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This Article takes an In-depth look at Balers
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Modern balers are descendants of hay presses, invented in the mid-nineteenth century, that made it easier to gather and stack hay. The earliest hay presses were stationary units built into a barn and extending two to three stories into the hayloft. They used a team of horses that raised a press weight then dropped it to compress the hay. Others used horse or mule powered sweeps at the press bottom geared press or jackscrew. Before hay presses, farmers collected hay by hand with forks and rakes. Stationary presses led to portable ones.
The first mobile, man powered, hay baler was invented in the 1860s and required the help of several workers. During the late 19th Century, inventors continued to improve balers making some that worked with one person and plungers. The baler market lacked a consistent, standard model for several years and did not stabilize until after the turn of the century.
The 1900s saw the introduction of mechanical balers. In 1936, the first automatic baler, the round baler, was invented by George Innes. It had a self-tie system that used Appleby type knotters from a John Deere grain binder. In 1939, Ed Nolt patented a modified version of Innes' baling machine, which was more reliable and became the standard. The round baler continues to be the most common type of baler used today.
As farms became more mechanized and the number of farmers decreased, farm equipment manufacturers lost their market. Since most equipment was designed to last for many years, remaining farmers were unlikely to need new equipment for many years. As their market dried up, manufacturers looked for other sources of revenue.
In their search for a new market, producers landed on waste management. Industry produces tons of waste in the form of boxes, paper, and cardboard. When it is placed in trash containers, it takes up a great deal of room. In the 1940's, the first industrial baler, using the design of a hay baler, was introduced to handle industrial waste. By compacting waste into bundles, it took up less space and made it easier to dispose of it.
The surge in balers came during the rising environmental concerns of the 1970's and 1980's. Companies created the position of waste management director that supervised the recycling and proper handling of industrial waste products. Out of their efforts came the recycling baler whose initial use was to recycle cardboard.
Waste balers are heavy equipment used to compress waste products into a form that is easier to handle for recycling or disposal. They are designed to take large volumes of trash and reduce it to a fraction of its size. The types of materials compressed include cardboard, foam rubber, plastic, and other materials left over from production and manufacturing.
A waste baler has three parts: the container, compactor, and power unit. Waste is collected in the container. When the container is full, the waste is compacted into a bundle or bale by the compactor. After compaction, the bundle is wrapped to protect the waste material from water damage, contain it from being windblown, seal in any odors, keep vermin out, and prevent damage that could be caused by dislodged waste.
The development of waste balers has led to several designs to fit specific conditions. A baler can be a critical addition to a company's operation. Choosing the right one to fit the conditions is essential. The many types include vertical, horizontal, auto-tie horizontal, closed door horizontal, and two ram.
The most common type of baler is vertical where waste material is crushed using downward force. They are smaller than other balers and can operate in areas that have an eight foot ceiling. Vertical balers are used by stores and small companies with little waste.
The horizontal baler operates similar to the vertical version except that it compresses waste material from the side. Waste is dumped into a hopper. A ram compresses the waste into a closed rectangular space. Unlike vertical balers, horizontal ones can be larger as much as 40 feet in length and can handle larger loads of trash.
Special versions of the horizontal baler are the auto-tie and closed door varieties. Auto-tie horizontal balers automatically tie the completed horizontal bale. Closed door horizontal balers include a wall at the end of the bale chamber with a sturdy surface for the baler to push against. Bales produced in this manner are very tight and dense making them easier to ship and contain more waste.
The two ram baler has the same design as the single ram version but with two rams. One ram collects and compresses the material while the other ram ties and ejects the bale. This form of baler has a very large feed opening to handle and compress material faster.
These basic designs are a few of the many types available. Each manufacturer has developed machines with other features that can handle a wide variety of materials in several different volumes. To get more information, it would be wise to contact manufacturers to get their guidance and assistance.
The process of choosing a baler depends on the type of waste material, the amount of material, the available space, and the cost. Manufacturers have balers designed to fit a wide variety of customer needs. Some producers specialize in equipment for a specific industry from food waste to metal scrap. It is important to determine why a baler is needed and how it will be used.
heavy duty balers are used for waste that requires a great deal of pressure to be compacted. The baling press version of heavy duty balers uses one or more hydraulic arms to compress material against itself to form large rectangular bales. Materials for a heavy duty baler can be larger and denser such as truck tires. A special version of a heavy duty baler is the drum crusher that can compress full or empty 55 gallon drums to a height of 2.5”.
The distinctive characteristic of heavy duty balers is their all in one processing method that can take paper, cardboard, OCC, ONP, books, magazines, plastic bottles, plastic film, rigid plastic, fiber, textile, cans, tins and aluminum scraps and press them with several tons of force into tight bales for shipment and remanufacturing. The size of heavy duty balers requires the use of a highly efficient conveyor feeding system that automatically feeds the baler at nearly four tons per hour.
A common form of heavy duty baler is a vertical baler that has a smaller footprint but produces the same performance as larger balers. They are a specialized baler capable of baling high density plastics, aluminum cans, paint cans, tires, and large plastic bottles. Heavy duty vertical balers have two rams with a press force of 50 tons to produce bales of 610 kg (1645 lbs.). They are manually fed and have an automated tying system.
