Case Study: Application of 400 Ton car Baler auto baler in an Australian Recycling Facility

1. Market Background: Australia's Growing Need for Efficient Automotive Scrap Recycling

Australia’s automotive industry, both in terms of manufacturing and recycling, has been a key contributor to its economy. With an increasing number of vehicles being decommissioned every year, the demand for efficient recycling solutions, particularly for automotive scrap, has surged. The process of recycling old car shells and other automobile parts has become vital not only for environmental sustainability but also for the recovery of valuable materials like steel, aluminum, and copper.

In Australia, the challenge lies in efficiently compressing large volumes of automotive scrap into compact bales to facilitate easier transportation, storage, and further processing. The need for specialized equipment capable of handling bulky automotive shells and producing high-density bales has led to the adoption of heavy-duty baling machines in many Australian recycling facilities.

To address this demand, we exported our 400 Ton Automobile Shell Baler to an Australian recycling plant, which has significantly improved their efficiency in processing decommissioned vehicles.

2. Client's Pain Points: Challenges with Existing Baling Equipment

The client, a major Australian recycling plant specializing in automotive scrap processing, faced several issues with their existing baling equipment:

• Limited Baling Capacity: Their previous balers could not handle the large and heavy automobile shells efficiently, leading to low productivity and frequent breakdowns. The machines were not designed to handle the tough, irregular shapes and sizes of automobile scrap.

• Inconsistent Bale Density: The client struggled with inconsistent bale quality, leading to inefficient transportation and storage. The existing equipment could not generate the high-density bales required for cost-effective logistics and further processing.

• Slow Cycle Times: The old machines had long cycle times, leading to lower throughput. This inefficiency created a bottleneck in their production line, hindering their ability to process the increasing volume of automobile scrap.

• High Energy Consumption and Maintenance Costs: The existing balers were energy inefficient, and the frequent breakdowns resulted in high maintenance costs and extended downtime.

The client required a high-capacity, efficient, and durable baling machine capable of processing large automobile shells, improving bale consistency, and reducing downtime.

3. Solution: 400 Ton Automobile Shell Baler

After discussing the client’s operational requirements, we recommended our 400 Ton Automobile Shell Baler, a powerful and efficient machine designed specifically for processing large-scale automotive scrap. This machine provides the necessary cutting force, high-density bales, and faster cycle times to address the challenges faced by the client.

Key Features of the 400 Ton Automobile Shell Baler:

1. Powerful Cutting Force:

   • The main pressure cylinder (model YG450/310-2600) delivers a maximum thrust of 4000 kN (400 tons), allowing the machine to handle large, heavy automobile shells with ease. This high cutting force ensures that the machine can compress automotive scrap into high-density bales without compromising on performance.

2. Efficient Side and Door Cover Cylinders:

   • The side pressure cylinders (model YG320/220-4300) provide a maximum thrust of 2000 kN (2 sets), while the door cover cylinders (model YG280/200-2350) provide a maximum thrust of 1600 kN (2 sets). These cylinders work in tandem to ensure even and consistent compression of the scrap material, leading to uniform bale density and better control during the baling process.

3. Optimized Compression Chamber:

   • The machine features a large compression chamber size of 5000×2000×1200 mm, allowing it to process large automobile shells and other bulky automotive parts. The size of the chamber ensures that the machine can accommodate a variety of scrap shapes and sizes, making it versatile and efficient for the client’s needs.

4. High-Density Baling:

   • The machine produces bales with a density of ≥1800 kg/m³, which ensures that the bales are tightly packed for easy storage and transportation. The bale size ranges from 100–1500 mm in length and 700 mm in width, which is ideal for shipping and further processing.

5. Quick and Efficient Cycle Times:

   • The machine is designed to complete a single cycle in approximately 150 seconds when empty, which significantly reduces the processing time compared to previous equipment. The fast cycle time increases throughput, allowing the client to handle more material in less time, improving productivity.

6. Advanced Hydraulic System:

   • The baler’s hydraulic system operates at a working pressure of ≤25 MPa, powered by A4V-250 hydraulic pumps. These pumps are rated for a pressure of 31.5 MPa and a rated displacement of 250 ml/r. This powerful hydraulic system ensures that the baler operates smoothly and efficiently, even during prolonged use.

7. Energy-Efficient Operation:

   • The total power of the equipment is 111 kW, ensuring that the baler operates with a high level of energy efficiency. The oil tank volume is 4500 liters, with 4000 liters of hydraulic oil, providing sufficient capacity for continuous operation without the need for frequent oil replacements.

8. PLC Automatic Control with Remote Monitoring:

   • The baler is equipped with a PLC automatic control system that enables precise control over the baling process. The system includes a remote control feature, allowing operators to monitor and adjust settings from a distance, improving convenience and efficiency.

9. Durable and Low-Maintenance Design:

   • The 400 Ton Automobile Shell Baler is built with durable components designed to withstand the rigors of continuous use in harsh recycling environments. The machine’s robust construction reduces the frequency of maintenance and minimizes downtime, ensuring long-term reliability and reducing operational costs.

4. Client Feedback: Improved Productivity and Quality

After the installation and commissioning of the 400 Ton Automobile Shell Baler at the Australian recycling facility, the client reported several positive outcomes:

• Increased Throughput: The new machine significantly increased the plant’s ability to process automobile scrap, handling large volumes of material in a shorter time. The client was able to process more scrap per shift, leading to higher output and reduced production bottlenecks.

• Consistent and High-Quality Bales: The 400 Ton baler produced consistent, high-density bales that met the client’s needs for transportation and further processing. The bales were more compact and easier to handle, improving logistics and reducing transportation costs.

• Reduced Downtime and Maintenance Costs: The plant experienced fewer breakdowns and reduced maintenance costs thanks to the baler’s durable design and high-performance hydraulic system. The client was able to keep operations running smoothly without the interruptions that had been common with the previous equipment.

• Improved Energy Efficiency: The energy-efficient design of the 400 Ton baler resulted in lower power consumption, helping the client reduce operating costs while maintaining high levels of performance.

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The client summarized their experience with the 400 Ton Automobile Shell Baler as follows:

“The 400 Ton baler has revolutionized our recycling operations. It has allowed us to increase production, improve the quality of our bales, and reduce downtime. This machine has exceeded our expectations and is now a key asset in our facility.”

5. Conclusion: The 400 Ton Automobile Shell Baler – A Game-Changer for Automotive Scrap Recycling

The 400 Ton Automobile Shell Baler has proven to be the ideal solution for the Australian recycling plant, helping them overcome the challenges associated with processing large automotive scrap materials. With its powerful cutting force, efficient hydraulic system, high-density baling capability, and fast cycle times, the machine has significantly improved the plant’s productivity, bale quality, and energy efficiency.

This case study highlights the importance of selecting the right equipment for high-volume scrap processing. The 400 Ton Automobile Shell Baler from Jiangyin Huake Machinery Co., Ltd. provides the necessary force, precision, and efficiency required for handling automotive scrap, making it a valuable asset in the recycling industry.

Jiangyin Huake continues to provide innovative solutions that help recycling plants across the world optimize their processes and achieve greater productivity, cost savings, and environmental sustainability.