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.
Cardboard balers are essential for any retail or manufacturing operation that regularly handles components, parts, and products. These machines help to conserve space and prepare cardboard for efficient transport. The adoption of cardboard balers has increased in recent years due to growing regulations and laws aimed at managing pollution and reducing waste.
Cardboard balers are primarily classified by their orientation, which can be either vertical or horizontal. This choice depends on factors such as the type of cardboard, available space, and the volume of material to be processed. Despite these variations, all balers operate on the same fundamental principles and share common features, including a hydraulic-powered ram, a large compaction chamber, and a platen driven by the ram.
Balers come in various configurations to suit different business needs. Offices that handle small boxes may use aesthetically pleasing compact balers capable of creating small bales. In contrast, large manufacturing facilities that deal with bulk cartons often use massive balers with rams weighing over 500 pounds and pressing forces reaching 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.
Vertical balers come in various configurations for their hydraulic ram systems. Some models feature a single hydraulic cylinder, while others may use two or more cylinders. The pressure exerted by these systems can range from 10 tons to over 200 tons. The choice of the number of cylinders and the amount of pressure depends on the waste processing needs and the volume of material handled by the 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.
Horizontal balers are notable for their wide pressure range, which can vary from 20 tons to several hundred tons. Their large capacity allows for continuous feeding, and they can automatically activate once they reach a preset level of material.
Horizontal balers come in two types: open-ended and closed-ended. Closed-end horizontal balers are typically used for lower bale production, while open-end horizontal balers are designed for high-volume production.
A closed-end horizontal baler features a sealed compression chamber and is typically smaller than open-end models. Waste is compressed automatically against a closed door, eliminating the need for operator intervention. Once the baling process is complete, the bale is removed through a rear or side door, either by extending the ram or using the next bale to push it out. Closed-end balers are generally limited to producing one bale per hour.
An open-end horizontal baler features an open rear end of the compression chamber and comes equipped with an automatic bale tying system. These balers are designed for heavy-duty, high-capacity baling, making them ideal for organizations with substantial volumes of cardboard waste. Materials can be loaded into the hopper using a conveyor, manually, or with a forklift. Once the hopper is full, the ram pushes the material toward the open end of the extruder.
Compared to vertical balers, open-end horizontal balers significantly reduce labor requirements since they do not require manual loading or activation. Most models automatically tie or wire the bales, although some versions still perform this task manually. The baling process in open-end horizontal balers is highly efficient, producing up to four times as many bales per hour as closed-end horizontal balers.
Due to their high capacity, open-end horizontal balers are best suited for companies that generate over 25 tons of cardboard per month. Investing in an open-end horizontal baler can lead to significant savings in both labor and material handling, as well as provide optimal control over waste management.
A two-ram horizontal baler features two rams that perform distinct but complementary functions. When material is loaded into the hopper and the compression chamber is full, the first ram compresses and compacts the material into a bale. This operation is similar to that of a closed-end horizontal baler.
The key difference between a two-ram baler and a closed-end baler is the role of the second ram. After the cardboard has been compacted and formed into a bale by the first ram, the second ram performs two critical tasks: it attaches wire or twine to secure the bale and then ejects the finished bale from the baler.
The image below illustrates the operation of a two-ram horizontal baler. On the left, the first ram compresses the cardboard material within the compression chamber, while the second ram on the right waits for the compaction process to complete. Once the bale is properly formed, the second ram secures it with wire or twine and ejects it to the left.
Portable cardboard balers are well-suited for organizations with minimal cardboard waste and limited space. These compact balers typically handle bales weighing up to 140 lbs (63.5 kg) and use vertical downward force to compress the cardboard. Despite their smaller size compared to more robust models, portable balers are built with the same heavy-duty construction.
The low profile of portable cardboard balers allows them to fit through standard-sized doors and be transported by freight elevators. Some models are equipped with castors, facilitating easier movement and more flexible placement within the facility.
A top-loading cardboard baler is a compact version, smaller than portable balers, designed to load cardboard from the top. These mini balers are ideal for businesses with minimal cardboard waste, producing bales ranging from 90 to 130 lbs (40.8 to 59 kg). Their compact size allows them to be positioned conveniently near the source of the waste, and the lightweight bales can be easily moved using a dolly.
One notable feature of top-loading mini balers is their ability to be preset to produce bales of specific sizes.