The distinctive feature of vertical balers is the way that they apply their force, which is a downward thrust that applies pressure using a pneumatic or hydraulic powered ram that moves from the top of the baler down. Vertical balers are able to process many forms of waste materials including corrugated cardboard, paper, textiles, cans, plastics, and non-ferrous metals. They have a small footprint and provide an economical solution to waste management.
Unlike horizontal balers that require an operational space, vertical balers are small enough to fit into a wide variety of conditions. Although they require little floor space, they do need height clearance. Vertical balers are loaded from the top and are seldom connected to a conveyor system. In most cases, they are manually loaded and unloaded. High performance vertical balers can produce bales as heavy as 454 kg (1000 lbs.). The compression system produces high density bales that are normally automatically tied.
Although vertical balers can handle any type of waste materials, they are restricted by how much can be fed into them due to the small feed opening, which makes it difficult for vertical balers to compress large pieces of waste. The popularity of vertical balers is due to the many sizes, capacities, and configurations of vertical balers that are available. The sizes of bales for vertical balers vary between 30 in and 42 in (76 cm and 107 cm) up to 60 in (152 cm) with larger vertical balers having a bale volume of 90 cu ft (2.54 cu meters).
Horizontal balers are large industrial balers that compress waste material into large bales. The two styles of horizontal balers are closed end and open end with closed end balers designed for lower volumes of waste materials. Open end horizontal balers are continuously operating balers that are normally connected to some form of feed mechanism such as a conveyor or shoot. Waste material is dumped into the pressing chamber through a hopper or opening above the chamber.
Most horizontal balers are automatic and activate when the level of waste material in the pressing chamber reaches a certain level. At that time, a single ram moves horizontally along the chamber to compress the waste material. With closed end horizontal balers, the compressed material is automatically tied when the size of the bale reaches sufficient volume. Open end horizontal balers tie off the compressed material and move it out of the pressing chamber in a continuous cycle.
Unlike vertical balers, horizontal balers have a large footprint and are designed for high volume compacting. They are used in facilities that produce more than 20 tons (18 metric tons) of recyclable waste per month. Horizontal balers are hard working heavy duty pieces of equipment that can bale paper, cardboard, non-ferrous metals, plastics, tires, rubber products, and textiles. Open end horizontal balers come with a shear blade that removes excess waste material during the compression cycle of the ram.
Industrial balers are machines that compress waste material into manageable bales for shipping and disposal. Although the vision of an industrial baler tends to be a baler that is large and horizontal, the term industrial baler applies to any form of baler that handles heavy waste materials and compresses the material into a bale. There is an endless list of the materials that an industrial baler is capable of compressing and includes tires, rubber products, textiles, non-ferrous metals, carpet, dense plastics, and heavy corrugated cardboard.
The majority of industrial balers are a part of high volume waste disposal systems that have waste material fed by a conveying system or are manually loaded. The classification of industrial balers includes vertical, horizontal, and two ram balers, each of which are distinguished by how they compress waste material. Vertical balers are upright small footprint balers that use a downward thrust under great pressure to create compact bales. Although they come in small sizes for office use, vertical balers are also produced in larger sizes capable of producing several tons of compression.
Horizontal industrial balers are the image that most people have of an industrial baler since they are typically very large, have a large footprint, and produce several tons of pressure when compacting waste material. The bales produced by horizontal industrial balers can weigh several tons, which requires that they be moved, positioned, and loaded using a forklift. This type of industrial baler is used in facilities that produce several tons of recyclable waste every month.
Two ram industrial balers have a larger hopper and charge box, which allows the baler to process bulkier and larger waste material. Additionally, the larger hopper makes it possible for the feeding system to feed waste material faster using a wider conveyor. Since the two ram system compresses bales against a wall, the bales are denser and easier to maneuver and load. The increased pressure of the two ram version makes it possible to bale heavier materials such as steel cans and high density plastics. A factor that is difficult with the baling of plastic bottles is the expansion the plastic creates in the bale, which is not a factor with two ram balers.
The selection of an industrial baler is a complicated process that requires careful consideration in regard to the materials to be baled and the volume that is produced by a facility. Industrial balers are like any other heavy duty equipment that require constant monitoring and management. They are labor saving and cost saving devices capable of changing high volumes of waste material into compact and well formed bales for easy shipping and handling.
Round balers are a baling method that replaces the traditional rectangular bale of the past. As with other baling methods, they collect hay or straw to form huge cylindrical bales that can be loaded and transported to a barn for storage for feeding livestock or creating livestock beds. Unlike the rectangular bales, large round bales can be left outdoors due to how tightly packed they are and their ability to shed rain if stored outdoors or left in the field.
Prior to the baling process, the hay or straw in a field is raked into windrows, long rows organized in a line. The round baler is driven or pulled over the windrows where it picks up the hay or straw. Once the collected material enters the baler, a series of rollers and belts tightly roll it into large bales as more and more material is fed into the process. When the diameter of the roll reaches five or six feet, it is wrapped in twine or mesh and ejected out the back of the baler.
