What is Baler Machines?
A baler refers to a machine used to condense various materials into rectangular bales using a ram system for easy transportation, storage, recycling, or processing.
Baler machines are capable of compressing both heterogeneous and homogeneous wastes into manageable size, which optimizes valuable floor space and utilization of assets.
Preserving value and facilitating proper disposal or processing as raw materials are fundamental in baling agriculture products and refuse. Animal feed, including hay, grass, and straw, is an essential part of livestock nutrition and must retain a high energy and protein value.
Due to its bulk, as well as decomposition, fodder requires drying and/or is shaped to prevent spoilage. In addition, spoilage can be combative to animals because as fodder decomposes heat will be produced and causation for a potential fire hazard if not addressed properly.
A crucial function of the baler is moisture control. If moisture is too excessively low hay becomes brittle with less nourishment and if infrequently maintained excessively high can be hard to manage because of spoilage /decomposition and combustion issues. Fodder bales are always wrapped in plastic film or covers (or both) to entrap moisture.
Baler machines perform an important function within the industrial sector, especially in recycling operations to manage their materials.
In processing waste, balers condense materials into bales that are roughly 3-5 times more dense and stackable so that more volume can be transported at one time, which enormously reduces transport costs.
Recycling returns have increased on compacted bales, because their form reduces material handling, resulting in higher throughput, decreased costs to operation and more money in general.
Key Takeaways
- Used to compact and bundle materials (like ag products and recyclable material), balers deliver more effective and manageable storage options.
- Balers were originally designed for agricultural, specifically hay, operations. The tractor baler has eliminated the need for raking, bundling, and wrapping haystacks. After the agricultural application, balers were then used for industrial and domestic wastes to realize storage and shipping cost savings.
- Balers vary according to ram orientation, and number of strokes, or cylinders. Types of balers include vertical and horizontal. Vertical balers are simpler, smaller, and most often, easier for a worker to operate. Horizontal balers are used for larger-scale material processing applications.
- Single ram balers can be defined into open-end balers and closed-end balers. Open-end balers operate in a manner like an extruder whereby the scrap material is compressed against the existing bale. Closed-end balers have a closed door at the opposite end where the material is pressed.
- Two ram balers are able to compress the bale from two directions. Two ram balers are usually designed in an L shape. With the width of the opening is not constrained to the dimension of the bale, two ram balers can have a quicker feed rate.
- Ferrous balers are two or more cylinder machines. The only differentiator of ferrous balers is the pressing lid which pre-presses the scrap materials before the materials become a bale.
What is the historical background of balers?
Balers have been around since the 1930’s to help farmers deal with complicated haystack sizes.
Before the development of automatic balers, hay was cut by hand, and stacked using rakes and forks. Haystacks had to be of optimal size, not too big, to cause heating and burning, nor too small, to dry and decay.
The first automatic baler, known as a round baler, was developed by Allis Chalmers in 1947, called Roto-Balers.
In time, various types of balers were developed, such as rectangular and small square balers, which have now been adopted throughout the agricultural community.
The earliest scrap materials balers were compactors invented by MS Wells, patented in 1941, as a method to compact oil cans. By the 1970s, these compactors were modified to also condense household wastes using hydraulic pressure from water lines.
Parts And Accessories Of Balers Machine
A baler’s most basic parts includes the ram, chamber, material feed gate, and an action that produces force. These not only develop the basic components but develop them to produce more compressive force and process the material faster.
Some other parts usually included are hoppers and wire-tying apparatus, in order to further automate the processes required, and ease the burden of cost and labor for everyone.
Here are the major parts involved in a typical baling machine make-up.
#1. Hydraulic Cylinder
This important part applies the necessary force to compact the material. The working liquid is pressed by positive-displacement pumps to achieve needed packing density.
The baler usually employs very tough and durable hydraulic cylinders, suitable for scrap metal baling, along with the ability to deal with shocks and side-loads.
It is also necessary to keep the hydraulic cylinders in good working condition, hence condition monitoring and lubricating becomes a very important
#2. Ram
The ram is the component that connects directly to the hydraulic cylinder, and the one that pushes against the material.
#3. Hydraulic System
The hydraulic system consists of pumps, hoses, fittings, and valves. It provides the motion for the cylinders to actuate as required.
