Baling Efficiency and Best Practices - Recycling Today

Baling Efficiencyand Best PracticesTips for increasing productivity anddecreasing downtime

Maximum Performance Through• Baler Choice• Bale Density• Bale Integrity• Operator Productivity• Maintenance and Housekeeping

Bale Density and IntegrityAchieving Proper BaleDensity and IntegrityFor bale density and integrity you firsthave to look at what type of materialyou are going to process. Differenttypes of material have their ownunique properties.

Bale Density and Integrity - PaperCommon paper products recycled•OCC•CPO•CBS•SWL•ONP•OMG•White Office Paper

Bale Density and Integrity - PaperChallenges of recycling paperSince many types of paper will cometo the recycler in a tight package,preconditioning is necessary to ensuregood bales. Two pieces of equipmentused to precondition paper areFluffers and Shredders.

Bale Density and Integrity - PaperFluffers(also known as conditioners, rufflersor distributors) will pull the paperapart and fluff it up.

Bale Density and Integrity - PaperShredders• Will shred tightly-packed paper• Can increase baling production speed• Can create very tight bales• Create short fibers

Bale Density and Integrity - PaperTwo challenges when baling OCC• It comes in many different sizes.• It has a lot of memory when baled dry.

Bale Density and Integrity - PaperHandling varied OCC sizes• Large infeed opening on baler• Precondition large pieces• Shredder• Precrusher flaps• Tramper

Bale Density and Integrity - PaperHandling OCC memory• Very dry bales are not as dense• A small amount of moisture will reducethe memory

Bale Density and Integrity - PlasticCommon plastic products recycled• HDPE• PET• E-WASTE• PVC• LDPE

Bale Density and Integrity - PlasticChallenges of Recycling PlasticThe main challenge of baling plasticis air trapped in bottles, which canlead to lower bale density andintegrity as well as increased balingtimes. Two solutions for this problemare pre-crushing bottles in acompactor and perforating bottles toallow air to escape.

Bale Density and Integrity - PlasticPre-crush bottles in a compactor• Removes most of the air, allowing morebottles to be stored in a bunker• Reduces the time it takes to make a bale• Creates tighter bales

Bale Density and Integrity - PlasticPerforate HDPE and PET• Allows air to escape from bottles• Allows baler to process bottles faster• Integrity of the bale will be tighter

Baler ChoiceChoosing a Baler ForYour MRFThere are many types of balers on themarket today. Choosing the rightequipment for your MRF can be a realchallenge.

Baler ChoiceChoosing a Baler•What size MRF is being considered?•What is the throughput of the MRF?•What is the projected growth of the MRF?•What will be the material flow?

Baler ChoiceClosed-End Balers and Downstrokes•Pros•Cons• Lower initial investment• Smaller area needed to process material• More labor-intensive• Equipment will need to be upgraded with growth• Bales are strapped by hand

Baler ChoiceOpen End Auto-Tie•Pros• Fits in a smaller designed area• Works very well for an inline system flow control• Makes all ties on a bale at the same time• Designed for fast paper and plastic operation• Two process to make a bale (compaction and tying)•Cons• Infeed hoppers somewhat small• Large materials require some preprocessing• Requires 10 or more spools of tie wire• Some do not have shear blades• Not the best for light metals

Baler ChoiceTwo Ram Auto-Tie Balers•Pros•Cons• Capable of shearing material if necessary• Uses only one spool of tie wire at a time• Has a large infeed hopper• Can have a larger compaction cylinder• In a multi-material operation, it has the option of aseparation door to eliminate material cross contamination• Capable of being fed over the side with a loader• When baling plastics, preprocessing works better forbale integrity• Has a large footprint• Will always eject bale at right angle to baler• Has three processes to make a bale (compaction, ejection and tying)

Operator Do’s and Don’ts - SafetySafe Operators Increase EfficiencyThe consequences of poor safety practices include injury, downtime,repairs, and more.

