In this article, you will learn about the different types of cardboard balers and their use.
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A cardboard baler is a mechanism that uses a metal plate driven by a hydraulic ram to apply tremendous pressure and force to crush, compact, and compress pieces of cardboard into tightly formed and easy-to-transport cubes and rectangular bales. The purpose of cardboard balers is to take a huge volume of cardboard packaging and transform it into manageable bales to be transported to recycling centers.
Every retail or manufacturing operation that consistently receives components, parts, and products uses a cardboard baler to save space and prepare cardboard for transport. The use of cardboard balers has grown steadily in recent years due to the many regulations and laws communities have enacted to control pollution and waste.
The initial classification of cardboard balers relates to their orientation, which can be vertical or horizontal depending on the manufacturer, types of cardboard to be crushed, available space, and amount of cardboard. Aside from this single difference, all balers have the same basic principle, purpose, and design, including a hydraulic-powered ram, a large compacting box, and a plate driven by the ram.
The many configurations of balers make it possible to fit one to the needs of any business. Offices that receive shipments in small boxes have balers that have visual appeal but still pack the force to create a small bale. Large manufacturing operations that receive cartons of parts have huge balers with rams that weigh over 500 lbs and have a pressing force of hundreds of tons.
A vertical cardboard baler compresses cardboard using a vertically placed ram that crushes cardboard into a bale through the use of downward force. They are the most economical form of baler and require very little space. A factor to consider regarding vertical balers is ceiling height, which has to have sufficient clearance to accommodate the height of the baler.
There are different configurations of the hydraulic ram system for vertical balers; some have a single hydraulic cylinder, while others may have two or more. The amount of pressure applied by the different systems can vary from 10 tons to over 200 tons. The number of cylinders and pressure depend on the number of waste cycles of an operation or facility.
Horizontal balers are larger than vertical balers and are semi-automatic. They have a hopper at the top where cardboard is fed manually or by conveyor belt, forklift, or cyclone, which is a set of pipes at work locations that are fed small pieces of cardboard. Horizontal balers are designed for large amounts of cardboard, with an hourly output of one to 15 tons.
A significant aspect of horizontal balers is their pressure range, which can be from 20 tons up to several hundred tons. Their large capacity makes it possible to feed them continuously. Once they reach a preset capacity, they can self-activate.
Horizontal balers can be open-ended or closed-ended, with closed-end horizontal balers designed for low bale production and open-end horizontal balers for high production.
A closed-end horizontal baler has a closed-off compression chamber and is smaller than open-end horizontal balers. Waste is automatically compressed against a closed door without the need for an operator. At the end of the baling process, the bale is removed by a rear or side door and is pushed out by extending the ram or by the next bale. Closed-end balers are limited by the number of bales they produce each hour, which is generally one.
An open-end horizontal baler has an open rear end of the extrusion chamber with an automatic bale tying system. They are designed for heavy-duty, high-capacity baling for organizations with a high volume of cardboard waste. Materials are loaded into the hopper via conveyor, manually, or forklift. Once the hopper is full, the ram pushes the material toward the open end of the extruder.
Horizontal open-end balers save more labor than vertical balers since they do not necessitate manual loading or activation. Most varieties automatically tie or wire bales, though some versions perform this manually. The baling process continuously produces four times as many bales per hour as closed-end horizontal balers.
The high capacity of an open-end horizontal baler necessitates meeting certain criteria before purchase. A company that produces over 25 tons of cardboard per month should have an open-end horizontal baler for financial savings, labor savings, and optimum control of waste materials.
A two ram horizontal baler has two rams that complete similar but different functions. When material is dumped into the hopper when the compression chamber is full, the first ram compresses and compacts the material into a bale. In many ways, the first ram functions like a closed-end horizontal baler.
What differentiates a two ram cardboard baler from a closed-end baler is the second ram that completes the baling process in two ways. Once the cardboard has been compacted, pressed, and shaped into a bale, the second ram attaches the wire or twine to the bale to hold the compacted material. The compacted bale is then ejected from the baler by the second ram.
The image below provides a graphic representation of the workings of a two ram horizontal baler. As seen on the left, the first ram moves down the compression chamber to compact the cardboard material, while the second ram on the right waits for the completion of the compacting process. Once the bale is shaped, the second ram secures it and ejects it to the left.
Portable cardboard balers are ideal for organizations with a low volume of cardboard and limited space. The bale size for a portable cardboard baler weighs up to 140 lbs (63.5 kg). They use vertical downward force to compress the cardboard material. Though portable cardboard balers are smaller than their more robust counterparts, they still have the same heavy-duty construction.
The low profile of a mobile portable cardboard baler makes it possible to fit through a standard-sized door and be carried by freight elevators. Certain designs have castors for ease of movement and more flexible placement.
A top loading cardboard baler is a mini baler that is smaller than a portable baler and has cardboard loaded from the top. They are ideal for companies that generate very little cardboard and produce bales of 90 to 130 lbs (40.8 to 59 kg). Their small footprint makes it possible to place them wherever cardboard waste is created. The bales are light enough to be removed using a dolly.