A hydraulic system will see dynamic movement as the various parts are under dynamic loads, which will require maintenance and ultimately replacement due to wear.
#4. Oil Filter
The oil filter allows the hydraulic system to stay clean. Oil can age as it is used and deposits may form in the oil that can damage fittings and pumps. Oil filters, should be replaced on a routine basis, as specified by the manufacturer.
#5. Motors and other electrical components
The motors, wires, conduits, and cooling fans make up this component. The motor drives the pump and usually is used in a gearbox combination.
#6. Proximity Switches and other types of sensors
This may be specifically, proximity switches, photo eyes, limit switches, or linear potentiometers, which gather data about the movement of the bales, or the relative location of the components in the machine, in order for the baler to work in an automated function.
#7. Bale Chamber
The bale chamber is the part that closes and shapes the bale. Bale chambers are made of thick steel to handle the compression due to the material that is being compressed into the thickness.
Agricultural balers use variable chambers to produce bales of density that can be more consistent. Unlike industrial bales that use chamber designs, variable chambers, similar to those found on the corners of other equipment, generally make use of tensioning belts.
#8. Hopper
Hoppers help with the collection of materials for baling. Another feature of the hopper is that it adds area to the chamber opening so that more material can be fed.
#9. Conveyors
Conveyors are used for feeding material at a lower level. This will allow materials to be fed without a larger crane that is usually needed to reach into the hopper.
Loader trucks will dump material onto the conveyor; the conveyor has an upwardly inclined flat bed, which will lift material and transport it to the hopper.
#10. Pressing Lid
This part is found on ferrous balers. The pressing lid acts as a pre-compression ram when closed. Once the pre-compression is at the desired value; the pressing lid locks in position.
#11. Tip Pan
This component is a pre-staging machine integrated into the balers. It will aid in the loading process as a staging hopper to where we will initially load materials.
When the baler is ready to accept more materials, hydraulic arms will tipp the pan so that the initially loaded materials fall into the chamber.
#12. Ejection Rams or Arms
When the balers perform pre-compression to the desired limits, ejection rams will eject the baled material from the chamber. It is critical that the bale is fully ejected from the chamber along with other loose materials that did not form together, ie, a formation of materials will ultimately minimize cross-contamination.
#13. Automatic Tying Mechanism
This is part of an automatic baler machine. Once the bale has been completely compacted, the mechanical systems will wrap tie wires around the outside of the bale.
The bale tie assembly is either completed prior to ejection or while the bale is being discharged. This is an assembly usually found in horizontal balers which consists of tie wire cutters, twisters, knotters and tensioners.
#14. Bale Ties
Bale ties are wires or straps that wind around the bales and keep them from becoming loose after compaction. The bale ties must have enough strength to resist the rebound or expansion of the materials. There are several different types of bale ties based on material, finish and loop. Following are the most common.
#15. Galvanized Wire
This is a wire finish in which the wire is coated or dipped in a molten zinc bath. Wires are galvanized for corrosion resistance. Galvanized wires are silver or grey with minimal oil residue.
#16. Black Annealed Wire
This is a type of finish in which the wire goes through the annealing process, where wire is wholly heated and cooled at a particular rate that makes it more flexible and ductile.
Black annealed wires are easier to use due to the added ductility. It has a very thin coat of oil which lubricates it against the baling machine and resists corrosion.
#17. Control System
This is the area where the operator can enter any operating commands. The hydraulic system is normally operated by programmable logic circuits or PLCs, which open and close the valves.
The control circuit would also reference or monitor functions such as pressure, bale dimensions and temperature. For more elaborate systems, this component of the machine may have diagnostic and fault detection systems.
Types Of Balers Machine
Balers can depend upon the type of material to be baled, material load methods, required purity, dimensions required for transport and milling, and throughput.
Since producing a positive economic impact is the primary reason for using balers, it is essential to consider the baler’s capital and operational costs against what will be saved from reduced storage and transportation costs.
A large, high-output baling machine may not be the best choice. There are numerous baling machines available on the market with specific intended materials and specifications.
