Project Details
Client
FG7 Auto-Parts
Customer Type
Warehouse
Location
UK
Model
CK450HFE
Material
Cardboard
The Challenge
FG7 Auto Parts experienced rapid growth in warehouse throughput, placing increased pressure on waste-handling processes, particularly the management of cardboard packaging.
Their existing vertical baler was not fit for purpose, leaving staff to manually break down cardboard and fill pallets, which diverted time from core operations and reduced overall productivity.
CK International was thus tasked with providing a reliable, high-performance baling solution that could handle FG7’s increased cardboard volumes, support lean workflows and reduce the labour burden on the warehouse team.
01
Managing rising cardboard waste from increased warehouse throughput
FG7 Auto Parts, a leading distributor of automotive parts in the UK, experienced rapid growth in warehouse throughput, placing increasing pressure on waste-handling processes, particularly the management of cardboard packaging waste. To maintain operational efficiency while adopting Lean methodologies, the company required a reliable, high-performance baling solution to improve material flow and reduce unnecessary waste-handling activity.
02
Labour-intensive cardboard handling impacting warehouse productivity
The warehouse team was experiencing significant strain on resources, with staff manually breaking down cardboard and filling pallets. Their existing vertical baler was not fit for purpose, and these labour-intensive tasks were taking valuable time away from core warehouse operations, increasing costs and reducing overall productivity.
50T
Compaction Force
450kg
Bale Weights (Cardboard)
Different Materials
Cardboard
The Solution
01
Source a High Quality, Second-Hand CK450HFE
FG7 had a defined budget for an upgrade to their existing baler to find an effective way to manage their waste and a solution that would help reduce pressure on staff resources. CK International sourced a high-quality second-hand semi-automatic baler with a bin tipper, delivering a cost-effective system that met their operational needs while staying comfortably within budget.
02
Operational Impact
The baler aligned seamlessly with FG7’s Lean process initiatives, freeing up valuable floor space and improving the overall flow of goods throughout the warehouse. This created a more efficient, organised, and safer working environment.
03
Efficiency Gains
The new system delivered a significant reduction in waste-handling time and manual effort. With the baler taking over the bulk of the waste management process, staff can now redirect their time and energy toward value-adding activities that support core warehouse operations.
04
Improved Workflow & Safety
By positioning the baler outside, FG7 eliminated the need for staff to carry waste up and down stairs, reducing workplace strain and congestion inside the warehouse. This improved overall workflow, enhanced safety, and minimised disruption to daily operations.
The Benefits
High-Capacity, Heavy-Duty Compaction
The CK450HFE delivers up to 60 tonnes of compaction force and produces large bales (cardboard bales up to ~500 kg), enabling efficient handling of large volumes of waste.
Cost-Effective Through Robust, Low-Maintenance Design
Built with a durable Hardox® Castellated floor and a reliable horizontal tying system, the machine has a long service life and lower maintenance requirements, reducing total cost of ownership.
Optimised Loads For Transport
The press-plate is mounted on a Hardox® Castellated floor, thereby reducing maintenance costs and ensuring long life of the machine.
Labour & Space Efficiency
By compacting loose waste into dense bales, CK450HFE reduces volume significantly, meaning fewer waste collections and less floor clutter. This frees up staff from repetitive manual handling and frees warehouse space for core operations.
The new baling system has transformed our warehouse operations. Not only has it reduced the time and effort spent on waste, but it’s also allowed our team to focus on tasks that add real value. CK International really understood our needs and delivered a practical, cost-effective solution.
Working closely with FG7, we were able to identify a solution that not only addressed their waste challenges but also improved operational efficiency. Seeing the team freed from manual waste handling and the warehouse workflow significantly improved has been incredibly rewarding.