Showing Some Strength (Baler Supplement)

That’s why makers of balers used in scrap applications must design and build their machines with durability as a focal point.

Metallic scrap feedstock is eventually headed for a fiery fate, but before it reaches a furnace it may face pressure applied by a machine that has to be tougher than the steel it is squeezing.

IRON-CLAD BALES

The ferrous scrap stream is not only among the highest volume recycling streams in the world, it can also contain some of the largest and heaviest scrap items.

The equipment that has been designed to squeeze and sever this scrap stream must be sturdy enough to face up to the task. “We’ve got thick liners on all the ram faces,” says Dwight Carter, engineering manager with Harris Press & Shear, Peachtree City, Ga. Carter, who works at the company’s Cordele, Ga., manufacturing facility, says equipment makers in the scrap market are well aware that their machines will be involved in heavy-duty tasks in tough environments.

Despite the perils of (in most cases) outdoor duty and the likelihood of encountering materials that will test the machine’s limits, ferrous balers have been made that have been serving for two decades or longer, says Carter. “The balers made now, because we’ve had such a lengthy learning curve, are similar to Sherman tanks. You can’t hardly destroy them.”

For a baler to be that durable, any number of design features need to be included. Manufacturing engineers have found that strong steel for the parts that will come into contact with the scrap stream is essential. “The first compression ram needs to have a thick liner, and so do the second and third liner surfaces,” says Carter. “Any time the liners inside wear considerably, you open up cracks that allow material to go under the ram. When that happens, you’ve got to replace the liner.”

The bale exit area is another part of the baler that can require extra armor. “We still have customers who will try to extrude oversize bales,” says Carter. “We make that portion of the baler out of thicker plates to withstand the brute force of trying to extrude a bale.”

Although minimizing the effects of metal-on-metal squeezing and scraping is the most obvious durability consideration, protecting the purity of the hydraulic fluid that comes into contact with the cylinders and other important parts is why the extra protection is so important in the first place.

Harris has developed a Teflon piston head the company claims has allowed its machines’ cylinders to endure more of the inevitable abuse that will be encountered in the scrap climate. “That Teflon piston head is very forgiving if a metallic particle gets inside the cylinder,” notes Carter. “It will absorb the metal piece instead of scoring the metal.”

Nonetheless, keeping the hydraulic fluid pure should be one of the primary aims of a ferrous baler maintenance plan. “Keep those liners in good condition,” warns Carter. “Do not let them chip or have material force itself down the side of the wall or under the ram.”

Carter recommends a daily maintenance routine. “Go around and look at the machine; make sure it’s not leaking oil into the power unit. Check the cap screws and make sure they’re tight. Cylinder mounts can come loose if maintenance is not vigilant,” he remarks. “If one cap screw comes loose, the others cannot take the load for very long.”

Some ferrous balers include a shearing function, which involves more moving parts and more maintenance and parts replacement considerations. In the Harris line, balers with shears are identified with the TGS model name designation. “The TGS balers require a little more maintenance, because you have to keep the knives adjusted,” says Carter. There is a clearance level that has to be kept or you could encounter a jamming condition.”

The blades on shear-balers are a part that will require regular replacement. How often they must be replaced “depends of how long the customer is running the baler,” says Carter. That amount of time can vary, he notes.

Inspectors need to see what the blades actually look like. “When they get rounded over or notched, you have to replace them,” says Carter.

ON THE MOVE

The quick processing of materials generated at demolition or other job sites is often accomplished with a portable baler.

In many industries, deadlines and schedules seem to have accelerated and the pace of business seems to have quickened. Demolition contractors have certainly noticed the difference, as construction contractors often seem to have their equipment on site before the demolition task is finished.

Despite the deadline pressures, demolition firms still want to stay involved in the recycling process, and portable baling units have helped them do this.

The machines are also used by scrap processors who call on auto dismantlers and salvage yards and compress car bodies on site to make them easier to transport.

Jim Langland of Al-jon Inc., Ottumwa, Iowa, notes stricter cargo securement laws are motivating dismantlers and processors to pay more attention to how car bodies are transported. “Customers are looking down the road and want more efficient and affordable ways of moving cars to market,” he comments.

While car flatteners and portable ferrous balers are a good deal smaller than fixed-site ferrous balers, that does not mean they are less sturdy. “When we manufacture a portable, we go to higher strength material,” notes Carter.

Even though keeping a machine light enough to be transported with fewer (or no) permits is ideal, durability may ultimately count for more in the eyes of scrap recyclers. “The weight of the machine-meaning the heavier the machine is the longer it lasts and the more sturdy and durable it is-is something that buyers look at,” says Langland. “This is an area where there is no substitute for iron. A lot of operators want heavier machines that don’t break down.”

“What we have found is that quality of manufacturing is very important to buyers of these machines,” he continues. “They want a durable piece of equipment that is easy to work on.”

Ease of maintenance has also proven important to many auto dismantlers and scrap companies that perform most of their own maintenance and repair work. Newer Al-jon models have engines at a lower height. “Operators don’t need a step ladder to check the oil and for other maintenance tasks. The valve package is also down low at the end of the machine, which makes a difference.”

As with fixed site ferrous balers, routine maintenance can help reduce the likelihood of unplanned downtime. “Daily maintenance is important,” says Langland. “Hit all the grease points, check the baler for loose material that might scratch the rods. Generally, keep an eye on any kind of engine wear, and check the engine oil and other fluids.”

Baler owners can rely on their own experiences to design maintenance routines, and can accept the advice of the manufacturer. “The service manual tells customers what to check and over what period of time to check it,” notes Carter.

With a little bit of care and caution, the life expectancy of these machines can reach remarkable lengths, considering the difficult tasks and harsh conditions to which they are exposed. RT