Vertical Balers
Vertical balers, also referred to as downstroke balers, utilize vertical downward force to compress material. They are typically used for the recycling of cardboard, plastics, metals, and foam materials.
The compression chamber is orientated along the side of the machine, but is higher to make operations more efficient.
Once the chamber is filled, the ram will move in a downward motion through a hydrostatic (hydraulic or electric motor) source to compress the material.
Vertical balers are much more space saving than horizontal balers and are better fitted for smaller scale applications (supermarket or retail store) type recycling.
A vertical baler will save space not only be reducing a footprint but will also cost less, since vertical balers are usually much less expensive than horizontal balers.
Vertical balers can recycle a variety of materials, providing flexibility for what is being recycled. As noted before, there may be inconsistencies with output, because there is no standard ram force and bale sizes.
This can increase inefficiencies in the transportation of bales and introduce additional technology into the recycling mills’ process, which may complicate the sale of bales.
Some vertical baling manufacturers have produced a marketable vertical baler that has increased machine specifications such as heavy-duty vertical balers that use high-power reciprocating pumps which provide immense power to their pistons, resulting in the ability to produce denser standard size bales.
Horizontal Balers
Horizontal balers utilize horizontal force to compress materials. For horizontal balers, the materials are not fed directly into the chamber, landed into a hopper located on top of the machine.
Once the material enters the machine, it will sit on the ram. There are multiple systems that can be combined with horizontal balers to assist in loading, including conveyor systems, sorting systems (for single stream materials), and shredding systems.
Horizontal balers can use these systems to make the baler as convenient as possible for the operator while also minimizing the chance of manual loading, which uses valuable labor time and effort.
To maximize efficiency, these machines must not jam or clog as the ram continues to ram the material through the cylinder preventing the materials from moving properly.
Horizontal balers in most instances are bigger than vertical balers, so they can process high volumes of material. Basically, horizontal balers use higher compaction forces, so they can produce very densed bales that can weigh half of a ton.
These bales will all weigh the same having a consistent circular aspect ratio (bale density), which is important for transporting bales to other locations or other regions of the recycling system for further processing.
Baler manufacturers are always looking for ways to solve any potential issues that may jam the horizontal balers and to ensure a smooth production process.
The industrial baler industry has developed multiple anti-jamming devices including shear blades to cut materials in an efficient manner so the baling process can keep moving along.
Shear blades will trim around the excess material which has the potential to cause the ram to jam either in the feed chamber or the baler, increasing production delays.
The baler blade system will also create a consistent compression stroke in order to prevent jams.
Because a vertical baler does not feature the shear blades system, it does not have the capability to use shear blades like horizontal balers. Any single stream materials for vertical balers must be pre-cut prior to loading single stream materials into horizontal versus vertical balers.
Horizontal balers can utilize shear blades either with a saw-tooth blade function or staged blade function which enhances the processing time with vertical balers by reducing idle time and increasing processing.
Single Ram Balers
Single ram balers with a single hydraulic cylinder to apply compression, are one of the most popular designs of balers for recycling material.
They can either be horizontal or vertical based on the way the ram is positioned. Horizontal single ram balers are further classified into closed-end and open-end extrusion balers.
Closed-end (closed-door) balers
Closed-end (closed-door) balers compress the materials by means of a single ram or cylinder against the door of the chamber.
Once the material is compacted, the chamber door opens and the bale drops out. Automatic ejection rams are also put in place to help eject the compacted bale.
Horizontal closed-end balers are the standard in the industrial baler market. They allow companies to make larger and heavier bales, regardless of the materials being baled. Closed-end balers are distinguished by a closed-off baling chamber.
Closed-end balers have a smaller baling chamber, compared to open-end auto tie balers. The waste material is compressed by means of a single ram which uses its weight and force to compact the material by pushing it into the chamber.
Closed-end balers are fully automated, with no human operator present. The closed-end balers will only engage when it is full. They are designed to keep working until the material is fully compacted. Closed-end balers can also compact too many times until they are at full capacity, and the ram can no longer move.
Open-end balers
Open-end balers use an extrusion chamber that is long and compress the materials through that chamber. This process is often called continuous horizontal baling. Essentially, the ram compresses the bale against the side of the last bale formed in the extrusion chamber.
