Blog / New
Baler for Streamlined Scrap Management
12 February 2025
integratedAIR was approached by a client who faced a
pressing need to upgrade their scrap management system by replacing a baler
that had been in operation since the 1980s to address immediate operational
needs while laying the groundwork for a more efficient scrap management
solution in the future. As the existing baler comprised long-since obsolete
parts, integratedAIR advised that the Austropressen DS-700 baler was the ideal
replacement. However, integrating this modern equipment into a complex set-up
that was outdated by decades presented a tough challenge.
The project presented several difficulties stemming from the
complexity of a scrap system that had evolved over decades. Integration posed many
perplexities, as the new baler needed to interface with a network of
interconnected components that included line scrap infeed, whole can infeed, a
bypass conveyor, and bale outfeed to a dumpster conveyor. Compatibility with
existing conveyors was another consideration, as the upgrade needed to minimise
disruptions and avoid extensive modifications to the current setup.
Balers are machines designed to compress waste materials
such as cardboard, paper, plastic, and metal into compact bales so they can be
easily stored and recycled. By reducing waste volume, storage space is
increased, and the balers also provide cost-saving benefits as transportation
expenses are reduced, and businesses can sell baled materials to recycling
facilities. Along with the economic advantages, balers help to work towards
sustainability goals as they reduce carbon emissions from fewer transport trips
and support recycling efforts by minimising landfill use. Additionally, they
boost operational efficiency by streamlining waste management, improving
workplace safety, and maintaining a more organised environment.
integratedAIR systems approached this project with a focus
on integration, precision, and efficiency. The existing conveyor logic and
operation were retained. The new baler infeed chute was custom-designed to
match the current conveyor drop position which ensured coherent integration.
The drop chute feeding line scrap to the baler was modified
to align with the new baler’s infeed and scrap discharge position. The existing
conveyor’s functionality was left untouched for the whole can infeed, with a
custom-designed baler infeed chute ensuring a perfect fit with the current
conveyor drop point.
The bypass conveyor, which previously moved into position
when the baler was unavailable, was adjusted and fixed into position for
simplicity. A divert was added to the line scrap drop chute, allowing scrap to
be redirected without the need for conveyor movement. This enabled efficient
redirection of scrap when the baler was unavailable.
The new baler was raised to align with the existing
discharge conveyor. A dead plate extension ensured that bales could seamlessly
transfer to the dumpster conveyor without altering its setup. The bale outfeed
system remained unchanged, but the new baler was raised to align with the
existing discharge conveyor. A dead plate extension was installed to ensure
that bales transitioned smoothly to the dumpster conveyor without requiring
modifications.
The installation was carefully planned to fit within a tight
shutdown schedule, and the client removed the obsolete baler before the
integratedAIR team began working with it. Over the next two days, modifications
were made to the area beneath the scrap drop chute, preparing it for the new
baler. Once the baler was positioned, the remaining work was completed, with
integratedAIR’s five-person team ensuring all systems were fully operational
before the shutdown ended.
The successful installation of the Austropressen DS-700
baler considerably enhanced the reliability of the client’s scrap management
system. Importantly, it maintained compatibility with existing baler components
that could still be used. Despite the complexity of the setup, integratedAIR’s
solution minimised disruption, avoided unnecessary modifications and provided a
solid foundation for future system improvements.
integratedAIR’s expertise in designing and implementing automatic
bale handling solutions ensured that this project was delivered on time and
within scope. integratedAIR proved to be a trusted partner for this client’s
operational upgrades by focusing on minimal disruption, precise integration,
and future scalability.
integratedAIR Systems has designed and installed baler
systems for production lines in various industries – get in touch with our team today to learn more about our expertise in your industry and the distinct
requirements of your production process.
