We all know how a waste baler works. It’s simple, you feed it with material and it produces bales. But I will develop this topic, and you will find here information on important points such as: what is the productivity of a waste baler machine, how do some optional accessories modify the productivity and operation of a waste baler; what to keep in mind when thinking about buying a waste baler, and more.
When you want to buy a waste paper baler, or other recyclable material, it is obvious that you want to buy what is best for you, and if it has a low price it would be perfect. But how do you know what suits you?
One of the most important aspects of a waste baler machine is the productivity and power of the equipment. These two aspects are in close connection. The productivity of an equipment can be calculated in processed volume. From the processed volume we can tell how much material we can press, respectively the productivity of the baler.
Calculating the hourly productivity of an automatic cardboard baler, PET or other recyclable materials is simple. The volume of the pressing chamber multiplied by the pressing cycles of the equipment in one hour. That is, from the technical data we find the volume of the pressing chamber. Also from the technical data we find out in how many seconds it takes the ram of the baler to execute a pressing cycle. Thus we can calculate how many hourly cycles we have, and respectively the hourly volume in cubic meters per hour.
After finding out how many cubic meters the equipment processes per hour, we can calculate the productivity of a baling machine in tons or kilograms per hour, approximating, or if we can, even calculating how much a cubic meter weighs of the material we want to process. This calculation is valid for any waste baler, and not just for our models.
Take our most sought-after model, SPR75, for example. This baler is ideal for processing cardboard, but it can also press other types of recyclable materials, and also RDF or household waste. The baler has a press chamber with a volume of 1.1 cubic meters and 20 seconds press cycle. Thus, this baling press can process a volume of 198 cubic meters per hour.
Further, finding productivity in tons per hour is simple, for any equipment. We need to multiply the processed volume by the weight of the chosen material per cubic meter. The different types of material, influenced by their quality degree, have a certain weight to a cubic meter.
For example, in the SPR75 model, for a material that weighs 20 kg per cubic meter, the productivity is 4 tons per hour, for a material with 35 kg per cubic meter, the productivity is 6.9 tons per hour.
If we had materials with a weight of 50 or 70 kilograms per cubic meter and we calculated these weights at the processing power of the SPR75 model, they boost the productivity at 10 and 14 tonnes per hour. But this is only possible in a large baler press.
Although the equipment is capable of processing the calculated material, the human factor must also be taken into account. Calculating the human factor, and its dead times, you need a margin of error. For this reason, we recommend that, when you use the system to calculate the productivity of the equipment you want to purchase, you should only consider 70% of the result.
In our case, the SPR75 baling machine, processes PET (20 kg per cubic meter material) with a productivity of 4 tons per hour in theory and 2.5 tons per hour in practice, respectively on cardboard (35 cubic meters material) has a productivity of 6.9 tons per hour in theory and 4.5 tons per hour in practice.
Productivity helps us understand if a baler is able to process the managed material within a month, but also to manage the material flow. Also this information is useful for knowing what kind of baler you need in a sorting station for example, where we have a flow of different material.
The productivity of a waste baling machine is directly influenced by its feeding conveyor. An automatic baling machine can never reach the productivity calculated above without a feeding conveyor because of the human factor. The operator’s feeding capacity increases when there is a feeding conveyor, because in this case, the operator can feed the conveyor directly with an equipment provided as a forklift truck, or it can be unloaded from the truck directly on the conveyor. The conveyor will take as much material as necessary for processing, and the hopper of the baling press has a temporary storage role, if the material taken over is more than the volumetric capacity of the pressing chamber.
The feeding conveyor of the baling machine can be different, depending on the needs of the customer, location, or the flow plan of the materials. One of the most common and productive is the V-type power strip, with the horizontal base part inground. This is the type of conveyor discussed in the paragraph above, with a horizontal part at the base of about 3 meters in general, but also with possibility of extension in case of need, for example to retrieve the material from a waste sorting station. The V-type conveyor consists of a horizontal section, which can be inground or above ground, and a diagonal section, which raises the material at the press’s hopper, with a slope not exceeding 32 degrees
Other types of conveyors are type Z, which is similar to type V, except that it consists of the third section, which is also horizontal, at the end of diagonal section. This is usually very short. And last but not least, the type I band, which consists of a single diagonal section, with a feed tank. You can find more here: https://recondis.com/contact/?lang=en
Types of materials
In addition to the technical details and the feeding conveyor, the productivity of the baler is also influenced by the material that is being processed. For example, the cubic meter of cardboard will always be heavier than the cubic meter of PET, and thus productivity is higher on cardboard than on PET processed on the same equipment.