They can achieve much higher production rates than closed-end balers and they don’t need components such as ejection rams or separation doors.
A key feature of open end extrusion balers is they have an automatic tying feature, which is advantageous when baling products with high rebound properties such as cardboard, rubber and textiles.
Open-end balers work similarly to closed-end balers automatically and continuously. However, with an open-end baler, an open-end baler gives you the option to remove bales autonomously without stopping due to the fact that the chamber is open and the design uses an automatic tying mechanism. They provide a reliable solution for companies with high volume and multiple shifts.
Open-end balers are heavy-duty extrusion-type balers that can radically compress a large amount of waste material in motion and at an ongoing fast pace.
However, open-end balers are also reasonably economical and require little energy as the design of the single ram is well suited for energy savings.
An open-end baler can have one ram or two rams, with the two ram or two-cylinder baler having the ability to operate even faster and compress a fuller range of products due to two rams.
The chamber is under constant tension because an open-end baler is always applying some compression force. The tension maximizes the solidity, security, uniformity, and density of the bales produced.
The tension is tension is only released on the baling cylinder between bales; the design or structural components of an open-end baler is not supposed to stretch to maintain high pressure; if it stretches, there is damage to the mechanism.
Two Ram Balers
Two-ram balers, sometimes referred to as two-cylinder balers, are equipped with one ram for compressing material and a second ram specifically for controlling the movement of, and removing, the compressed material.
These balers can be configured as either vertical or horizontal balers. The compression occurs with the main ram, while the secondary ram ejects the material into a new compression cycle.
Two-ram balers are very effective for high rebound materials (e.g., rubber), and are used for compacting larger, denser materials. The two ram design optimizes the management of rebound, which must be confined during compression
A different two-ram baler that is common is the L-Shaped two-ram baler. In the L-Shape baler, the material is compressed along one axis first, and after the ram is fully extended, the compression begins on the perpendicular axis.
The L-Shape design also affords a larger feed opening to allow bulkier materials to load easier, and the larger opening and design assists loading time and the possibility of bridging in the hopper.
Another beneficial outcome of a two-ram baler is a decrease in the amount of tie wire on each tie. Since the two ram balers generate a denser bale, it requires less tie wire to maintain the figure of the bale.
The dense bales depict that a greater compaction pressure has forced the materials into plastic deformation; meaning that they will not revert back into their earlier shapes.
Therefore, the bales are essentially permanent in shape, and again, will not need to have as many strong ties, thus less overall tie wire is used, resulting in cost savings.
Liquid Extraction Balers
Liquid extraction balers do precisely what the name implies; they compact materials and allow for liquid extraction while compacting.
Liquid extraction balers are very effective with food rejects when extractions of any remaining liquids are required from the by-products of food rejects, rejects from bottled goods, rejects from brewed products, etc.
Unlike traditional balers, liquid extraction balers contain nearly 90% stainless steel components to hold up against possible liquid exposure while the remaining components are coated in anti-wear and corrosion resisting paint.
Liquid extraction balers also contain a closed-loop catch system to effectively catch any extracted liquid for a clean and efficient discharge.
Ferrous Balers
Ferrous balers are mainly used in scrap metal operations and can withstand heavy weights (i.e., metals). Ferrous balers are designed with either two or three cylinders.
The two-cylinder ferrous baler has a pressing lid or wing door to compress metals with the main ram. The three-cylinder ferrous baler (also known as a ferrous trommel) employs two rams that compress metals at three different points.
A pressing lid is used to pre-compress the metals and obtain the desired size while the next two in-line rams complete the compression process similar to the arrangement of L-shaped two-ram balers.
Ferrous balers, like two-ram balers, have those large openings as ferrous metal is a large material; therefore, more material can be fed into the ferrous baler.
The above-mentioned feed opening is designed to allow fed materials to move freely within the baler’s large openings without size restriction. Feeding is generally done by crane.
Ferrous balers do not have automatic tying systems which means the metals are not tied in the baler. Metals undergo plastic deformation when they are compressed, so the metals do a good job of maintaining shape after they have been baled and do not generally require tying.
Track Balers
A track baler is mobile and can be parked directly where the scrap is located therefore reducing the amount of handling to baled scrap material. Reducing the amount of handling means reducing costs and wasted time while collecting the scrap, thereby increasing operational efficiency.
