FAQ – questions about fully automatic channel baling press made specially for MRF plants to bale MSW, RDF / SRF waste
1. What is the most common terminology (synonyms) for balers adapted for Waste Management Centres?
Fully Automatic Channel Baler
Single Ram Horizontal Baler
Channel Continuous Pressing Machines
Waste Baling Press Industrial Balers
Pre-Compression Baler with Lids
Lid Channel Baling Press
Single Ram Extrusion Baler
Automatic Cardboard Baler
Continuous Automatic Baler
Automatic Baler Machine
Rectangular Baler Presses
Wastepaper Processing Press
Refuse Baling Presses
Automatic Baling Press
Baling Press Machine
Waste Compaction Baler
Automatic Waste Baler
Paper Baling Press
Waste Baling Machine
Shear Press Continette
Horizontal Channel Baler
Residual Waste Presses
Auto Tie Baler
2. What are the advantages of a single-ram baler vs. two-ram baler?
The single-ram baler or channel baling press has a higher capacity; it can bale more material during the same period, because the tying cycle has shorter than a two-ram baler. This also gives the benefit of having a consistent throughput which makes feeding easier for the loader operator which is more convenient for the automated feed chain belt conveyors.
Another big advantage is found in single stream MRFs plants because they process multi-material waste. Bunker management is made easier because you can tie bales of various lengths with constant bale density.
3. What are the main factors for increasing bale weight?
The whole purpose behind baling any material is to densify it – to squeeze more material into less space and produce highly compacted and stackable bales for optimal truck loading. These facts are the best proof of the excellent efficiency of these channel balers.
Kilograms per cubic meter are the standard measurement of density. Density achievement should be most important fact when selecting baling equipment. The density of a bale can be considered more important than its weight, even though the weight of a bale is usually the focus of recycling processors such as balers. Why? Because the same material e.g., cardboard can be process wet or dry and the bulk density of this material can vary up to 100%, which effect of the bale weight. Maximizing density can save a processing plant a tremendous amount of money in reduced wire use, storage, shipping, handling, and maintenance costs.
The density is increased by the compaction force. For this reason, you need to consider a Specific Pressure Force in the baler’s specification. When choosing a baler, you must consider the diameter of the cylinder rod; a bigger cylinder will have a better compaction capacity (higher Specific Pressure Force). Also, a higher capacity hydraulic pump will play a role in the compaction force. The design and conception of the extrusion chamber is also critical, the smaller press chamber (in cross-section) area has higher Specific Pressure Force.
4. How to increase throughput of the channel baler.
In the previous answer I explained how important “Specific Pressure Force” for bale density achievement is. But bigger you have Specific Pressure Force slower is the main ram movement which influence on lower baler throughput.
To increase the baler throughput at the same Specific Pressure Force you can only do to speed up oil current in the hydraulic system with the hydraulic pump, for this reason you need to increase the power (in kW) of the hydraulic pack.
5. What the new generation channel baling presses include to increase compaction capacity?
The new horizontal baling presses include increased high-capacity retention in the pressing chamber and increased compaction capacity. With this new hydraulic baler technology, the density obtained can easily be compared with those obtained with two ram balers without sacrificing the throughput. Higher density bales ultimately reduce wire cost, optimise truck loading, and minimize the amount of bale storage needed.
6. How does a pre-press (preflap) and shear (cutting) technology increase efficiency?
The pre-press is a very interesting technology since the pre-compaction increases the volumetric efficiency of the baler when baling fluffy material or those having flow characteristics like plastics or cardboard boxes which haven’t been pre-conditioned.
In combination of a shear blade eliminates the potential material blockages or jams of the pre-press when baling large products like cardboard. With these type materials, eliminating the operation of the pre-press results in reduced cycle time and increase throughput when baling other materials like smaller cardboard trims, mixed paper, newspaper or perforated pet bottles.
The combination of a pre-press flaps and shear baler technology brings the best versatility as you can comfortably bale many materials regardless of their density and eliminate the jam. Further, the pre-press will reduce wear on the knives and shear blade.
7. What pre-press or pre-compaction technologies exist in the baler?
Most baler manufacturers offer a specific baler technology (some strictly advocate pre-compacting technology with a Single Big Flap, some with Double lateral Flaps, some advocate cutting press technology).
