Optimising production and increasing profits

Written by: RWW | Published:

With the recycling sector estimated to be worth around nine billion pounds, high quality recyclable materials are now commodities with baling technologies sitting at the heart of this growing industry. Claire Col reports.

Although recycling is now embedded in our everyday lives, most people in the UK have no idea what happens to their waste after they place it in the recycling bin. Indeed, research shows that 32% would be ‘much more likely or more likely to recycle’ if more information about end destinations was made available to them.  

In a bid to encourage recycling, householders in Wales can now find out more about what happens to the glass, plastic, metal, wood, paper and card they send for recycling, with the publication of the latest Destinations Dataset by the Welsh Government. 

The dataset allows anyone interested to search for almost 20 groups of material recycled and shows that between 2011-12 local authorities sent 475,770 tonnes of waste to sorting facilities and re-processors, and that 24,269 tonnes was sent for export. 

The remainder was mostly organic material sent for treatment.   

Much of this waste will be shredded or baled in the recycling process and so this dataset has the potential to be extremely useful to businesses looking to source materials for use in manufacturing. 

Compact & Bale

Indeed, it was to Compact & Bale whom Cannon Packing & Logistics recently turned to for help in re-evaluating their waste management logistics so that the staff could spend more time on core business and less time on waste handling.

“Cannon, a contract packaging company, bales over 20 tonnes of cardboard per month, and this enormous amount of loose boxes were being double handled,” explains MD Denise Wilton. “Firstly by the packing team throwing them into pallet boxes, then by a member of the team on a truck and then handled again to be placed into the existing baler - this process would take 10-15 minutes per pallet box”. 

So Compact & Bale conducted a waste audit which identified that although baling cardboard generated income for the business, it was labour intensive. 

With space at a premium, Compact & Bale’s solution was to install the Strautmann’s AutoLoadBaler, which has a small footprint and lower cost than a horizontal semi-automatic baler.

“The AutoLoadBaler and collection cart system located at source of waste eliminates the double handling and saves 15 man hours per week. Fifteen collection carts are now placed at the ends of the packing lines so the Cannon waste team simply wheel the cart to the AutoLoadBaler, replace the empty cart with the full one, push the button and walk away,” adds Wilton. 

“This has led to productivity remaining at a high level and our operator even has a smile on his face while handling the waste packaging now,” 

Canon director, Greg Alder enthuses. “With payback in two years we are very happy with the AutoLoadBaler.” 

Compact and Bale are the sole UK agents for Germany-based Strautmann.

Presona

Presona says it has earned a solid reputation for quality and reliability, manufacturing fully automatic balers, compactors and complete air transportation systems for waste management. 

According to the company, efficiency is key to optimal production and Presona balers are certainly that; their pre-press technology in their LP series creates high density bales which uses 50% less power than conventional balers, saving energy and time. 

Indeed, Presona stresses that it’s this focus on efficiency and a life-cycling approach which has informed their most recent development, the new LP 85 VH.

“The LP 85 VH is a state-of-the-art baler with a range of functions to enhance performance and to bring a favourable life cycle cost for our customers,” explains sales manager Matt Hawkes. “It has a new friction channel design with two heavy-duty pulling cylinders to enhance bale density and reduce wear and tear. The baler has a smart relation between fixed bale channel and friction channel to better control the added press force, to warrant the best possible bale density.” 

All the Presona LP Series balers can be equipped with a frequency control system which connects the RPM of the motor to the current requirement of flow from the pump. “This results in increased energy efficiency and reduced energy cost,” says a company spokesperson. Waste disposal company Wallisch & Strasser in Germany recently invested in their third baler from Presona when the LP 85 VH was launched. 

Marco Lenz, owner and CEO, says: ”We are more than satisfied with our new LP 85 VH baler. It is the strongest we bought and the output is very high. Another point for our decision to buy a Presona baler is the fast and good after sales service and the client service through Presona.”

DRB

Baling wire is an essential commodity in the recycling industries and DRB says they have been manufacturing it for 50 years. 

“Our pedigree is gained by knowledge and experience spanning over half a century, and with our constant investment in the most sophisticated production processes,” says DRB’s MD Peter Robinson.  

Indeed, recent changes in the market has motivated DRB to again look at developing their wire for the newly emerging RDF sector. 

Refuse derived fuel uses a technology that produces energy from waste that is unsuitable for traditional recycling. “When baling and strapping solid waste for incineration, the traditional steel baling wire must be removed before the burning begins which is labour intensive and costly,” explains Robinson. “So we’ve developed PlasLOC which is suitable for baling waste for RDF.”

DRB’s new PlasLOC wire (pictured above) can be burned during the incineration providing a calorific value. Moreover bales can be loaded into furnaces fully wrapped without intervention which will significantly improve processing systems saving money and time. 

PlasLOC has also been specifically designed for compatibility of use with most of the larger baling machines. “PlasLOC is available in various reel sizes up to 13,000 meters per reel, and manufactured right in the heart of Yorkshire, DRB will be the sole manufacturer and supplier for PlasLOC in Europe,” adds Robinson. DRB also supply baling wire in a cut and loop form, rewound coils and black annealed or galvanised formers to suit customer specification.  

HSM

HSM has been providing the recycling business sector with their products including recovered material baling presses, high volume security shredders, shredder-baler combination systems and PET/hard plastic perforating, crushing and baling solutions for more than 40 years. Included in their range are the V-Press vertical baling presses. 