A track baler can process ten or more tons (and is capable of handling and processing as much as ten tons) of scrap, compressing it and shearing it all at one pass. A track baler’s movement and compression are controlled using radio frequency remote controls.
Shear/Baler/Loggers (SBLs)
This machine compresses materials to a log-shaped, compact form that is cut to length by either shearing or compacting further to form a bale. This “logging” action is an initial pressing operation. The machines are also termed scrap shears because they create both sheared logs and high density bales.
SBLs have versatility in terms of travel. They are typically transported on trailer trucks, have hydraulic landing gears, and are easily set on site which is advantageous for small junkyards, demolition projects, or any cleanup project.
Round Balers or Tractor Balers
Round balers do baling of agricultural products and are towed by a tractor which collects forage from the field.
The forage is packed into the baling chamber, and as the rollers and belts compress the materials, once the density and size are achieved, an automatic wrapping mechanism wraps the material in mesh netting. After wrapping, the baler opens and the bale is released.
Round balers are for baling agricultural products, and are towed by a tractor that collects forage from the field. As the forage is collected, it is introduced into the baling chamber and rollers and belts compress the materials.
When density and size are accomplished, an automatic wrapping mechanism wraps the material in mesh netting. Upon tying off the ends of the round baler with the elevator bed closed, the baler automatically releases the round bale.
Applications Of Balers Machine
Most balers are used predominately in scrap material recycling. The most common uses of balers below. The recommended type for each use has also been included.
Steel Recycling
Steel and aluminum, as scrap material, are compacted with balers. Items such as steel cans, aluminum cans, sheets of steel, radiator caps, copper wires, and clips are all compacted in balers.
When utilizing balers for lighter metals, such as cans and sheets a two-ram baler is typically used. For heavier and thicker metals being compacted, a ferrous baler must be a mixture of three hydraulic cylinders.
Corrugated Cardboard and Paper Recycling
Balers are used with covers for the items produced by the recycling of cardboard, paper, office papers, magazines, newspapers, and so on. An average office worker produces approximately 2 pounds per day of paper products.
While mixed paper is usually around 70% of the total office waste. Large recycling operations typically employ one of these horizontal single ram balers for baling cardboard, paper, and mixed paper and are connected with automatic tying mechanisms.
For small and medium-term storage and recycling, usually standard mill-size balers and stand-alone vertical machines could be effective.
Plastic Recycling
Plastic recycling is used with PET and HDPE bottles, films, rigid PP containers, rigid and flexible PVC, and electric and auto plastic waste.
As with all recycling, sorting the materials according to type, source, and properties should be completed prior to recycling at a recycling plant.
It is essential to prevent cross-contaminating between batches when baled and mixed plastics are recycled and comply with the particular recycling standard of the selected recycling facility.
Foam Recycling
Foam in materials are very light and have low densities and take up a lot of space, especially in storage. Some foams, such as many polyurethane foams, are thermosetting plastics which means their properties cannot change back again after they cure.
This makes recycling such foams very challenging to meet recycling plants’ standard disposal options.
Many foam materials will have to be either incinerated or if necessary sent to landfill. The purpose of using balers to reduce the space occupied in storage or compressed weights over a thousand pounds in approximately 45 cubic feet.
Textile Recycling
This category considered used clothing, carpets, rugs, wool, and other fibrous materials. Baling textiles is dissimilar to baling materials such as steel and plastic because textiles need less compressing force but also needed to be clean and free of stains throughout textiles bale process.
Balers main goal when baling textiles is to reduce the storage space when transporting and increase efficient transport. Vertical balers are generally used when processing textiles
Agricultural Baling
Balers are used to compress animal fodder as previously discussed, to aid in moisture management and preserve nutrients.
The intended purpose of the balers is roller or bundling and storage of haystacks was adapted to handle scrap materials. Round balers are utilized for baling animal forage.
Balers play an important role in the compression of animal fodder to help manage moisture levels and the preservation of nutrients, as noted previously.
Originally developed to bundle animal fodder such as hay, the idea was then adapted to handle scrap materials in waste operations. Round balers are utilized for baling animal forage.