New Baler for Streamlined Scrap Management

Complex Challenges

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.

Role of Balers

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.

Line Scrap Integration & Whole Can Infeed

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.

By-Pass Conveyor Adjustment

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.

Bale Outfeed Configuration

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.

Professional Execution

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.

Project Outcome

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.

Why Choose integratedAIR?

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.