During the baling process, bales are monitored for their moisture content and weight. When a field is being cut for baling, the cutting process normally releases the moisture from the plants. In some instances, a field may need to be crimped to facilitate the drying process since moisture content over 50% can be harmful and dangerous.
Round balers come in a wide range of sizes with the smallest balers producing bales that are 4 feet wide with a 5 foot diameter. The largest round bales are 8 feet wide with a 6 foot diameter weighing over a ton. Small round bales can weigh between 500 pounds up to 700 pounds depending on the type of round baler. There are mini-round balers for farms with limited acreage that weigh 40 to 50 pounds.
The term bailer is an alternate term used to refer to various types of balers. The word Bailers describes machines that compact waste material into tightly packed bales for shipping, storage, and disposal. It is used in place of “baler” by individuals and bailer users. As with all forms of balers, bailers make handling, packing, recycling, and transporting recyclable material easier.
Industries that produce large volumes of waste depend on bailers to compact their waste for easy disposal. Additionally, bailers are becoming a necessary part of manufacturing due to the increasing restrictions on waste material management and the types of waste that can be sent to a landfill. By reducing the size of bulk materials, it is possible to reduce the cost of disposal and the volume of recyclable waste.
Industries, such as auto manufacturing, plastics production, and food processing, are being required to reduce the amount of waste they produce and to recycle their waste. This factor has led to the rapid increase in the use of bailers in order to meet governmental agency and environmental demands. Bailer manufacturers are engineering a wide selection of bailers that meet the requirements of every industrial or commercial operation that produces high volumes of recyclable waste.
In the baling and recycling industries, there are certain materials that cannot be handled by traditional balers and require custom designed baling equipment. To meet the needs of these unique applications, manufacturers have design techniques that allow them to 3D model balers that can meet the space requirements, pressure requirements, and compaction requirements of special materials.
There is an endless list of materials that require the use of specialty balers such as bottles and cans filled with liquids, which traditional balers are unable to bale. In this case, the specialty baler drains the liquid from the containers and bales the containers in one simple step. As with all balers, specialty balers capable of baling liquid filled containers have vertical configurations with a small footprint and large horizontal types for high volume baling.
One of the biggest challenges that faces the baler industry is the baling and crushing of metals, which requires an exceptionally durable, strong, and resilient type of baler capable of producing the necessary force to crush metals. This type of specialty baler has to be able to withstand the stress associated with baling scrap metals.
A very unique form of specialty baler is a sawdust baler used by paper mills, sawmills, and millwork plants. In order to bale sawdust, it is necessary for a specialty baler to exert tremendous force in order to create a bale due to the lightweight of sawdust. The particles of sawdust are less than 1 mm (0.039 in) in diameter, which requires a pressing force of 80 tons. As material gets smaller, the amount of friction generated between the material and the chamber radically increases, requiring balers designed for such conditions.
Specialty balers are manufactured to handle one type of material such as sawdust, metals, foam, plastic wrap, radiators, and extremely dense plastics. In most cases, they are required to produce extreme force and be able to withstand the friction created in the compression process. They are a unique form of baler that are designed by baler engineers to meet the needs of their customers.
Cardboard balers compress cardboard and empty boxes into a manageable bale or bundle for recycling or repurposing. Once compressed, the bundle is tied off for disposal or shipment. By compacting cardboard, companies are able to contain large amounts of excess cardboard and keep it out of landfills. Also, compressed cardboard is far less likely to be a fire hazard or obstruction and frees up warehouse space.
Cardboard balers are available as both vertical and horizontal balers, but because vertical balers are more well-suited to lightweight waste compression, they are the more logical choice. Note that vertical balers are named as such because their input zone, or where the material is loaded, is located at the top end of the baler. After it enters the baler, it is fed down into the baler's chamber, where one or more hydraulic arms pound and crush it into a compact bale.
Baler machines are designed to compress materials into a bale for storage, transport or handling. A bale is a tightly packed rectangular cube that is wrapped in mesh or plastic or bound with twine, straps, or cords. They are robust machines capable of transforming piles of scrap material and waste into a form that is easy to ship and handle.
There are several types, sizes, configurations, and capabilities of balers from ones designed to bale paper to ones that bale non-ferrous metals and heavy plastics. The industrial Baler Machine has become a necessity for any business that produces a significant amount of waste per month, which is normally in the range of several tons.
A baler machine can be a sound investment that saves money, reduces waste, and saves time and space. They are an essential part of waste management programs that have become a vital part of environmental saving programs. Choosing the right baler to fit the needs of an operation is an important part of compliance with governmental agency standards.
The primary parts of a baler machine are the press channel, pressing chamber, tying method, and power unit. Waste material is deposited in a baler manually or automatically depending on the design of the baler and the type of baler. Automatic balers are activated when a sufficient amount of waste is loaded in the pressing chamber.