A unique feature of top loading mini balers is their ability to be preset to create a specific size bale.
A critical differentiating factor for cardboard balers is the tonnage they produce daily, which can vary from a few tons for small offices to hundreds of tons for industrial and manufacturing facilities. When users are considering the purchase of a cardboard baler, it is imperative that they are aware of the amount of cardboard that needs to be processed each day. The weights below are regarding the tons of cardboard compacted daily.
The cardboard baling method depends on the size, capacity, feeding method, and type of the baler. Although large horizontal production balers are normally fed by a forklift or conveyor, they can also be fed manually.
With the growing concern regarding environmental preservation, using balers to prepare cardboard for recycling has become a standard practice for all businesses. Cardboard balers make the process more efficient and labor-saving and assist in packaging cardboard for easy handling.
Vertical balers are normally fed manually. The style of the vertical baler determines how it will be used. In addition, the types of cardboard are critically important for the baling process. If all the cardboard is the same, then separation can be eliminated from the baling process. This is normally true for high-volume operations.
The steps of the baling process change if several types of cardboard are being baled, like paperboard or triple-walled. In those instances, it may be necessary to separate lighter cardboards from the heavier ones. This is because heavier cardboards require the baler to apply more pressure and mechanical energy, while lighter cardboards, especially paperboard, require less energy.
The first step in the process of using a vertical baler is to ensure that the baling chamber has a flat surface for loading cardboard. Normally, a sheet of cardboard is placed on the bed. Once a flat surface has been assured, cardboard can be placed in the baler.
The top of the baler should be securely closed and the on switch activated. To ensure activation, the down bottom is held until the downward-moving ram begins its motion.
When the ram stops its motion, the baler should be turned off, and the door opened to the compacted cardboard.
Next, the bales from vertical balers are tied manually. There are channels at the bottom and top of the baler to insert the baling wire. The wire is pushed through the channels at the bottom of the baler, pulled up, and pushed across the top of the bale. The two channels for this yellow baler can be seen at the bottom and back of the image.
One end of the wire has loops through which the straight end of the wire can be inserted. The connections between the ends are then twisted tightly to secure the bale.
Sometimes, the wire is inserted before loading and compressing the cardboard. With the wide array of vertical balers, it can be expected that there are several methods for applying the wire to fasten the bale.
Finally, to remove the tied bale from the baler, the pressure of the ram has to be released by an unlocking clamp so that the bale can be moved forward and out of the baler. The methods for ejecting bales vary according to the type of vertical baler. With some versions, there is an ejection strap upon which the bale sits that extends up the back of the baling chamber. When the mechanism for the strap is activated, it raises and tightens, pushing the bale onto a pallet or dolly.
Unlike a vertical cardboard baler, the process for a horizontal baler is automated. The key features of the process are loading the bin with cardboard and removing the completed bale. Horizontal balers have a larger footprint than vertical balers and load from the top.
Though the feeding process for a horizontal baler can be manual, in most cases, horizontal balers are fed by a conveyor, forklift, cart dumper, skid steer, or front loader. When the amount of cardboard reaches a predetermined level, a photocell activates the mechanism of the ram to begin the baling process. Some horizontal baler designs are activated manually from a control panel, much like the control panel on a vertical baler. For high-volume cardboard operations, photocells are preferred to keep materials moving.
Shearing is a necessary feature of horizontal balers. Once the ram has been activated manually or by a photocell, it moves forward to compress the cardboard in the compression chamber. While the ram is in motion, cardboard continues to fill the hopper and rest on the top of the moving ram. A shearing blade or knife cuts away material above the bale compression chamber that could potentially jam and obstruct the movement of the ram.
Shearing blades are extremely tough and resilient. They are designed with tapered cutting edges and serrated blades, which reduces the area where the blade makes contact with the material. In the process, more recyclable material is cut at once.
Tying off the bale for a horizontal cardboard baler can be completed manually or automatically depending on the baler type. Since open-end cardboard balers operate continuously, automatic tying off is more efficient and productive. Closed-end cardboard balers do not produce as many bales per hour as open-end cardboard balers, making it possible to use a manual tying-off process.
Manual baling, regardless of the type of cardboard baler, is basically the same for all cardboard balers. Using channels or slots built into the baler, wire or twine is fed through the slots and wrapped around the bale. The bale is tightly secured by twisting it with wire and tying it with twine. The compressed cardboard material tends to adhere to itself, making the manual baling process easier.
Wire is the most common form of bale securing method since it is highly durable, has excellent tensile strength, and is long-lasting. However, some baler users prefer twine over wire because it is cost-effective, takes up less space, is easier to work with, and can be recycled.
The design and configuration of cardboard balers have been developed to condense and compact cardboard into viable shapes for appropriate reuse of the raw material. Specific components of the machine are necessary for the process’s successful completion.
At the center of cardboard baling technology is the crushing and compacting force provided by hydraulic power. These pump-driven devices can compress far more intricate materials than cardboard but are ideal for turning large volumes of cardboard into cubes.
