Baling cardboard and RDF efficiently

Doyle Bros is efficiently baling commercial and industrial waste at its Sydney Materials Recovery Facility with the MAC 108 from Macpresse.

The family-owned Sydney-based waste and recycling company has serviced Sydney’s commercial and industrial sector since 1989. Throughout this time, Doyle Bros told Inside Waste that it has been committed to preserving the environment through efficient recycling.

Since 2009, Doyle Bros has been diverting material from landfill into their Materials Recovery Facility (MRF) to recycle Old Corrugated Cardboard (OCC) and Refuse Derived Fuel (RDF).

According to Doyle Bros, RDF is an especially valuable recycling product in environmentally responsible approach of managing waste. The company has told Inside Waste that non-recyclable residuals and waste that would otherwise be destined for the landfill, can be turned into efficient fuel. It has a lower-emission rate than coal and reduces harmful landfill emissions.

To process both incoming waste streams, the company uses state of the art European sorting and separation technology. An integral part of Doyle Bros’ recycling process is the MAC 108 baler from the Italian company Macpresse.

Global leader

Macpresse is one of the world’s leading companies in the field of plants for waste and recyclables treatment with over 50 years of experience in the production of high-volume baling presses.

Over 1500 of their balers are installed worldwide and Macpresse is present with service centres in over 60 countries. CEMAC technologies is the distributor for Australia and New Zealand and supports local installations with service and local spare stock holding.

Key benefit

Doyle Bros, managing director Paul Doyle, bought the MAC 108 three years ago after a visit to the factory south of Milan where all Macpresse machines are designed and manufactured. He was impressed with the expertise and experience of Macpresse.

“Clearly they have been in business for a very long period,” he said.

After having used the MAC 108 for three years now, said that the machine’s reliability is a key benefit. “It’s a strong and solid thing that you can count on,”

Since he put the machine into operation, Doyle has experienced no downtime. It’s maintained it with a simple maintenance routine suggested by Macpresse and ever since the start Doyle added that “it just keeps going”.

To ensure the sturdiness of all Macpresse machines, HARDOX 450 steel liners are fixed to the structure of the frame with a patented bolted application system. This wear-resistant material protects the balers from abrasion and corrosion, with replacement liners on the floor, sidewalls, and top of the extrusion chamber.

HARDOX steel is 400 per cent longer lasting than normal steel and is resistant to wear and chemical agents. It can be rapidly replaced, thereby minimising baler downtime while increasing the overall lifetime of the machine.

Another feature that improves the lifetime of the MAC 108 are the blades that are used to cut off excess material in the hopper. These are tempered blades specially designed by Macpresse to guarantee a greater resistance to wear.

Reliably bales two different materials

Besides the sturdiness of the MAC 108, Doyle explained the machine’s ability to bale two different products. Doyle Bros bales both OCC and RDF “in different shifts and it handles it”.

Due to the input material which is “very light and fluffy”, Doyle also pointed out the machine’s high processing volume.

“When all the material is placed into the Macpresse and it can be compacted into the one metre squared bales,” he said.

The MAC 108 can also process 16 tonnes of cardboard, and 30 tonnes of RDF per hour and has been specially designed for compacting medium and large quantities of materials.

Macpresse offers a wide range of different balers, from the small-sized MAC 102 to medium-sized balers such as the MAC 108, until large-sized balers like the MAC 112 XL. Due to the variety of machines, Macpresse balers are suitable for a wide range of plants from smaller supermarkets to larger sites such as landfills and transfer stations.

Tying unit and hydraulic system

Macpresse balers are renowned for the most reliable tying unit in the industry. By tying all wires simultaneously, the tying time for each bale is reduced significantly. The operator also has the option to choose between plastic or steel wires.

Additionally, Macpresse offers the option of a mobile tying unit for all their balers. This unit rotates 90 degrees away from the balers frame and returns into position only during the tying and cutting cycle. This enables an even simpler cleaning and maintenance.

The MAC 108 also has low energy consumption, mainly due to the hydraulic system, which is comprised of a high-efficiency IE3 motor and a Rexroth variable flow piston pump. This motor allows for energy savings of 30 per cent compared with traditional motors, with the variable flow piston pump further reducing electrical consumption while also allowing the hydraulic pressure to be regulated on demand.

With Macpresse’s MAC 108 Doyle said that the company can reliably and efficiently bale recyclable material. Both input streams, OCC and RDF, can then be processed further in an environmentally responsible way.