Cardboard Balers | Cardboard Crushers - Compact and Bale

Cardboard balers come in a variety of sizes and have fundamental differences that impact how quickly and how much material you can load before needing to cycle the machine; as well as the size of material that can fit in.

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We have provided some general guidance below:

Filling Opening: Ease of Loading

Consider the size of the cardboard you are looking to recycle. For example, a cardboard sheet that is mm wide x 600m long would not fit in a small baler chamber of 700mm x 450mm without folding both sides.

A large model such as a mill size baler will also have significantly more depth in the chamber allowing you to fill more material before cycling the machine.

Both of these fundamental considerations can save you significant amounts of time, even with our models fast cycling time of only 32 seconds.

Bale Size: Storage and Floor Space

Consider how much space you have in your facility or yard. Two examples of bale sizes:

Typical small balers: 700 x 500 x 500 (L x W x H mm) versus mill size balers: x 800 x

A small bale will require ejecting from the machine regularly, a larger bale will not. A larger bale will also be more structurally sound and safer to stack using a forklift or bale stacker, whilst a smaller bale would be easy to move on a sack truck.

Bale Weight: Maximising Tonnage

If you are limited on space while looking to obtain the best rebates for your recycling bales, you may decide a large vertical baler is your best option.

This is typically the case as most of the larger models will provide a bale that weighs 450kg and up. This means that for every 1 square metre of floor space, with a double stacked bale, you could have around 1 tonne of material. Where safe and appropriate to do so, you could have at least 1.35 tonnes of material stacked 3 high (being 3.3 metres excluding pallets) for every square metre of floor space.

For bales typically stacked 2 high then, with 20 square metres of floor space, you would have an artic load of material.

Based on these tonnages, you would obtain the best market rates, with Compact & Bale offering the below rates:

Rates are per tonne as of April

• Selling cardboard up to £130
• Selling Plastic up to £300
• Selling paper (such as sorted office paper) up to £200
• Selling Tins & Cans up to £250
• Selling Polystyrene up to £550

When looking at a small or medium-mid-range baler you will find that due to the significantly reduced bale weight and size, recycling partners will have to break the bales open and reprocess them into a mill-size bale. This partner will have transported less tonnage on the collecting vehicle, which potentially results in greater costs handling the material. These factors result in a lower rebate paid to you unless the provider is flexibly collecting your material alongside other sites on a route.

Balers for cardboard vary greatly and whilst they are used for the same purpose, they produce vastly different results.

To help you identify which type of machine may be best for you, here are the five different types:

Vertical Balers

This type of baler is the most commonly found machine on the market and takes up the smallest footprint by standing upright. They are typically taller than they are wide.

Cardboard press machines of this type can be found in small and low headroom environments or could equally be as tall as 4 metres.

They are ideal for companies with limited space and provide options for small to mid volume producers of waste. You may find these machines are most suitable if you produce less than 20 tonnes of recycling per week.

The more material you need to recycle, the less this range is typically efficient however because you are restricted by the cycle time of the machine. During the machines cycle, the door is closed to the chamber to prevent further filling and potential for injury, you can not continue filling until the door re-opens.

Multi-Chamber Balers

This is a vertical baler but with multiple chambers (up to four). This means you could recycle your cardboard, plastic film, rigid plastics, tins and cans as example, in one machine. You could alternatively, cycle the machine and while it is crushing in one chamber,  continue filling in the other. You might only want to do this however if you do not have headroom for a larger machine.

Horizontal/Semi Automatic Balers

This type is particularly popular for mid to large size producers. This is because the models can come with a splayed hopper which sits atop the machine and can be continually filled while the machine cycles. You can also fit a photocell so that the machine cycles automatically, which ensures the operator only needs to focus on filling the machine with material until the bale is ready to be ejected. This machine typically has significantly less downtime than a vertical baler machine but still requires to be manually tied off once the baler is ready to eject.

Fully Automatic/Channel Balers

Like the above semi automatic balers, these models can be continually fed by a conveyer, chute, bin lift, extraction system by hand and from a dock or ground level.

They will also fully tie the bale and eject out onto a ramp. Dependent on the size of the ramp, you will save significant amounts of labour and prevent production stoppages.

With the right in-feed option you could have a fully autonomous baling operation.

They can also be fitting with modems and other specialist controls to notify remote operators of any issues (such as when the bale ramp is full requiring bales to be collected) as well as to provide controls and timing of material feeds.

Twin-Ram Balers

Two ram balers are the most effective balers for processing different types of material. This could be cardboard, hard plastics, RFD or plastic films; these models produce extreme bale weights and densities.

