integratedAIR was approached by a client who urgently needed to upgrade their scrap management system by replacing a baler that had been in use since the 1980s. This replacement was essential to meet immediate operational demands and to establish a foundation for a more efficient scrap management solution. Since the existing baler was built with long-obsolete parts, integratedAIR recommended the Austropressen DS-700 baler as the ideal replacement. However, integrating this modern equipment into a setup that was decades outdated presented a significant challenge.

The project encountered several challenges due to the complexity of a scrap system that had evolved over decades. Integration was difficult because the new baler had to connect with a network of components—including the line scrap infeed, whole can infeed, bypass conveyor, and bale outfeed to a dumpster conveyor. Compatibility with the existing conveyors was also crucial, as the upgrade needed to minimize disruptions and avoid major modifications to the current setup.

Balers are machines that compress waste materials like cardboard, paper, plastic, and metal into compact bales, making them easier to store and recycle. By reducing the volume of waste, balers free up storage space while also cutting transportation costs and allowing businesses to sell the baled materials to recycling facilities. In addition to these economic benefits, balers help achieve sustainability goals by lowering carbon emissions through fewer transport trips and supporting recycling efforts that reduce landfill use. They also enhance operational efficiency by streamlining waste management, improving workplace safety, and creating a more organized environment.

integratedAIR systems approached this project with a focus on integration, precision, and efficiency. The existing conveyor logic and operation were retained, and a new baler infeed chute was custom-designed to match the current conveyor drop position, ensuring seamless integration.

The drop chute feeding line scrap to the baler was modified to align with the new baler's infeed and scrap discharge positions. For whole can infeed, the existing conveyor functionality was maintained, with a custom-designed baler infeed chute ensuring a perfect fit with the current drop point.

The bypass conveyor, which previously moved into position when the baler was unavailable, has been adjusted and fixed in place for simplicity. A divert was added to the line scrap drop chute, allowing scrap to be redirected without the need for conveyor movement. This change enables efficient scrap redirection when the baler is not in operation.

The new baler was elevated to align with the existing discharge conveyor. A dead plate extension was added to ensure that bales transfer seamlessly onto the dumpster conveyor without any modifications to its setup. Although the bale outfeed system remained unchanged, raising the baler ensured proper alignment, and the dead plate extension guarantees a smooth transition of bales to the dumpster conveyor.

The installation was meticulously planned to fit within a tight shutdown window. Before the integratedAIR team began, the client removed the outdated baler. Over the following two days, modifications were made to the area beneath the scrap drop chute to prepare for the new baler. Once positioned, the baler was fully integrated, with integratedAIR’s five-person team ensuring all systems were operational before the shutdown concluded.

The successful installation of the Austropressen DS-700 baler significantly improved the reliability of the client’s scrap management system. It maintained compatibility with existing baler components that remained in use. Despite the setup’s complexity, integratedAIR’s solution minimized disruption, avoided unnecessary modifications, and provided a solid foundation for future system enhancements.

integratedAIR’s expertise in designing and implementing automatic bale handling solutions ensured that this project was delivered on time and within scope. They became a trusted partner for the client’s operational upgrades by emphasizing minimal disruption, precise integration, and future scalability.

integratedAIR Systems has designed and installed baler systems for production lines in a range of industries—contact us today to learn more about our expertise and how we can meet the unique requirements of your production process.