Conveyor belts and chains are essential for high volume cardboard balers. They make the process of baling more efficient and automated. Massive amounts of cardboard can be quickly compacted and stored for shipping.
Regardless of the feeding method, whether it is manual, conveyor, forklift, or another system, the section of the baler that collects the cardboard is the hopper, which is only present on horizontal cardboard balers. There are a few hopper varieties, most with angled metal walls designed to catch cardboard as it is sent to the baler.
The hopper holds the cardboard above the ram until the rams are positioned to allow the cardboard to pass through into the compression chamber. At the bottom of the hopper is a shearing knife designed to prevent the held cardboard from jamming the ram. The image below illustrates a four-sided hopper on a horizontal cardboard baler.
The crushing, compressing, and compacting power of cardboard balers is embodied in their hydraulic systems. The force of hydraulic systems is how the bales are shaped and formed into geometric configurations. The hydraulic components are the workhorse of the baling system and perform the bale-making function. Regardless of the differentiation between vertical and horizontal cardboard balers, both types depend on hydraulic power to produce their bales.
As essential as the feeding mechanisms and other parts of a baler may be, without the hydraulic system, the remaining components are without purpose. The driving force of the baler and hydraulic system is the hydraulic cylinder that accumulates the compressive force to drive the ram.
In the image below of a vertical cardboard baler, the hydraulic system can be seen at the top of the baler.
As global awareness of recycling has grown, more and more companies have been assessing their waste production to find methods for reusing, repurposing, and remanufacturing waste as raw materials for new products. Waste that was formally left in a bin for garbage pickup is now evaluated for its content and broken into its basic elements.
The wide proliferation of cardboard for shipping has made it the primary target for recycling efforts. Companies can use cardboard balers for crushing cardboard into convenient and shippable shapes.
Placing cardboard boxes in bins or piling them for garbage collection takes up space and becomes a fire hazard. A cardboard baler can take a massive pile of cardboard and turn it into a compact, compressed cube for shipment or storage.
Any aspect of an operation that requires material handling heavily relies on labor costs. Disposing and storing waste requires several workers, from those who remove it from a work location to those who place it in storage. These costs can be avoided by using a cardboard baler, which significantly diminishes waste and removes the need for multiple handlers.
There are many costs related to running a business. Overhead costs are fixed costs that are difficult to adjust. A component of overhead costs is handling waste, which is an inevitability for all businesses. A cardboard baler provides a smooth and seamless method for handling waste and cutting overhead costs.
Every business is working to demonstrate to its customers that it is an eco-friendly operation that is well aware of sustainability and preserving the environment. This single factor has moved to the forefront of customer concerns and motivates customers to purchase from and work with certain companies.
Repurposing and recycling waste materials are the ultimate demonstration of a well-run and environmentally friendly organization. Cardboard balers are a central part of taking waste and converting it into raw material for future use, which is a goal of all ecological programs.
In a normal operation, without a cardboard baler, cardboard is collected during the day and removed by cleaning staff or dock workers. Collecting, gathering, and disposing of cardboard from shipping is time-consuming and labor-intensive. Having a cardboard baler closely positioned to where cardboard collects can reduce time spent cleaning up.
As items and packing materials are removed, they can be immediately placed in the baler that can operate automatically during high-volume periods or manually when needed. The amount of time for collecting and disposing of cardboard is eliminated with efficiency.
An important key to baling cardboard is being aware of the different types that can affect the operation of the baler. The term cardboard is a generic term used to describe a wide variety of paper materials that have been shaped and formed. Different grades of cardboard are designed to perform specific tasks, from shipping heavy machinery to protecting electronic devices.
Essentially, the type of cardboard baler and its durability has to match the type and grades of cardboard that will be processed. Using a vertical cardboard baler to process heavy, thick cardboard can radically decrease its baler’s performance.
Cardboard is known as corrugated fiberboard, which is made of kraft paper that is fluted with one or more flutes. All forms of corrugated fiberboard can be baled. Knowing what type of fiberboard is to be baled can be beneficial in preserving and protecting the integrity of a cardboard baler.
Single face fiberboard is very thin, inexpensive, lightweight, and offers very limited protection. Of the various types of cardboard, a single face is the least durable and is easy to crush.
Single wall fiberboard is the type that is used for shipping boxes for consumer products. It has one wall of flutes, or wavy paper, with paper glued on either side of the flutes. There are various sizes of flutes that run from size A to size F, where size A is 3/16 inch, and size F is 1/16 inch.
Double wall cardboard has two sets of flutes divided into two sections with a piece of kraft paper separating the flutes. Different sizes and shapes of flutes are used depending on the cardboard’s design.
Triple wall cardboard has three sets of flutes that are separated with two pieces of kraft paper. The increased number of flutes enhances the durability of triple wall cardboard and makes it capable of replacing wooden boxes. It is extensively used in industrial settings.
Paperboard lacks durability and is used to ship objects that are not fragile, breakable, and prone to wear or tear. It is the least expensive form of protective material and is widely used.
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