Balers vary according to several factors with the type of materials to be processed being the number one factor. Although baling paper and cardboard is a popular use of balers, there are more robust machines that are capable of processing heavier materials that require greater pressure and compaction power. Additional special features such as auto tie balers, two ram balers, and conveyor or auto loading balers increase the efficiency of a baler and make its operation easier and labor saving.
Baling machines are devices that have been designed to compress materials into a bale for storage, transport or handling. A bale is simply a bundle that is tightly wrapped and bound with hoops or cords. Baling machines come in several forms, each producing a different type of bale, either cylindrical or rectangular, of various sizes, bound by twine, strapping, netting or wire.
Some baling machines are stationary, while others can be towed behind a towing vehicle, like a tow truck or a tractor. The design of a baling machine can vary greatly depending on its intended application. Hay baling machines, for instance, feature tines to move the hay and hydraulic arms to compress it, but other machines may not have tines at all. Baling machines are frequently utilized in industrial recycling applications, but they can also be used for agricultural purposes. Baling machines come in many different configurations and are very versatile machines, being able to assist in the recycling of paper, plastic, metal, and many other materials.
A single ram closed door baler is a low capacity baler recommended for baling OCC, paper, plastic, UBC, light metals, and steel cans. They have a low capacity due to the short length of their extrusion chamber and their manual tie off system. Single ram closed door balers process three bales per hour or four to five tons (3.6 metric tons to 4.5 metric tons) of waste with bales at 30 in by 45 in by 60 in (0.8 m by 1.1 m by 1.5 m).
With a single ram closed door baler, waste material is compressed into a baling chamber that has a door at the end. The created bale is tied off and ejected when the door of the baler opens. Once the bale is clear of the baling chamber, it is moved for shipment or storage, and the door to the baler closes. The door for a single ram closed door baler opens to either side of the baler or raises vertically.
The door for a single ram closed door baler can be located on the side of the baler at the end of the baling chamber. With the side door configuration, the bale is held under pressure by the ram, both sides, and the top of the chamber. When the pressure is relieved, the ram is retracted, and the side door opens to relieve the side pressure. The bale is ejected or carried out of the chamber.
The tie off method for single ram closed door balers can be manual or automatic depending on the manufacturer. For manual tie offs, guides are provided to direct the operator and speed up the process. Created bales are very tight, dense, and secure with precise dimensions and shape.
For recycling purposes, the majority of balers specialize in baling one type of material such as plastics, ferrous and non-ferrous metals, aluminum cans, or cardboard and paper. Multi-material closed door balers are a generic type of baler that can be easily switched from one type of waste material to another, compacts all forms of waste material, and are designed for low to medium capacity recycling centers.
As with other types of balers, there are certain restrictions regarding the types of materials to be baled. Material baled by a multi-material closed door baler must be dry and free of moisture. This particular restriction applies to all balers except for those designed to handle liquids. Waste materials processed by a multi-material closed door baler includes corrugated cardboard, plastics, paper, cans, textiles, and non-ferrous metals.
Multi-material closed door balers are all purpose and can easily be changed to bale different materials due to its low capacity. This aspect of multi-material closed door balers differentiates them from open end balers that cannot be easily changed to provide for different waste materials.
One of the concerns of all businesses is an increase in efficiency to lower costs and increase productivity. Manual tie balers slow down operations and produce few bales per hour. A particular type of horizontal baler that helps improve all aspects of the recycling process is a single ram auto tie baler that produces multiple bales per hour and does not require manual interference.
Single ram auto tie balers are designed to process high volumes of waste with faster cycle times and bales per hour. They are capable of handling large boxes and operate using a single motor. Since single ram auto tie balers are automated, they lower labor costs, operate faster, and radically improve efficiency. Due to their horizontal design, single ram auto tie balers have a large footprint and require a great deal of space.
The speed at which single ram auto tie balers process waste material makes them one of the most popular forms of horizontal balers. They are high tech machines that use SMART technology with remote monitoring systems and diagnostics. Their technological features eliminate long downtimes, make maintenance easy, and make changing between materials quick and efficient.
Two ram auto tie balers are full penetration balers that are designed to bale and compress materials that are hard or difficult to process. They are capable of baling all forms of waste material with the exception of ferrous metals. All aspects of two ram auto tie balers are larger including the baling chamber and hopper. The larger size assists in increasing the speed of cycle times, bale volume, and the tonnage per hour.
The larger charge box and hopper of the two ram auto tie baler makes it possible for it to accept bulkier materials. The typical hopper for a two ram auto tie baler can be as large as 60 in (1.5 m) wide and 110 in (2.7 m) long with a bale size of 45 in wide by 30 in high and 60 in long (1.1 m by 0.8 m by 1.5 m) . The increased size of the hopper makes it possible for faster feeding by conveyors, which eliminates the need for pre-conditioning of the waste material.
Since the compression ram for a two ram auto tie baler compresses bales against a wall, it creates denser, tighter, and firmer bales. Bales are uniform and compact with exceptional precision and uniformity.
