Ecogen Recycling is a fast-growing recycling company. Throughput is increasing by 10% month-on-month, so it was clear that new plant was needed to maintain momentum.
With the focus placed firmly on expansion, the team specified a Presona LP65 VH K2 cross-tie baler to increase material processing speeds and bale density, adding an essential degree of future-proofing to the business.
The baler has increased the company’s processing capacity from eight tonnes to 22 tonnes an hour, an improvement which will enable it to become more competitive when it comes to commercial waste purchasing.
Ecogen bought its first Presona baler when it moved to Alresford, Hampshire, two years ago. The LP50 prepress baler was used to bale cardboard, paper, plastic and shredded paper. It was reliable and worked well – it still does, but the firm always had an eye on increasing throughput speeds to allow it to grow on this site.
The team started to look for a new baler which would increase throughput and bale density, and the LP65’s vital statistics were impressive. Ecogen wanted the baler to deliver improved compaction rates, provide increased cross-ties to accommodate densely packed plastic film and perform faster throughput rates.
The original baler produced a standard bale weight of 350- 400kg with plastic film. The new LP65 has increased this by 35% to an average of 550kg. In fact, the company processed a bale of cupcake skeletal waste at 860kg and the average cardboard bale is now 600-700kg. Ecogen is now running tests to see just how far it can increase its bale tonnage.
Based on an average 500kg plastic bale, Ecogen has increased its container rate from 18-20 tonnes to 24 tonnes, cutting logistics costs and making the whole process more profitable.
In addition, it is now able to process material much faster, which is critical because it operates on a small site. It processes up to 20 containers of cardboard a week.
Initially, the plan was to trade in the old LP50 prepress baler, but the team was reluctant to let it go because it had many years of operation left. So with the help of Presona’s engineering team, the LP50 will be moved to a different building where it will become part of a paper and shredding line.
Founded in 2010 by managing director William Nicholls, Ecogen regularly processes up to 3,000 tonnes of paper, card and plastic a month, all from commercial sources. It takes post-manufacturing material from customers located across the UK, working with organisations in a range of sectors including automotive and food packaging.
It also works with waste management companies of all sizes and often processes, aggregates and trades material from smaller organisations to optimise quality and maximise value. In addition, Ecogen provides a shredding service.
AT A GLACE: LP65 VH K2 BALER
Presona’s baler is ideally suited to high-volume recycling, waste management and logistics/retail locations. The details below provide typical minimum and maximum specifications.
Actual capacity: 370cu m/hr
Theoretical capacity: 940cu m/hr
Motor size: 45kW
Output per hour: up to 22 tonnes
Feed opening: 1,500 x 1,100mm
Press force: 65 tonnes main press/25 tonnes prepress
Bale size: 1,100 x 750mm x variable length
Bale density, paper: 575kg/cu m Weight: 21 tonnes
- Energy-efficient operation
- Five vertical needles and three horizontal needles
- Premi HMI system for operational control and monitoring
Toby Mottram is Ecogen operations manager