Operator Do’s and Don’ts - Safety• Do’s• Always walk around and inspect your equipment before turning it on• Inspect again after starting equipment• Make sure all alarms are in good working order• Always wear the proper protective gear• Don’ts• Never go inside the baler chamber orhopper while baler is running• Never ever stand or walk on a conveyorwhile the baler is running• Never enter the baling chamber orhopper improperlyThe proper way to enter the balingchamber or hopper is to:1. Make sure no material can fall offconveyor2. Push the Emergency Stop (E-Stop)button in3. Turn the key switch off4. Turn the Main disconnect off5. Lock and tag the Main disconnect6. Manually activate all hydraulicsolenoid valves

Operator Do’s and Don’tsProductivity and avoidingcatastrophic failuresWhether the equipment is operated manually orautomatically the operator is responsible forwhat happens during the operation. It is their jobto make sure nothing enters the baler that it wasnot designed to handle.

Operator Do’s and Don’tsProductivity and avoiding catastrophic failures•Make sure nothing enters the baler that it was not designed to handle•Feed material at a steady and even rate•Precondition materials, when necessary•Maintain the baler and operate it inside recommended parametersYou can’t t bale engine blocks, I-beams, Iblocks of metal, 24” trees and concretebecause they are as dense as they are evergoing to get. And you can’t t bale Jellobecause you can’t t put a tie on it.

Operators Do’s and Don’tHousekeepingCleanliness and MaintenanceKeeping the facility clean is more important than just sweeping the floor.Keeping the area around the equipment clean and free of obstacles is asafety matter as well.

HousekeepingWhen Baling Light Metals•Sharp metals can cause personal injury•Long extrusions are a tripping hazard•Thin metal under platens cancause damaged cylinder seals•Metal stuck in conveyor tracks,chain, head stock, tail stock,wings and drive chains canresult in major repair costs

HousekeepingWhen Baling Paper Products•Paper on floor is a slipping hazard.•Paper in conveyor tracks, chain, head stock, tail stock, wings and drivechains can result in major repair costs.•Paper under platens can cause damaged cylinder seals, hydrauliccylinders, any pivot points and fire hazard.•Paper laying around and on hydraulic units that have oil on them canraise the operating oil temperature as much a 40º F, causing parts to wearvery fast.•Cleaning off the operator’s panel will help reduce push buttons fromseizing up. It will also help the visibility of the readout.

Maintenance At What Cost• Importance of maintaining equipment• Maintenance Programs – Pros & Cons• The need to incorporate a maintenancebudget in the planning stages of a MRF

Maintenance At What CostImportance of maintaining equipmentPreventive maintenance (PM’s) normally consists of cleaning, checkingoil, repairing leaks, replacing worn parts and monitoring for properoperation. PM’s are performed on regular intervals based on equipmentworking hours.Most companies understand that rolling stock, including fork-trucks, tractortrailers, front end loaders and other vehicles, require service on a regularbasis. However, a maintenance program should be established for theentire facility including all stationary and mobile equipment.Material Recovery Facility equipment, such as conveyors, balers, sortingequipment, etc., equally require routine maintenance to decrease downtime and increase productivity.

Maintenance At What CostImportance of maintaining equipment

Maintenance At What CostImportance of maintaining equipment

Maintenance At What CostMaintenance Programs – Pros & ConsPros• Longer equipment life• Scheduled down timeverses unscheduled /emergency down time• Increases long termproduction• Able to identify and resolvemalfunctions before majordamage is causedCons• Considered an increase inbudgeted Operating Costs• Requires trained permanentemployee or contracted service• Requires purchasing parts forstock• Downtime required to performpreventive maintenance on adaily, weekly, monthly orquarterly basis

Maintenance At What Cost• The need to incorporate a maintenancebudget in the planning stages of a MRFMost of the budgeted costs and time for service and preventivemaintenance are allocated for rolling stock, leaving little or no fundsto perform preventive maintenance and service on other facilityequipment. However, emergency repair costs of MRF equipmentcan greatly exceed a budgeted preventive maintenance program.When preparing a budget for a MRF first consider an adequatemaintenance program. Programs are readily available from mostequipment manufactures, several publications and the internet. Byusing a good program along with precise documentation many ofthe unforeseen repair costs can be avoided.

Question & AnswerFeel free to ask questions….Buddy HimesHimes Service Company, Inc.Waco, Texas USA