The two methods for tying off bales are on the side or the top. With the top tie method, banding wraps from the front to the back of the bale, under the bottom and over the top with the banding being tied off at the top of the bale. It is the method that is used by two ram auto tie balers. Tie off on the top of the bale prevents it from being caught on a forklift when being transported.
Baling presses are designed to compress waste materials into compact bales for transportation, storage, and disposal. They are heavy duty machines that come in various sizes to meet the demands of the many types of waste materials. Small baling presses can be found in office buildings for disposal of waste paper and boxes. Larger baling presses have a more dynamic and aggressive construction and are built to manage tons of waste material.
The term baling press is used to describe a wide assortment of recycling equipment that are manufactured for efficient disposal of waste material. Baling presses have become a necessity in modern society as tons and tons of waste material is produced every day. Since the middle of the 20th century, environmentalists, scientists, and manufacturers have become concerned about how to manage modern waste. One of the solutions has been the development of Baling presses that takes huge volumes of waste material and transforms it into manageable bales.
Baling presses are made of steel or stainless steel and have one or more hydraulic or pneumatic rams to press waste materials into stackable bales. The orientation of baling presses can be vertical or horizontal where vertical baling presses use a downward stroke to compress materials while horizontal baling machines have a linear stroke. Both types of balers come in different sizes, shapes, configurations, and designs to meet the challenges of different kinds of waste materials.
A baling press is an industrial piece of equipment that is powerful, rugged, and strong. They produce immense pressure to compress tons of waste material, under force, into a tight, dense package. The loading portion of baling presses is the compression chamber that is loaded with waste material. Once the chamber is full, the ram is activated and drives forward to apply intense pressure to the waste material to form it into a compact cube.
Scrap balers or scrap metal balers are a form of specialty baler that is designed to crush and compress metals, ferrous and non-ferrous. They are extremely powerful balers capable of compressing all forms of heavy materials. Metal products manufacturers use scrap balers to process the metal waste for recycling.
The essential part of a scrap baler is its hydraulic cylinder that provides the strength, force, and power to compress metals. Scrap metal hydraulic cylinders are hard working and durable components that are capable of withstanding the load capacity of a scrap baler and the stress that is part of the compression process. Attached to the hydraulic cylinder is the ram, which is a large heavy metal piece that is pushed by the hydraulic cylinder against the waste material. The hydraulic system includes valves, fittings, hoses, and pumps that use incompressible hydraulic fluid to produce the power transferred to the hydraulic cylinder.
The baling process of a scrap baler takes place in the bale chamber, which is where the metals to be compressed are loaded. The nature of the scrap baling process necessitates that the bale chamber be constructed of reinforced steel in order to withstand the friction, force, and movement of the ram. As would be imagined, the baling process for metal requires a great deal of intense pressure that the bale chamber must be capable of enduring.
There are several forms of scrap balers including ones with one, two, and three rams. Of the three types, three ram models are the most robust and dynamic. They have a main ram that compresses the metal material along the length of the bale chamber and another ram that compresses from the top pressing lid. A third ram shapes the bale, compresses the bale, and ejects the bale.
Scrap balers are fed in various ways depending on the type of scrap and the size of the scrap. Large pieces of scrap may be fed into the bale chamber using a hoist or crane while pre-staged scrap can be fed using a conveying system. Metal materials processed by scrap balers include 10 mm (0.39 in) thick steel, aluminum, copper turnings, oil tanks, steel windows, bicycles, and vehicle shells. They are used at steel mills, metal recycling plants, metal casting factories, and in the smelting industry.
Metal balers crush, cut and bale ferrous and non-ferrous metals. They are capable of baling scrap metal, aluminum cans, washing machines, and whole vehicles. The purpose of metal balers is to transform and compress metals into manageable bales for easy transport and removal. Metal balers can be stationary in place at locations where metal is collected or mobile to be brought to sites where metal is located.
The various types of metal balers are used to prepare scrap metal for recycling, lower transport costs, and increase the amount of metal per load. The baling process cold presses metals into cubes, cylinders, hexagonal, and octangle shapes. The cold pressing process ensures that the grain structure of the metal is not changed by being baled.
Metal balers have thick reinforced steel plating with high rigidity and a long service life. The hard surface of the steel plating protects the interior of the baler from being damaged by the sharp jagged edges of metal scraps. The baling process makes melting and reprocessing scrap metal easier due to bales being denser and more compact than loose metal pieces and in a size for easy handling.
The compression force of metal balers varies between 1200 KN and 1600 KN (120.4 tons and 160.6 tons) to produce bales of 305mm x 305mm (12 in x 12 in) up to 457mm x 457mm (18 in x 18 in). Output of metal balers can be 6 tons per hour, which translates into 30 to 60 bales per hour, depending on the type of scrap being baled. As with scrap balers, metal balers come with single rams, two rams, or three rams.
Various methods have been developed over the years to recycle plastics, which include shredding, crushing, and baling. Since most widely used plastics can be recycled, the baling of plastics from commercial and industrial facilities has become a common practice. Plastic balers are a cost effective, practical, and an efficient method for the handling of plastic waste. They come in a variety of designs and can include gravity, pneumatic, or belt conveyor automatic feed systems.
