Manual handling of cardboard in retail is tough and costly, with little or no rebate.
Finding the right recycling solution cuts labour costs and boosts efficiency. We recently helped a leading Irish retailer with a custom-engineered system that meets those goals.
The Challenge
The retailer wrestled with large clothing boxes, cutting and flattening them by hand before packing them into 1,100 L containers. Staff then hauled the containers away and tipped the contents into a compactor. They moved around 3 T of material each day, but expansion plans required capacity for at least 5 T. The process wasted time and yielded almost no rebate. Their logistics firm asked CK International for a solution that could support growth.
The Solution
After consultations, we designed a custom system. Conveyors played a key role in moving material through the new setup, so we designed them to avoid fire exits and other obstructions. With support from Conveyor Tek, CK International installed a 30 m flat feed conveyor that feeds an incline conveyor and then an Avermann Channel Baler AVOS 1211.
The fully automatic system now moves material on conveyors to the machine outside the building. It produces bales of at least 400 kg and handles up to 5 T per hour, matching the growth plan outlined at the start of the project. The new process lets the customer refine de-packaging: staff can place boxes on a conveyor in their original format—uncut—for immediate compaction.
“When we approached CK International, they delivered an integrated solution that addressed every challenge,” said the client representative. “Our customer now operates far more efficiently. Staff focus on packing and shipping goods to stores instead of handling waste. They can grow confidently, knowing the system can handle the volume. We are delighted with the results.”
The Benefits of a Channel Baler
Fully automatic Channel Press Balers excel at compacting large recycling materials such as clothing boxes. Operators can feed them continuously with conveyors, forklifts, or suction units. Their small footprint saves warehouse space. The Avermann Channel Press combines state-of-the-art technology with a solid, durable design.
For more information on our Channel Balers, click here.