A key differentiator for cardboard balers is their daily tonnage capacity, which can range from a few tons for smaller offices to several hundred tons for industrial and manufacturing operations. When selecting a cardboard baler, it's crucial for users to consider the volume of cardboard they need to process each day. The following weights reflect the daily tonnage of cardboard that these balers can handle.
The method of baling cardboard is influenced by factors such as the baler's size, capacity, feeding method, and type. While large horizontal production balers are typically fed by forklifts or conveyors, they can also be loaded manually if needed.
As environmental concerns continue to rise, recycling cardboard has become a common practice across various industries. Cardboard balers enhance this process by improving efficiency and reducing labor, while also facilitating the packaging of cardboard for easier handling.
Vertical balers are typically loaded manually. The specific design of a vertical baler determines its usage. Additionally, the types of cardboard being processed play a crucial role in the baling process. When dealing with uniform cardboard, separation can often be skipped, which is common in high-volume operations.
However, if multiple types of cardboard are involved, such as paperboard or triple-walled cardboard, the baling process may need to adapt. In such cases, separating lighter materials from heavier ones might be necessary. Heavier cardboards require more pressure and mechanical energy from the baler, while lighter materials, like paperboard, need less energy.
To start using a vertical baler, ensure that the baling chamber is prepared with a flat surface for loading cardboard. Typically, a sheet of cardboard is placed on the bed to create a level surface before adding more cardboard.
Securely close the top of the baler and activate the on switch. Hold the down button until the ram begins its downward motion.
Once the ram has completed its motion, turn off the baler and open the door to access the compacted cardboard.
Next, manually tie the bales from the vertical baler. Insert the baling wire through the channels at the bottom and top of the baler. The wire is pushed through the bottom channels, pulled up, and then threaded across the top of the bale. The wire channels are visible at the bottom and back of the baler in the image.
One end of the wire features loops for inserting the straight end. Twist the connections tightly to secure the bale.
In some cases, the wire is inserted before the cardboard is loaded and compressed. Due to the variety of vertical balers, different methods for applying the wire may be used to fasten the bale.
To remove the tied bale from the baler, release the pressure of the ram using an unlocking clamp. This allows the bale to be pushed forward and out of the baler. The ejection method varies by baler type. Some models feature an ejection strap that extends up the back of the baling chamber. Activating this mechanism raises and tightens the strap, pushing the bale onto a pallet or dolly.
In contrast to vertical cardboard balers, horizontal balers operate mostly automatically. The primary tasks involve loading cardboard into the bin and removing the finished bales. Horizontal balers generally occupy more space than vertical models and are designed for top-loading.
While manual feeding is possible for horizontal balers, they are often fed by conveyors, forklifts, cart dumpers, skid steers, or front loaders. Once the cardboard reaches a set level, a photocell triggers the ram mechanism to start the baling process. Some horizontal baler models use a control panel for manual activation, similar to those found on vertical balers. For high-volume operations, photocell activation is preferred to maintain continuous material flow.
Shearing is a crucial function in horizontal balers. After the ram is activated—either manually or by a photocell—it moves forward to compress the cardboard within the compression chamber. During this process, additional cardboard continues to fill the hopper and rest on top of the moving ram. A shearing blade or knife then trims away excess material above the bale compression chamber to prevent potential jams and obstructions in the ram's movement.
Shearing blades are built to be extremely durable and resilient. They feature tapered cutting edges and serrated blades, which minimizes the contact area with the material, allowing for the cutting of more recyclable material at once.
Tying off the bale in a horizontal cardboard baler can be done either manually or automatically, depending on the type of baler. Open-end cardboard balers, which operate continuously, are typically equipped with automatic tying systems for greater efficiency and productivity. In contrast, closed-end cardboard balers, which produce fewer bales per hour, can use manual tying methods.
Regardless of the baler type, the manual baling process is largely the same. Wire or twine is threaded through channels or slots built into the baler and wrapped around the bale. The bale is then secured by twisting the wire and tying it with twine. The compressed cardboard material tends to stick together, which simplifies the manual baling process.
Wire is commonly used for securing bales due to its durability, high tensile strength, and longevity. However, some users prefer twine because it is more cost-effective, occupies less space, is easier to handle, and is recyclable.
The design and configuration of cardboard balers are optimized to compress and compact cardboard into manageable shapes for effective reuse of the material. Essential components of the baler are critical to ensuring the success of this process.
Central to cardboard baling technology is the crushing and compacting force generated by hydraulic power. These pump-driven systems are capable of compressing more complex materials than cardboard but are particularly suited for transforming large quantities of cardboard into compact bales.
