The Planning Process

While the scrap metal market and the equipment manufacturing industry that serves it have gradually rebounded over the past few months from the market collapse in the second half of last year, business has a long way to reach the volumes and the record-high prices experienced prior to that.

In light of the events of the past year, many scrap metal recyclers are holding out hope that the scrap metal market will experience a full recovery but are operating with a more cautious business approach, where every dollar spent is scrutinized.

"The bells have slowed considerably. There is a lack of industrial scrap out there. A lot of scrap has been cleaned up over the last few years with the high prices," says John Sacco, president of Sierra International Machinery, Bakersfield, Calif., a supplier of equipment to the recycling industry.

As a result of declining material streams, equipment operators at scrap recycling companies are focusing on the most efficient operating practices to maximize the value of machinery they have purchased or rented. Among the pieces of equipment most vital to their operations may be the portable baler. While manufacturers and distributors report that sales and rentals of their portable balers have declined during the recession, they also offer advice to processors seeking to maximize the value of their equipment.

Before purchasing or renting a portable baler, recyclers should evaluate one primary consideration. To take advantage of the most opportunities available to their operations with these machines, recyclers must become familiar with the transportation regulations and restrictions present in the states or regions they serve.

"Recyclers will need to get the weight of the machine from the manufacturer, know the weight of the truck they will be using to pull the machine and check with each state they work in to ensure that they are following any route restrictions and overweight regulations," says Shawn Morris, president of Lexington, Ky.-based Environmental Recycling, a scrap metal processor with a fleet of portable balers.

Without doing proper research, metal recyclers may find themselves with a piece of equipment that they cannot use because regional transportation regulations prohibit it from being on the road.

"In the North, some states have frost laws, where heavy equipment is forbidden from traveling the roadways, which is additional homework for recyclers," says Curt Spry, scrap sales manager for Al-jon Manufacturing, Ottumwa, Iowa.

In some areas, a permit is needed just to move the equipment on the highway, according to Sacco. Whether or not a portable baler needs a permit is determined by the amount of weight on the axles, he adds. "Most states are the same when it comes to permits, but a lot of states have different bridge laws. So you just have to make sure you comply with them, so when you go across the scales you don’t get stopped because something was not recorded properly in the permit process," Sacco says.

Andrew Lincoln, vice president of Erie, Pa.-based National Recycling Services Inc., which runs a fleet of portable balers, says basic vehicle maintenance also can prevent unnecessary downtime. "Check that the taillights are not damaged and the tires are not flat. This will prevent any delay in arrival of your machine plus any unnecessary headaches with your carrier who is transporting the machine," Lincoln says.

Additionally, Spry cautions metal recyclers to "make sure that their equipment is free of any debris that could fly off while transporting the machine down the road." He adds that keeping equipment clean makes working with the Department of Transportation easier.

After addressing transportation concerns, scrap recyclers also should be mindful of the conditions present at their job sites and the nature of the material they will be working with before renting or purchasing a portable baler. By previewing the location the portable baler will be working at, processors can avoid unexpected problems and costs once they employ the equipment at the job site.

"First of all, contractors have to have the material there," Sacco says. "It’s not free to move a baler in and out, so they have to make sure that the material is substantial enough to justify the cost of moving it in, or that the people who are hiring them will pay those costs."

Morris also notes that there are many red flags that recylers should look for before transporting portable balers to job sites. "Portable baler operators should look for uneven ground, soft ground and power lines. As well, the operator will want to ensure that he has a safe working area away from the public and other personnel where he can stack bales and load trucks safely."

In the case of soft or uneven ground, Morris advises that "cribbing (supporting from below and/or the side with timber or steel framing) may be necessary to keep the baler from sinking in the mud or damaging a parking lot surface."

Jon Lanker, ferrous products sales manager for Harris, an equipment manufacturer based in Peachtree City, Ga., says the company’s portable balers are equipped with stabilizing jacks that come out of the machine’s sides, but for those that aren’t, railroad ties are commonly used for cribbing.

Additionally, Lincoln says considering the actual location where the portable baler will be set up is pivotal. He says, "To get the most production, it is best to find the ideal location for the machine, then move the pile of sheet iron or whatever you are baling to the machine as it gets worked down."

Lincoln adds, "If you are responsible for supplying the fuel for the baler on or off site, it is important to have a fuel supply established before you begin."

After successfully navigating the transportation regulations and previewing the job site conditions, scrap metal recyclers can turn their sights to efficient operation when actually employing the portable baler at the job site.

Before beginning the job, contractors should foster positive communication with their customer. "Make sure that you have communicated with your customers to ensure that you know what their expectations are and that the customers understand your needs and expectations as well," Morris says.

No matter what conditions recyclers are working in, Lanker says, when using a portable baler, moving material to the machine is the biggest efficiency concern. "The portable baler is going to bale at a certain rate that it’s designed to," he says. "It’s a matter of how effectively they are going to load the material in and unload it once it has been processed through. For instance, some balers are equipped with a crane to load and unload material. If there is a large volume to be moved, some operators bring in a second crane to either stage material or unload it after the bale is made."

Balers that are configured with a crane are more likely to stay stationary. Eventually the operator will have to adjust the baler to the pile of material. "After awhile, you’ll eat into the pile and the crane can’t reach anymore, so you’ll have to readjust," Sacco says. "After 30 or 40 minutes, that crane is going to be out of reach, because [the baler] processes high volumes."

Additionally, ensuring efficient operation can be as easy as paying attention to logistics concerns and preventive maintenance. Ensuring your equipment has enough fuel is vital, Sacco says. He also advises operators to be ready for unexpected mechanical failures.

"In any portable application, everybody should have a little spare parts package with some O-rings and hoses, because when you are dealing with scrap, scrap flies," Sacco says. "If you cut a hose or if you’re in a real hot day or a real cold day, sometimes O-rings can have failures in extreme temperatures one way or another. You should have a toolbox and spares for everyday wear items, because that will help you get up and running faster without having to go to a hydraulics store."

Finally, even after the portable baler has finished baling material, operators should make one final check to maximize efficient operation and avoid unnecessary downtime.

"Always remember to check under the baler tires and around the baler for any loose material or foreign objects that could puncture a tire," Morris says. "Most flats occur at the job location when the baler is being moved to or from its original operating position."

As the scrap recycling industry begins to rebound, metal recyclers will benefit by adjusting their operations to achieve maximum efficiency before, during and after employing a portable baler at a job site. Implementing efficient practices now, during a period when many contractors can afford to devote additional time and attention to improving efficiency, can help scrap recyclers maximize their output and improve their bottom lines when demand strengthens and workloads increase.

The author is assistant editor of Recycling Today and can be reached at zlloyd@gie.net.

EFFICIENT OPERATIONS

ASSESSING THE JOB

FIRST THINGS FIRST