Automated waste collection makes for clean and sustainable production

Bukit Muria Jaya – High volume cartons in Indonesia

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L- R: Ari Budiman Handaka, purchasing manager PT BMJ and Darusman Husein, factory manager PT BMJ with the Hunkeler Systeme automated wasted handling equipment in the background at the PT BMJ Kudus plant

Bukit Muria Jaya is the largest packaging company in Indonesia that prints and converts more than 24,000 tons of paperboard each year in its plants in Kudus and Karawang for the tobacco, food and pharmaceutical industries. Bukit Muria Jaya’s plant in Karawang also has its own paper mill and is one of the largest suppliers of specialty cigarette paper, plug wraps and tipping paper in the world.

Altogether the company runs three Lemanic Delta, two Atena and one Schiavi webfed presses and two Heidelberg and a Komori sheetfed press. For maintaining clean, dust-free environments in both the plants and for collection and recycling of trimmings and other paper waste, Bukit Muria Jaya has installed automated and customized waste handling systems from Hunkeler Systeme.

The Bobst Lemanic presses in the Karawang plant are directly connected to the Hunkeler waste system with pneumatic pipes which take the waste and rejected printed products, put them through the separator and fill large bags on pallets for shipping to a nearby paper mill with which Bukit Muria Jaya has a collaboration agreement. Since the waste is sent directly to the pulper, it is recycled almost immediately for the production of paper.

In the Kudus plant the evacuated waste paper and rejected print product are collected by the Hunkeler system and sent on a conveyor to a shredder; the shredded waste is pneumatically transported to the separator and then automatically down to the large bags on pallets through a Y outlet so there is non-stop operation. At the same time the paper dust in the waste is filtered and clean air is sent back to the production area. The total waste of the original printed volume is about 10%.

The Hunkeler-Jet-Filter is a very compact unit with the filter elements automatically de-dusted, so that it saves energy and is suitable for non-stop operation as is the entire waste collection and disposal system. Bukit Muria Jaya’s Manufacturing Director, Her Irawan says, “It is very important to collect the waste properly and recycle immediately so we can reduce the consumption of pure fiber. The shredder is important so that the printed and other waste are destroyed perfectly.”

The other savings for Bukit Muria Jaya are in terms of working space in the plant and the cleanliness of the machine area. While there are savings from recycled waste, the company has not put a number on this yet. The destruction of printed and trim waste maintains the integrity of its customer’s brands so that no counterfeit or low quality cartons are leaked to the market. Dust in the work areas is not only unhealthy but also affects the quality of printing and converting.

Safety, health and environment

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Darusman Husein, factory manager PT BMJ and Ari Budiman Handaka, purchasing manager PT BMJ with the Hunkeler Systeme automated wasted handling equipment in the background at the PT BMJ Kudus plant

Above all, Bukit Muria Jaya is mindful of its responsibility to protect and preserve the environment and takes appropriate actions to ensure that its responsibility is upheld. The company uses paper produced using only PEFC or FSC pulp from well-managed forests that provide environmental, social and economic benefits, and is committed to reduce the environment impact of its business. It is ISO 14001 certified and considers human safety of utmost importance for which it is OHSAS 18001 certified.

Bukit Muria Jaya’s Purchasing Manager, Ari Budiman Handaka explains the overall rationale of the company, “To us, sustainability represents a shift in our thinking—from a focus on our own operational footprint to a broader view of our responsibilities throughout our value chain. A sustainability vision is no longer a ‘nice to have’; it is now a ‘must have.’ In our own most essential definition, sustainability is a tool for achieving long-term growth while making a positive contribution to the environment and society.”

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Editor of Indian Printer and Publisher since 1979 and Packaging South Asia since 2007. Trained as an offset printer and IBM 360 computer programmer. Active in the movement to implement Indian scripts for computer-aided typesetting. Worked as a consultant and trainer to the Indian print and newspaper industry. Visiting faculty of IDC at IIT Powai in the 1990s. Also founder of IPP Services, Training and Research and has worked as its principal industry researcher since 1999. Author of book: Miracle of Indian Democracy.

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