The choice of the most suitable press technology depends on your type of business and the materials you process.
Sometimes a baler with shear blades, called a shear baler, is better; sometimes a pre-press with a big single flap at the rear of the feed hopper is better with materials like PET and plastic film; and sometimes a high pressing force (up to 200+ tonnes) and throughput requirements makes a press with double lateral pre-press flaps on both sides of the feed hopper is the best option.
8. What does a pre-fill valve do on the hydraulics system?
The pre-fill valve increases the main ram moving speed in both forward and reverse modes. This device allows to reach higher throughput than regular baler with significantly less energy consumption. The baler can obtain an increased speed up to two and a half the speed of a traditional regenerative hydraulic circuit for the same flow at the pumps. This reduces cycle time and increases energy efficiency.
The vertical tie has a reduced footprint than a horizontal tie, but the horizontal tying mechanism is easier to maintain being at the operator level also horizontal tying simplifies the cleaning process for the tying device and enables less pollution by small waste into needle slots which results in lower wear and greater tying success. Horizontally tied bales are easier to manipulate by the fork-lift operators.
For production of bale size (in cross section) which is not equilateral e.g., 110 cm horizontally x 75 cm vertically the vertical tie enables tying with 5 wires instead of 4 (at the same feed opening size) and this is the main advantage when choosing the suitable tying orientation.
+ easier maintenance
+ easier wire installation
+ easier cleaning
+ greater tying success
+ manipulation by the fork-lift
+ cheaper tying unit
+ reduced footprint
+ enable tying with another wire for not equilateral bale size
10.Which baler accessories need the channel baler for processing different material from RDF (refused-derived fuel), MSW (municipality solid waste) to PET and OCC waste?
Single stream of waste management plants (MRFs) is equipped with fully automatic channel baler which allows the greatest degree of versatility, all with purpose to be capable of baling various waste (RDF, SRF, MSW, residual, mixed paper, OCC, UBC / cans (tin, Al), hard plastics, plastic films, PET bottles, HDPE bottles, foam, …). However, a machine that effectively bales multi material waste must have a lot of additional equipment such as stamper, bottle perforator, cross-wise tying, ruffler, needle slot sliding shield, etc.
To cope with “Hands-off” operation (means you only need someone to take away finished bales) and multi material waste the baler needs to be equipped with many accessories and sometimes these baler accessories doubled the price of the standard baler.
The ANIS High Load Volume series baler has been specifically designed by ANIS to solve the processing needs of high-volume recycling plants. This baler is designed with an exceptionally heavy built frame to provide maximum service in the difficult environments found in Material Recovery Plants (MRF). The heavy built frame is constructed with both welded and bolted steel beams and plate steel. A special hydraulic lock balances the compaction force (up to 200 tons) with the counterpressure force restricting the material in the extrusion channel maximizing density on every bale. This simple hydraulic system greatly reduces operating costs and reduces the risk of mechanical failures. Maximum density is achieved to increase truck loading, reducing transportation costs. Production of over 25 tons per hour OCC is available.
ANIS balers come in a wide variety of configurations, sizes, and costs based on the materials being recycled and the output demands. ANIS provide industrial balers for a wide range of customers, from municipal recycling facilities and high-volume warehouses to smaller businesses just looking for a way to stop paying for cardboard removal.
11. What functions do baler accessories perform?
An unjamming device called a “Stamper” or »Material blockages remover » is designed to automatically clear jammed material from in front of the cutting edge, when processing heavy grade material (such as OCC). It is positioned directly above the shear blades for maximum effectiveness and easy maintenance.
The perforator for PET plastic bottles punctures and extrudes the air from the bottles for high-density, heavier and the homogeneous bales which lowers transport costs and prevents tie wire cracking especially when the sun shines on the bales and heat them.
Croswisse tying system: To hold the baled material together in uniform bales and obtain the best possible bale weight for expanding materials (in the case of PET, HDPE, foam or foil baling) the cross-tying system baler is recommended.
The material distributor (often known as a fluffer or ruffler) is retractable and used to break up compacted newspaper or disperse bundled newspaper and magazines in the feed hopper to produce a more uniform bale. It is a rotary blade driven by an electric motor into the hopper immediately above the baling chamber and speeds up the loading into the press chamber of bundled materials which weren’t pre-conditioned before baling.