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—be it manual, conveyor, forklift, or another system—the part of the baler that collects the cardboard is called the hopper, which is specific to horizontal cardboard balers. Hoppers come in various designs, typically featuring angled metal walls intended to direct the cardboard into the baler.
The hopper stores the cardboard above the ram until it is ready to be pushed into the compression chamber. At the bottom of the hopper, a shearing knife helps prevent cardboard from jamming the ram. The image below shows a four-sided hopper on a horizontal cardboard baler.
The crushing, compressing, and compacting capabilities of cardboard balers are driven by their hydraulic systems. These systems provide the force necessary to shape and form the bales into geometric configurations. Hydraulic components are the core of the baling process, ensuring that the bales are effectively made. Both vertical and horizontal cardboard balers rely 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.
The image below of a vertical cardboard baler illustrates the hydraulic system located at the top of the baler.
As global awareness of recycling has increased, companies are increasingly evaluating their waste production to find methods for reusing, repurposing, and remanufacturing waste into raw materials for new products. Waste that was once discarded is now analyzed for its content and broken down into its basic elements.
The widespread use of cardboard for shipping has made it a primary focus of recycling efforts. Companies use cardboard balers to crush cardboard into manageable and shippable shapes.
Storing cardboard boxes in bins or stacking them for garbage collection not only takes up space but also poses a fire hazard. A cardboard baler can transform a large pile of cardboard into a compact, compressed cube suitable for shipment or storage.
Material handling operations heavily depend on labor costs. Disposing of and storing waste typically involves several workers—from those who remove the waste from work areas to those who manage its storage. By using a cardboard baler, these costs can be significantly reduced, as it minimizes waste and decreases the need for multiple handlers.
Running a business involves many costs, including overhead expenses that are often difficult to adjust. Waste handling is a significant component of these overhead costs, as it is an unavoidable aspect of all businesses. A cardboard baler offers an efficient and streamlined method for managing waste, helping to reduce overhead costs.
Businesses today strive to show their customers that they are committed to sustainability and environmental preservation. This concern has become a key factor influencing customer decisions and drives their choice of companies to work with or purchase from.
Repurposing and recycling waste materials are clear indicators of a well-managed, eco-friendly organization. Cardboard balers play a crucial role in transforming waste into raw materials for future use, aligning with the goals of environmental programs and sustainability efforts.
In a typical operation without a cardboard baler, cardboard is collected throughout the day and removed by cleaning staff or dock workers. The process of collecting, gathering, and disposing of cardboard from shipping is both time-consuming and labor-intensive. Positioning a cardboard baler close to where cardboard accumulates can significantly reduce cleanup time.
As items and packing materials are removed, they can be immediately placed into the baler, which can operate automatically during high-volume periods or manually as needed. This streamlines the process, eliminating the time required for collecting and disposing of cardboard.
An important aspect of baling cardboard is understanding the different types that can affect the operation of the baler. The term "cardboard" is a broad descriptor for various paper materials that have been shaped and formed. Different grades of cardboard are designed for specific tasks, ranging from shipping heavy machinery to protecting electronic devices.
It is crucial that the type and durability of the cardboard baler match the type and grades of cardboard being processed. For instance, using a vertical cardboard baler to process heavy, thick cardboard can significantly reduce the baler’s performance.
Cardboard, also known as corrugated fiberboard, is composed of kraft paper with one or more fluted layers. All types of corrugated fiberboard can be baled. Understanding the type of fiberboard being processed can help in maintaining and protecting the integrity of a cardboard baler.
Single face fiberboard is thin, affordable, and lightweight, but it provides minimal protection. Among the different types of cardboard, single face fiberboard is the least durable and is easily crushed.
Single wall fiberboard is commonly used for shipping boxes for consumer products. It consists of one layer of flutes, or wavy paper, with paper glued on both sides. The flutes come in various sizes, ranging from size A, which is 3/16 inch, to size F, which is 1/16 inch.
Double wall cardboard features two layers of flutes separated by a layer of kraft paper. The size and shape of the flutes can vary depending on the design of the cardboard.
Triple wall cardboard contains three layers of flutes separated by two sheets of kraft paper. This additional layer of flutes significantly enhances its durability, making it a viable alternative to wooden boxes. It is widely used in industrial settings.
Paperboard is not very durable and is best suited for shipping items that are not fragile or prone to damage. It is the least expensive form of protective material and is commonly used for this purpose.
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