When choosing a plastic baler, it is important to consider the types of plastic to be processed since some plastics retain their shape while others are easy to compress. The different types of plastics include polyvinyl chloride, high density polyethylene, low density polyethylene, polyethylene terephthalate, and polypropylene, each of which has a different density. Most plastic balers are able to handle multiple types of plastic but it is important to be sure a chosen machine can handle the plastic it will be processing.
The installation of a plastic baler is part of a waste management program and recycling effort. Compressing plastic into bales significantly lowers waste removal costs, makes waste more manageable, and assists organizations in their compliance with government regulations. Vertical balers are a common form of plastic baler. They come in a wide variety of sizes with single or double rams powered by pneumatic or hydraulic power.
The baling process for plastic takes a fraction of the time required to bale other types of material. A normal baling cycle can last as little as 10 to 20 seconds. Bales come in varying sizes and can weigh as much as 500 lb up to 700 lb (4.5 kg up to 9 kg) depending on the type of plastic baler and the type of plastic.
Aluminum can balers are one of the most widely used types of balers. They are capable of taking all forms of aluminum and compressing it into tight dense bales for recycling. Aluminum can balers form bales that are easy to ship, load, and used as raw material for new aluminum products. Of the many materials used to package products, aluminum is the most sustainable and can be recycled multiple times without losing its properties.
The process for baling aluminum cans is much like that which is used to process other types of waste materials. Aluminum can balers can be vertical or horizontal but may not be as large as balers for ferrous metals. The bales produced vary in size and weight depending on the size of the baler. Aluminum can balers have a large hopper that is normally loaded from collection containers. The process for crushing aluminum cans and transforming them into a bale begins when the hopper has been filled.
Balers for aluminum cans are generally closed ended since they do not need to operate on a continuous basis. Once the bale chamber is full, the hydraulic powered ram forces the collection of cans along the length of the chamber and crushes them into a bale. Aluminum can balers can have one, two, or more rams depending on their design. Since aluminum bales are metal, they may stay together without the need for wires, straps, or plastic. In most cases, the bales are held together with wire to avoid having them fall apart.
Compacted aluminum bales do not weigh as much as other types of baled material but have sufficient weight to require the use of a forklift to move them. The weight and size of aluminum can bales depends on the type of baler. Small aluminum can balers produce 60 pound (27 kg) bales of 3 cu ft (0.08 cu meter) while large aluminum can balers produce 900 pound (408 kg) bales that are 50 cu ft (1.4 cu meter).
The goal of aluminum can balers is to make use of a reusable resource that can be processed multiple times. Although aluminum is one of the most prevalent metals on the earth’s crust, the extraction of it is a long arduous process. Recycling aluminum cans makes a valuable resource readily available with less processing.
Paper balers have become a common piece of equipment in offices, retail stores, and shipping operations. The types and kinds of paper balers are much broader than any other form of baler. They can be as small as a trash can or as large as a horizontal industrial balor. The principles for baling paper and cardboard are taken from the baling of hay and straw.
The many types of paper balers or baling presses are designed to apply pressure to form paper into bales or bundles of various sizes and shapes. Regardless of the computer age and information being stored electronically, paper is still a major part of conducting business and saving documentation. The amount of paper thrown away each year is equal to one billion trees with Americans using 85 million tons per year at 650 pounds per person. In the past, this huge volume of paper was thrown away and dumped in a landfill. With the rising concern for the environment and the rate at which landfills are being used, businesses have had to develop methods for compacting paper and cardboard into a more manageable form.
Paper balers, as with all balers, compress and bind paper in solid dense bales to make the paper waste easier to handle. Paper is collected in various ways at schools, businesses, and offices and placed in large bins that are used by recycling services. Every business has an agreement with a recycling company to dispose of its paper waste.
Recycling services have large horizontal balers that receive paper waste via conveyors. Depending on the collection method, waste paper is dumped on a conveyor and fed into the chamber of the paper baler. Many businesses have paper shredders or have a paper shredding service that collects and shreds waste paper. Shredded paper is processed like other paper by being loaded into a hopper with access to the bale chamber.
There are some restrictions to the baling and recycling of paper. In order for paper to be processed, it has to be clean and dry. Items such as food containers can contain grease, oils, or other residue from food. This makes the paper dirty and unable to be recycled. The list of recyclable paper is very long and includes cardboard, newspaper, kraft paper, chipboard, and business mailings.
Since each bale of waste paper contains hundreds of pieces of paper, even the smallest paper baler produces bales that weigh over 100 pounds (45.4 kg). Bales produced by horizontal balers can weigh up to a ton (907 kg). In all cases, lifting equipment such as forklifts and dollies are required to move paper bales. As with the weight of the bales, their sizes vary widely from 10.4 cu ft (0.3 cu m) up to bales that are 50 cu ft.(1.4 cu m).
Waste balers have become a necessity as the restrictions on the use of landfills has been steadily increasing. Commercial and industrial organizations produce several tons of waste every month that has to be disposed of and transported. Waste balers convert the huge volume of waste into bales that reduce the amount and size of waste and prepare paper, plastics, and metals for recycling.
