting the speed of the shredding rolls and modifying the waste guide. After two months, we had no more problems.”

Operator training was also handled by BOBST. “They trained our operators, but the system is very easy to use,” said Marc. “It’s simple to operate and simple to maintain.”

Hunkeler HKZ700 Shredder

90% fewer blockages, lower maintenance costs, higher uptime
Since installation, the results have been clear. Marc estimates that waste-transport blockages have been reduced by around 90%, with a corresponding increase in uptime on the MASTERLINE. The improvement has also contributed to the site’s sustainability goals by ensuring more consistent recycling of production waste.

Day-to-day maintenance has been simplified too; the previous standalone shredder required quarterly servicing and frequent blade replacement, but the new integrated Hunkeler system uses two shredding rolls instead of knives, eliminating the need for regular maintenance and reducing costs.

“It’s extremely easy to maintain,” said Marc. “Just daily cleaning to remove waste pieces - that’s all. It’s also good for maintenance costs because there’s practically no servicing required.”

For VPK, the project has strengthened both productivity and sustainability - key pillars of the group’s 2030 strategy. “The machine being more efficient absolutely helps us meet our goals,” Marc said. “In turn, that means we can also help our customers meet theirs.”

Marc credits the professionalism and responsiveness of the BOBST team for the smooth process. “The collaboration was very good. We were kept informed about the order, delivery, and installation. The commissioning went well, and every step, including software and connection changes, was clearly explained. The after-service for fine-tuning the system was also very good. We are very satisfied with BOBST, and I can recommend them to everyone.”

Performance through partnership
For BOBST, the project demonstrates how close collaboration and smart integration can unlock greater efficiency for converters.

“Integrating technologies like the Hunkeler shredder with existing BOBST lines means customers can maximize the value of their equipment in new ways,” said Sander Wildiers, Performance Solutions Manager at BOBST.

“For VPK Group, this investment means smoother production, less waste, and improved sustainability - all essential for maintaining competitiveness in today’s packaging market.”

BOBST