Bollegraaf Single Ram Balers: Usage Example

Challenge

Let’s say a recycler grows its volume of incoming recyclable material to 5,000 tons per month. The material comes in “clean” and only needs baling.

The recycler’s existing baler can only bale at an average of 15 tph. It needs an operator and has to be constantly worked on, which leads to high maintenance costs. Further, it is an “electricity hog.”

To bale 5,000 tons in a month, the recycler has to run its baler for two 10-hour shifts each day. When it breaks, the recycler has to repair it and then try to keep up with the incoming material.

Solution

The recycler buys a Bollegraaf baler from VAN DYK Recycling Solutions that averages a production speed of more than 35 tph. It does not need an operator and, because of its unique features, requires far less maintenance than the recycler’s previous baler. What’s more, it runs on half the electricity cost.

The recycler can bale all 5,000 tons in one shift per day with no overtime hours. It does not need a baler operator, nor does it need to run a second shift.

The decision to buy a Bollegraaf baler results in:

• Savings of labor costs
• Savings of maintenance costs
• 50% reduction in electricity bill
• Achieving tons-per-month goal with ease
• Quality end product due to the no-shear pre-press flap feature.

Bollegraaf Feature Spotlight: Pre-press Flap

The main benefit of Bollegraaf’s pre-press flap is that the baler does not shear. It uses compression to shape the bales into homogeneous cubes.

No shearing means less energy used, lower maintenance costs, faster baling cycles, denser and more even bales, less wear on floor and frame, no hydraulic shock caused by shearing, and no rebaling necessary.

High Speeds: The baler runs at a higher speed since material can be loaded on top of the flap during the compression cycle. This enables faster production. On some grades, Bollegraaf balers run 2 and 3 times as fast as other balers.

Better Quality Output: The pre-press flap helps the material be homogenized into evenly distributed bales and allows you to stack bales more effectively.

Ability to Bale Difficult Grades: The pre-press flap enables baling of grades that are difficult to shear, such as phone books and magazines.

Bollegraaf Feature Spotlight: Ram on Wheels

Benefits: No constant metal to metal rubbing. The wheels run on manganese strips, and wheels and strips can easily be replaced instead of relining the baler floor. This significantly reduces maintenance and relining costs.

Bollegraaf Feature Spotlight: Integrated Tying System

Benefits: Enables you to control your wire costs with 5 wires for every bale, every time. Compare this with a manual “strapper” on a two ram, where an operator can add 5 or 6 or 7 wires to each bale.

The result is reduced downtime, because if one wire is missed by Bollegraaf’s wire tier, you can still bale with 4 wires. When a two ram tier is down, the baler is down.

Bollegraaf Feature Spotlight: Visual SCADA Control System

The Bollegraaf Recycling Solutions Visual SCADA is a user-friendly visual SCADA interface. It has four fully integrated layers and can be scaled to the appropriate plant size. Each layer can be purchased separately, so small systems do not need to buy more features than needed, and large recycling MRFs can have all the necessary control, service, data collection, and management information they require. You only pay for what you need!

The Bollegraaf Recycling Solutions (BRS) Visual SCADA’s four layers are:

• BRS Visual Plant
• BRS Visual Service
• BRS Visual Management
• BRS Visual MRF Data Collector

Benefits include:

• Reduced downtime
• Increased productivity
• Increased safety standards
• Reduced energy usage
• Reduced inventory cost
• UL/CSA certification
• Follows green initiatives

Features:

• Power supply redundancy providing emergency backup
• E-stop zone indication enabling immediate identification of E-stop location
• Early warnings to operator substantially reduce downtime
• PLC flash-card backup enables immediate recovery from a PLC failure
• All motor data available to both operator and the control logic for intelligent PLC responses and increased productivity
• Modular construction enables instant replacement of failed components

COMING SOON! Bollegraaf’s newest AI powered Robot!

Stay tuned for more updates!