A key part of a sustainable and waste management program is a waste baler that provides an efficient method for handling and disposing of waste material. Much of the waste created by organizations has been classified as recyclable, which leaves a small amount of unclassified waste. Each company has provisions for handling recyclable waste and leaving the disposal of other waste to garbage removal and waste management companies.
The process for the disposal of waste has been revolutionized by the introduction of the waste baler that is capable of taking huge volumes of waste and compacting into a convenient and manageable size. Waste balers are designed to handle all forms of waste from paper and cardboard to used appliances and plastics. The different forms of waste balers are found in retail outlets and offices where they limit the size of waste.
The two basic types of waste balers are vertical and horizontal with horizontal normally being a large robust machine with a large footprint while vertical waste balers are smaller with a limited footprint. Each type of waste baler comes in a wide range of sizes to fit the waste disposal needs of any size organization. They have become an important tool for companies that have committed themselves sustainability and saving the planet.
The categorization and specifications for waste balers varies in accordance with the types of materials an organization produces and their volume of waste. In many cases, companies hire recycling companies that separate waste material and prepare it for recycling. The initiative of most companies is focused on ensuring that they place the greatest emphasis on their waste management plan and adhere to it.
The main attraction of used balers, aside from their lower cost, are their addition to the effort to reduce environmental waste and the recycling of displaced equipment. By purchasing a used baler, a company can reduce its carbon footprint and further protect the environment. All of the various types of balers are available.
The purchase of a used baler includes the same process used to purchase a new one with the added step of a thorough testing of the machine‘s capabilities. The best guarantee of a quality used baler is buying it from a reputable knowledgeable refurbishing agent. Proper guidance and advice from an experienced provider can be very helpful and remove risk.
Compactors are designed to compress waste materials and scrap products for easier transportation, handling and better space efficiency. Industries such as food processing, manufacturing facilities, retail and consumer businesses and automotive factories all benefit in terms of environmentally and economically from compacting trash. Reducing the bulk volume of trash reduces the money and effort required to dispose of it.
Compactors are similar to industrial balers in that they reduce waste, but are typically used for non-recyclable materials in order to save space in landfills and other trash disposal locations.
A trash compactor is a device that has been fitted with a hydraulic arm to compress and tightly pack any type of material. The best example is a garbage truck that has a large compacting arm on the back of the truck that presses garbage to increase the truck‘s collecting space.
Several years ago, in-home trash compactors were very popular and are still available. Their biggest drawback is their cost, which is between $400 and $1500. They are a perfect solution for homes that collect large amounts of waste and have little room to store it.
The main purpose of a waste compactor is storage. Waste in baskets, barrels, and bags takes up space and decreases storage area. A waste compactor can reduce waste to a more reasonable size for storage before disposal. This is especially true with small operations that produce waste but do not have the room to store it until it is picked up. Compacting it removes the worry of what to do with the waste and forms it into a manageable shape for collection.
Industrial waste compactors help businesses to simplify their waste management and help them save money. They come under several names such as trash compactor, dumpster, and dumpster compactor. Several versions are available on the market from ones designed to compact cardboard to others that crush furniture.
Typical industrial compactors are pre-crushers, self-contained, X-press pack, and indoor. Pre-crushers break up large pieces of trash before it is moved on to a compactor. Self-contained compactors are a version of the horizontal or vertical baler and are preferred by restaurants and businesses that have organic waste. They are tightly sealed to contain odors and liquids. X-press compactors are smaller and designed for companies that have limited space but large amounts of waste. Indoor compactors are larger versions of the household compactor that is used by businesses that cater to the public and need immediate containment of waste.
American Baler has a complete line of industrial balers with solutions to meet every customer's needs. The goal of American Baler is to provide high quality baling equipment that is economical and efficient and meets recycling and environmental standards. They have single and double ram models that are manual tie and auto tie for high and low volume applications. American Baler’s two ram model is designed for handling and recycling scrap metal with minimal operator involvement.
Orwak is dedicated to reducing the volume of waste and protecting employees. They have a complete line of balers from their Britebin™ Solar litter bin to their large volume fully automated horizontal balers. Orwak has a baling solution for every size customer regardless of the amount of waste they produce. The key to the company’s success is providing baling solutions with a small compact footprint. The versatility of Orwak Balers makes it possible to install them indoors or outdoors depending on the requirements of a customer.
ERS is an industrial equipment manufacturer that offers a wide selection of vertical and horizontal balers of all sizes from two ram 5000 psi units to vertical balers that are capable of baling plastics, paper, cardboard, aluminum, other non-ferrous metals, and an assortment of waste materials. In addition to their huge inventory of balers, ERS also manufactures conveyor systems of different lengths designed to handle varying weights of waste to feed a company’s balers. They are a full service baler company that reconditions, repairs, and installs all forms of balers. ERS has technicians trained to customize their balers for unique and challenging applications.