The types of materials that can be pressed on an automatic baling machine, taking the example above, the SPR75 model, are varied. From cardboard and PET to HDPE, doses, foil, paper, even RDF or household waste. But the productivity will be different for each type of material.
Productivity – Conclusion
The productivity of a baling machine can be influenced by several factors. Recondis waste balers have a productivity between 1 and 30 tonnes per hour, depending on the chosen model and the material that needs to be processed. The balers have engines between 18.5 kW and 120 kW, with resulted bales between 250 kg and 1000 kg.
Automatic balers can be accessorized with optional components for specific applications or materials. Components such as:
-High-tech oil cooler or heater, for situations where the equipment runs at temperatures that make it necessary to heat or cool the oil.
– Automatic lubrication system for the conveyor chain.
– Start-stop system for the engine to reduce the consumption of electricity.
– An anti-lock system in the feeding hopper, for balancing the difficult materials, or just for the safety of the instant unlocking of the material in the feeding hopper in case a blockage occurs.
But two of the most important optional components, apart from the supply band which in most cases is essential, are the PET Perforator and Fluffer.
The pet perforator is an optional component of a baler, but can also be an individual equipment. This equipment perforates the PET bottles so it can be processed by the baler. The working chamber of a PET perforator is generally composed of 2 axes, which have mounted knives for perforating the PET bottles. These axes rotate in the opposite direction each, and thus the PET is perforated.
Pet perforator also influences the productivity of a baling machine . The more PET it perforates, the more can be processed using a PET baling machine .
The Recondis PET perforator comes with an innovative knife system. Generally, knife wear occurs after approximately 1 year of use, and it is necessary to replace them in order for the equipment to continue operating. But our perforator is equipped with knives that have a triangle shape, with 3 sharp tips, as you can see in the image above. Only one tip of each knife is used for perforating. When the tip is worn, it is not necessary to replace the knives, but only to change the worn tip with one of the 2 sharp tips of the remaining triangle knife. Thus we have at least 3 years of use without the need to purchase a new set of knives.
The fluffer is a component of a waste paper baling press, but it can also be an individual equipment, for maculature. Like PET, maculature is a difficult material to bale, with a horizontal baler, if there is no fluffer. The books, magazines and so on, pin great force on the ram, which presses this material, and can destabilize it, or even move it off its guide rails..
Both the fluffer and the PET Perforator are optional components that can be positioned directly in the feeding hopper of the baler. These are incorporated in the control system of the equipment and can be operated automatically, from the control panel of the baling press, when the materials in question need to be packed.
What do you have to keep in mind?
What do you have to keep in mind when you want to buy a baler and how do you plan your production? There are two very important questions when you are on the verge of a purchase.
The summary of the above is the answer to the second question. How do you plan your production with the new equipment? With all the data about the materials that require baling, the experience with their processing, their flow, but also the expected result in mind, you can find the equipment that fits your process. If you want to take a test, contact us, and we will find out together what equipment you need.
But the equipment that suits you, can be provided by several manufacturers.
Here comes the answer to the first question. What should you keep in mind when you want to purchase a reciclables baler ?
In this context I do not know if we can define quality very well. Every equipment has its perks. But some equipment comes with something extra, and these are the factors you should consider:
– Support from the manufacturer; In addition to the installation of the equipment, it is very important to train operators, monitor the behavior of the baling machine and last but not least the fine settings. After installing the equipment, Recondis provides operating assistance, training the staff, performing practical tests on the equipment, and adjusting the equipment to function at the optimum capacity for each individual customer. All of these operations extend over the course of a month, from commissioning.
-Maintenance and warranty ; The warranty is a very important aspect for a purchase. But I think that the maintenance of the purchased equipment is even more important. Better to prevent than to repair. Recondis offers maintenance for its equipment by technical inspection every 6 months, but also provides the necessary indications for the daily maintenance performed by the operator. Thus we ensure together that the equipment will have a longer life.
– Parts in stock; Supplies and spare parts are an important aspect. In this domain, a break in operation can be very costly for the business. It is important to have spare parts in stock, and not wait for manufacturers from other countries to send them. Recondis recommends that customers purchase spare parts, but also keep itself stock parts for the equipment sold.
-Service; In addition to Recondis teams, which will intervene as soon as possible after any referral, Recondis also offers a service platform called Recondis Reports. Here you can monitor maintenance actions, equipment history, error report and more.
Last but not least, a very important aspect in choosing the right equipment is the price. If you’ve reached this point in reading the article, all I can say is ask us for an offer. You will be pleasantly surprised.