What’s the difference between a Fully Automatic or Twin?

The main consideration is heavier bale weights and on average a twin ram baler will process wider and greater volumes of waste materials whereas a fully auto or Channel baler is suited only for one material at a time such as for processing cardboard in a production plant, or in a distribution centre.

Our business has been trading since and with a long history comes experience and reach. Our team has grown significantly over this period from a small office to a large production workshop with a highly skilled team of engineers.

Servicing

Our engineers are based around the UK in the South, Midlands and North providing regular Baler Servicing to all our clients.

Servicing is typically carried out every six months and all our customers have an account to access all their maintenance records.

In some instances, servicing may be scheduled more regularly dependent on the size of the cardboard baler and how much use or material it receives.

Breakdowns

For more information, please visit Cardboard Baling Wire.

In the unlikely event that your cardboard press breaks down, we operate a standard 24 hour call out time to attend and carry out repairs.

Our baler engineers are experienced with repairing all manner of typical faults including those that are very much unexpected.

The good news is, as suppliers of high quality machines, these instances are very much a rare occurrence.

Maintenance Plans

If you are looking to hire a baler then you are fully covered for both periodical servicing and breakdowns.

All repairs include baler parts unless the damage is as a result of user error or negligence.

If you are looking to outright purchase a baler, then we have a number of plans providing excellent cover which are bespoke to each type of machine.

A good cardboard baling process boosts workplace efficiency and helps sustainability efforts. This guide covers cardboard baling in detail. It includes instructions, safety tips, and maintenance advice. It also explains how recycling cardboard benefits the environment.

Understanding Cardboard Balers: Types and Applications

Cardboard balers have different designs. The most common are vertical and horizontal configurations. Before diving into the baling process, it’s essential to understand these differences.

Vertical vs. Horizontal Balers

Vertical balers have an upright design. You load materials from the top and compress them downward. These units are perfect for small to medium-sized businesses. They work great in retail stores, supermarkets, and small factories. They save space. They typically produce bales weighing approximately 660 lbs (300 kg).

Horizontal balers work in a horizontal position. They are great for handling high volumes. They provide more automation choices and can manage bigger amounts of cardboard. However, they need more floor space.

Bale Sizes and Weights

The dimensions and weight of cardboard bales vary depending on the baler type:

• Small vertical balers produce bales weighing between 67-176 lbs (30-80 kg)
• Medium-sized bales from vertical balers usually measure 47.2 x 31.5 x 31.5 inches (120 x 80 x 80 cm). They typically weigh about 660 lbs (300 kg).
• Larger balers produce heavier, more densely packed bales suitable for industrial recycling operations

Essential Safety Precautions

Safety should be the top priority when operating cardboard balers. These powerful machines can cause serious injuries if proper procedures aren’t followed.

Operator Requirements and Training

• Only trained workers aged 18 and older should use baling equipment.
• Operators should thoroughly understand the manufacturer’s instructions specific to their baler model
• Wear personal protective equipment (PPE) when handling baling wire. This includes safety boots, eye protection, hearing protection, and safety gloves.

Pre-Operation Safety Checks

Before operating a baler, conduct these essential safety checks:

Test all safety mechanisms including emergency stop buttons and safety gates

Ensure the chamber door closes and locks correctly

Verify that raising the safety gate during operation stops the ram movement immediately

Check that the baler stops operating when the gate is lifted off its ramp during the automatic cycle

If any safety feature fails these checks, do not use the baler and have it serviced by authorized personnel.

Detailed Step-by-Step Baling Process

Step 1: Prepare the Baler

Place two flat pieces of cardboard behind the baler. Fold them to fit across the bottom of the chamber. This helps stop uneven cardboard from blocking the wire paths. This gives you a clean surface to start your bale. It also protects the ejector chains at the chamber’s bottom.

Ensure the ejector chains are untwisted. They should fit snugly in the grooves of the baler chamber floor. Then, close and lock the main door by tightening the hand wheel lock.

Step 2: Load and Compress the Material

Open the safety gate and load flattened cardboard into the chamber. For optimal efficiency, flatten boxes as much as possible before loading. Spread the material evenly in the chamber. This helps with uniform compression and stops side-loading damage.

Close the safety gate fully to activate the ram safety switch. Then, turn the key switch to ON. Finally, press the DOWN button to begin the compression cycle. The ram moves down, compressing the material. It will then reverse when it hits full down-stroke pressure.

Step 3: Preparing for Wire Insertion

Keep loading and compressing cardboard until the full bale light comes on. You can also stop when the alignment arrows on the ram face and sidewall match. At this point, the machine will stop with the ram against the compressed bale.

