A mixed blessing - Baler Applications

Recycling Today, Dec, 2003 by Brian Taylor

Bigger is better seems to have become the operating philosophy for recyclers in all segments of the industry in the past decade, as having one large processing facility is now considered more efficient than having several recycling outposts.

The combination solid waste-recycling companies have been busy retrofitting their processing plants, often putting in automated sorting systems and high-production balers. Similarly, scrap metal companies may keep some feeder yards open to attract obsolete scrap, but they are often doing their processing and baling in one central plant.

Although bale dimensions themselves are not getting ,any larger, most recyclers have been eager to chum out more bales in one shift at one plant than they were just a few years ago.

ALL IN ONE. The trend toward massive material recovery facilities (MRFs) in the municipal segment ,and larger "super yards" in the scrap sector has created several challenges for plant managers and equipment providers.

According to equipment suppliers, installing high-volume balers is just part of the solution. Plant operators also want to be able to measure results, have reliable equipment and increasingly possess machinery that can handle a variety of materials efficiently.

In addition to large MRFs and scrap facilities dealing with more volume, they usually also handle a wide variety of materials. In the case of MRFs, this material may enter the plant in a commingled form, providing an entire additional set of challenges and equipment needs before material ever reaches the baler (or balers).

After material has been through all the automated sorting equipment and past the sorting line stations, what emerges at a MRF are several grades of paper and several types of separated rigid containers that need to be baled.

MRF operators can take different ways of handling this cross-section of grades, according to equipment suppliers.

Ken Ely of recycling equipment distributor Ely Enterprises Inc., with locations in Cleveland and Chicago, says some of his customers are handling enough material to have designated balers for certain materials. "One of my larger customers has five balers at their plant," Ely comments.

"One is for news grades (ONP), another for OCC (old corrugated containers), another is for rigid containers. We're seeing more balers designated for one material."

A plant manager may choose this option because one baler simply won't handle everything; because certain styles of balers are more suitable for certain materials; or even because some recyclers are reluctant to have just one baler on hand in case a worst-case scenario of unplanned downtime throws production hopelessly behind.

"There are still some people who think it's risky to have a single machine, because if the plant doesn't have room to store more than one day's worth of incoming material, then if you have prolonged downtime it creates serious problems," says Joe Szany of Marathon Equipment Co., Vernon, Ala.

Szany also says that MRFs that bale considerable paper and container volumes may choose different style balers for these two portions of their output.

"Many non-fibrous items, such as plastic containers, steel cans, aluminum used beverage containers (UBCs), don't bale very well in anything but a two-ram baler," says Szany. "Companies that don't make two-ram balers might profess otherwise," he adds, "but you have to allow the density of the bale to relax before you tie it."

On the fiber side, however, those putting out high volume have gravitated toward single-ram extrusion balers. "People feel they can get more fiber tonnage out of a single-ram extrusion baler, and I would agree with that," says Szany. "If you want to do 6,000 to 9,000 tons per month, you may need an open-end [extrusion] baler."

European equipment makers such as Macpresse, sold in the U.S. through Sierra International Machinery Inc., Bakersfield, Calif., and Bollegraaf, sold in the U.S. through Van Dyk Baler Co., Stamford, Conn., have had success selling to large MRFs and paperstock plants with models that offer superior throughput.

With these machines retaining the heavyweight title, makers of smaller machines can still serve the large MRF market as secondary units baling containers and handling streams where grades entering the chamber may change frequently.

Equipment makers are offering modifications to address just this situation, according to Ely. "Anytime you switch grades, you're losing production. But stone newer balers are coming out with bale separation features such as a bale separation door," he notes.

Control panels now allow operators to change baler settings with the touch of a button when shifting from one material to another. Touchscreens that come with balers made by IPS Balers Inc., Baxley, Ga., "have a minimum of 15 materials programmed in; operators just hit a button," says IPS president Sidney Wildes.

IN AND OUT, Dealing with mixed materials is one challenge for recyclers, but a bottom line consideration for many is baling as much material as possible in one hour, one shift or one month. Additionally, with more material heading overseas, how to most quickly fill an export container is also a consideration.