Maren Balers and Shredders is an all purpose and complete solution provider that manufactures recycling equipment. Its highly durable and rugged baling and shredding equipment are designed to handle all forms of materials including plastics, corrugated containers, all forms of aluminum, steel cans, and copper materials. Maren offers horizontal auto tie balers, several two ram balers, closed door manual tie balers, and pinch conveyor and top feed shredders. They also provide engineering services for customers who require a unique custom designed recycling solution.
IBC balers are known for their reliability, performance, and ease of operation. They specialize in meeting the challenges of designing customized balers for unusual recycling applications with conveyors and balers that perfectly meet the types of materials and conditions. IBC balers come in multiple sizes and configurations at a cost that can meet any budget. With 200 models on hand, IBC can provide a baler that is a perfect fit for any customer.
Balers are complex pieces of equipment that rely on three basic features for their smooth operation, which are the feeder, hydraulic ram, and the compression chamber. All balers have these components in various forms, which change according to the designs of manufacturers. Since balers are heavy duty pieces of equipment, they have to be constructed from durable and long lasting materials such as steel and stainless steel. In addition, depending on the waste material being baled, the metal of the baler may be coated, finished, or treated to protect against the effects of various substances.
Feeding systems can take several forms depending on the type of baler. The simplest form is a manual fed baler where workers dump cardboard, metals, and other waste products into the baler. Manufacturers recommend that the workers that put materials in balers should be trained in the safety practices related to the operation of a baler.
Aside from manual feeds for a baler, there are various methods that include different types of conveying systems, which can be belt or chain driven. These types of systems are used by high volume organizations that produce a significant amount of waste.
Another form of manual feeding is the use of a forklift to dump large loads into a baler. In those conditions, the forklift driver is highly trained and certified to dump waste matter into the baler. Balers that use the forklift loading method normally have an angled walled hopper to make feeding easier and more efficient.
The main source of force in a baler is its hydraulic driven ram that crushes and compacts waste matter into transportable bales. The hydraulics of a baler function much like the piston on a car. Hydraulics are powered by incompressible fluids that serve as their energy transfer medium. As the fluid transfers from one chamber to another chamber, pressure builds up in the fluid to drive the piston that pushes the ram.
The ram moves along the compression chamber and compresses the waste material. The process is slow and requires a great deal of pressure. The activation of baler hydraulics can take several forms, which include control panels attached to the baler or remote controls located next to the baler. Control panels normally consist of an on and off switch and an emergency stop switch.
The baler chamber is where the waste material is loaded to be compressed and formed into bales. Each type of baler has a different process for preparing the chamber to receive waste material. Vertical cardboard balers may require the placement of a piece of cardboard at the bottom of the chamber to receive the cardboard to be baled.
In other situations, such as very large industrial balers, no preprocessing is necessary since the baler is able to complete baling without the need for additional preparation. What critical to the baler chamber is that it be maintained and kept in good condition. Balers are hard working machines that work constantly and have to be properly maintained, which is especially true of the baler chamber.
Common baler terms include:
The Accredited Standard Committee (ASC) Z245 for Equipment Technology and Operations for Wastes and Re-cyclable Materials established standards for trash compactors 27 years ago and for balers 18 years ago. As required by American National Standards Institute (ANSI), the requirements are revised every five years. ANSI Z245 covers operations involving mobile refuse collection, processing and disposal equipment, waste containers, and the companies that do recycling.
Regulations require that compactors and balers must be operated by a person who is 18 years of age or older, and the machine must be turned on or off by a key. The Occupational Safety and Health Administration (OSHA) uses the regulations of ANSI as part of their inspection process and will cite or shut down any operation that is out of compliance.
As trash compacting innovations and inventions are introduced, OSHA and ANSI adjust and amend their requirements to fit any new equipment or conditions. Many of the regulations are designed to protect equipment operators from hazardous conditions that could endanger their health.
With the ever growing concern for the environment and the continuing efforts of companies to meet governmental standards, it is very likely that the baler and compactor industries will continue to make an impact on controlling and minimizing waste. Advances in technology will most likely produce equipment designs that will perfect the present methods of waste management. Below are a few examples of future developments.
The electronics industry is constantly introducing new devices to replace existing ones leading to a need to dispose of outdated equipment. To meet the need to control electronic waste, Electronic Recyclers International has developed methods that can recycle several thousands pounds of electronic waste every hour. Though this is a small fraction of the over 90 million tons of e-waste produced each year, it is a major step in controlling what looks to be a major form of future waste.
Another innovation is biodegradable plastic that started out as a small part of the market but has been steadily growing each year. Researchers are presently perfecting a plastic that will biodegrade in a few hours instead of never or centuries. North Dakota University is developing a plastic that reacts to sunlight.
One of the largest electronics companies in the world, Texas Instruments, is perfecting a method of separating waste material using robotic technology to detect recyclable waste. The segregation process can cut down in waste that ends up in landfills.
Waste management will continue to be a concern to save the planet. Ecology researchers and scientists are continuing to find better ways to reduce what goes into garbage dumps and landfills to increase what can be reused. Balers have been the first step in their efforts.