To compact more, add a flat piece of cardboard on the bale. Then, lower the safety gate. Turn the key switch to ON. Set the up-down switch to DOWN. Finally, press the start button. This creates a flat surface for wire insertion.

Step 4: Accessing the Bale Chamber

Turn off the baler and remove the key for safety. Unlock the baler door by spinning the wheel to release the controls. Open the chamber door past 90 degrees. With the door open, the machine can only run in manual mode if needed.

Step 5: Clearing Wire Paths and Installing Wires

Carefully use a rod to check for blockages in the wire slots. Avoid the holes at the top where chains are visible at the bottom. Clear any obstructions to create clean paths for the baling wire.

For vertical balers handling cardboard, 12-14 gauge wire is typically recommended. Slide the baling wire into the front slots of the ram. Then, feed it through to the slots on the bottom floor of the baler. A minimum of 4 baling wires should be used to properly secure the bale.

Step 6: Securing the Baling Wire

Feed the wires through the bottom and back to the top. Then, secure each wire by putting one end through the hole at the other end. Pull the cable to remove slack. Then, braid or twist each wire connection 4-5 times. This helps keep it secure during bale ejection and transport.

Step 7: Preparing for Bale Ejection

Go behind the baler and attach the ejector chains to the red platen brackets on the ram. Ensure the chains are properly hooked and not twisted.

Position a pallet and pallet jack in front of the baler chamber opening to receive the bale when ejected. The pallet should be centered to properly catch the bale as it comes out.

Step 8: Ejecting the Bale

Stand clear of the opening and to the side of the power unit. Set the up/down switch to UP position and press the button to eject the bale. Some balers with international safety packages require pressing both eject buttons simultaneously.

As the ram rises, it will push the bale forward onto the awaiting pallet. Don’t stand right in front of the baler while it’s working. The bale can shoot out with a lot of force.

Step 9: Bale Removal and Baler Reset

Move the completed bale on the pallet to a designated storage area that doesn’t block access ways. Put two new cardboard pieces on the baler floor. Fold the bottom edges a bit so they fit when the door closes.

Go to the back of the baler. Take off the ejector chains from the platen brackets. Then, hang them on their storage pegs. This step is crucial - ensure chains are removed before loading new material.

Step 10: Resetting for the Next Bale

Close the main chamber door and tighten the door wheel lock to secure it. The baler is now ready for the next load of cardboard.

Troubleshooting Common Baler Problems

Even well-maintained balers can experience operational issues. Here are solutions to common problems:

Baler Won’t Turn On

If your baler doesn’t power up, check:

• Power connection and functionality of the outlet
• Circuit breaker or fuse box for tripped breakers
• Key switch position (should be in “ON” position)
• Control panel for error messages
• Safety features like gate closure and door locks

Slow or Struggling to Compact

For compression issues:

• Check for blockages or jams in the compaction chamber
• Ensure cardboard is being fed evenly and is the proper size
• Verify there’s sufficient material in the baler for proper compaction
• Inspect hydraulic fluid levels and pressure

Bale Ejection Problems

If the baler won’t eject bales:

• Inspect the ejection ram for damage
• Check hydraulic hoses, fittings, and seals for leaks
• Ensure bale straps are properly secured and not obstructing ejection
• Lubricate the ejection system according to manufacturer guidelines

Maintenance for Optimal Performance

Regular maintenance extends baler lifespan and ensures efficient operation:

Daily Maintenance Tasks

• Perform visual inspections for wear or damage
• Test safety mechanisms like emergency stops and safety gates
• Remove debris and buildup from the baler chamber

Weekly Maintenance Tasks

• Apply lubricant to moving parts including chains and bearings
• Check and tighten any loose bolts and electrical connections
• Monitor hydraulic fluid levels and check for leaks

Monthly and Quarterly Maintenance

• Inspect belts, chains, and hydraulic pressure
• Check electrical components including switches and sensors
• Replace hydraulic and air filters quarterly
• Inspect the baler frame and welds for cracks or stress signs

Environmental and Economic Benefits

Environmental Impact

Cardboard baling contributes significantly to environmental conservation:

• Reduces landfill waste and the associated methane emissions that accelerate climate change
• Recycling cardboard saves energy. It uses 50% less energy than making it from raw materials.
• Conserves natural resources by keeping materials in the recycling loop
• Reduces transportation emissions by enabling more efficient shipping of compressed materials

Economic Advantages

Implementing cardboard baling practices offers substantial financial benefits:

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