Designed to minimise environmental impact along the entire supply chain, the V-press reduces the volume of on-site packaging material by up to 95% and produces bales of the weight and size preferred by recyclers, in many cases turning a cost centre into a profit centre. 

Indeed, it was to HSM who the Robinson Club Daidalos on the Greek island of Kos turned to for help with their recycling. 

Annually, the hotel produces 70 tonnes of cardboard, 500 kg of aluminium cans and a tonne of plastic waste and because all clubs belonging to the group aim to be ’environment champions’, using a sustainable approach to waste was a pre-requisite and so chose a HSM V-Press 610 eco vertical baling press. 

“Because the V-Press 610 works around the clock, it reduces the volume of material and makes bales with a weight of up to 100kg, depending on the material,” explains club director Jörg Schwille. “And thanks to its user-friendliness, it is easily operated by all of the employees themselves.” 

Dicom

Derbyshire-based Dicom has been providing a wide range of baling systems for waste recycling plants and distribution centres for over 30 years and from their manufacturing plant in Alfreton, they produce a large range of static and portable waste compactors, vertical and mill-size baling machines, along with waste handling equipment. 

Energy efficiency is always the name of the game and this was the design focus for Dicom with the new ‘H’ range of Konti and Likon channel balers from PAAL. The Dokon range of channel balers are said to be ideal for RDF material because they are offered with the patented twine tying system which enables the tied bale to be incinerated. 

“The new features include high efficiency piston pumps which enable a smaller motor to generate a higher output, and both the cutting knife and the stamper have been fundamentally re-designed enabling more consistent bale lengths to be achieved,” explains Jason Greatorex, sales director. 

“The result is to reduce power consumption while simultaneously increasing throughputs and bale weights.”

For those producing large volumes of waste, a considerable reduction in the number of collections is reported to be achievable using the Dicom waste compactor. 

“Typically, a CE waste compactor will reduce the waste volume to a ratio of 4:1, making significant savings for the customer,” explains Greatorex. 

The CE 12/20 is a portable waste compactor built with an integrated bin lifting system and is reported to be ideal for locations where waste is collected around a site in bins of up to 1100 litres, while the CE32/30 portable waste compactor uses the latest twin ram compaction technology, giving it a massive 30 tonnes of force. 

The sales director adds: “The compactors are suited for compacting materials such as cardboard, plastic packaging and recyclables.”

Accent Wire UK

With over 50 years experience within the industry there’s nothing about baling wire Accent Wire UK says it doesn’t know. 

Specialising in high tensile, auto galvanised wire to suit ‘American Tie’ balers, as well as stocking pre-cut lopped, rewound coils and black annealed baling wire, they’re also experts in wire tie systems. 

“As well as designing and manufacturing our own system, the Accent 470, we also market the Envirobale system,” says sales representative, Liam Gulwell.

From the four-wheel drive system to the knotter unit, the Accent 470 is said to excel in performance and reliability. 

A primary feature of the Accent 470 is the pivot-out knotter unit which allows instant and full access to all wear parts while the bale is still in place. 

“If you remove two bolts the parts cartridge containing the twister pinion, bushings, guides and cutter, pivots out for easy cleaning, inspection or replacing parts. Return the parts cartridge to its original position for perfect alignment and trouble-free operation; it’s that easy,” explains Gulwell. 

But if customers want a system that doesn’t use baling wire, the Envirobale System fits the bill. 

“The Envirobale System is a containment system for solid waste baling designed with the environment in mind,” says the sales rep before adding: ”Solid waste or RDF bales are ejected from a baler with a single ejection stroke into an Envirobale bag. 

“The bag is then easily transferred, and with no wire in use, the bales can be sold on for energy from waste or refuse derived fuel facilities. The Envirobale System provides waste managers with many environmental benefits including a potential reduction in daily cover requirements and cleaner leachate at landfills.”

Mach Tech

Based in the North West, Mach Tech is a specialist engineering company working exclusively with industrial shredding machinery for the recycling industry. 

Specialising in a wide range of shredders including the high volume shredding of SRF/RDF with the award winning Komet range of machinery, Mach Tech also excel at shredding bulky wastes with the Jupiter range of single shaft heavy-duty shredders, and working closely with the engineers at the Austrian-based Lindner, they have recently introduced a new-look industrial mobile shredder, the Lindner Urraco 75 DK Powerline. 

David Ingham, operations director at Mach Tech Services, says: “We originally launched the Urraco on a trial basis in 2012 and following feedback from customers we’ve been able to develop and fine tune it to make it an even better offering.”

Tailored specifically for the British market, the Urraco 75 DK Powerline includes a Scania DC9 engine complying with euro-norm3, a hydrostatic drive with regulated pump system, touch screen operator’s panel as well as shafts that are specially configured for difficult UK waste. 

There’s also adjustable shaft speeds, a B2 Track system, a HB400 hard faced discharge chute and an internal compressor for cleaning. 

In addition, significant structural changes are reported to have been made to the discharge conveyor, making them much stronger with reinforced steel construction. 

The two shaft shredder is reported to be ideal for mobile and semi-mobile applications and can deal with a range of waste. 

These include domestic, commercial and bulky waste, mixed waste wood, biomass, logs and electronic waste. 

Mach Tech Services will be showcasing the Urraco 75 DK Powerline at this year’s RWM exhibition in September.


This material is protected by MA Business Ltd copyright.
See Terms and Conditions.

Comments
Name
 
Email
 
Comments
 

Please view our Terms and Conditions before leaving a comment.