Bath & North East Somerset Council Boosts Recycling Efficiency
Bath & North East Somerset Council set out to improve the efficiency and productivity of its recycling facility as part of a waste-strategy review. Because improving bale weights for transport was a key goal, the team had to think creatively.
The Challenge
The council needed a way to increase the bale density of plastic and cardboard waste. They were using a small Twin Ram baler that produced a wide-mouth American-style bale. As a result, once the bales were loaded onto a lorry, the low compaction left wasted space. Therefore, with such a limited footprint, the team was unsure what could be achieved.
Custom Design to Fit
After a site survey, we realised that a standard machine would not work. Instead, we proposed a tailored approach. The MRF in Keynsham, Bristol, required careful planning; consequently, we created 3D drawings with several design options.
We then built an automated bale push ram to move each bale through 90 degrees for better process flow. In addition, we installed the power pack to the side of the machine to save space. We also adapted the existing conveyors, added a new chain-drive conveyor, and re-engineered the picking cabin to allow an extra quality-belt picker. Finally, we supplied access ladders and handrails to improve safety.
Fast Installation and Remote Monitoring
Installation took place over a single weekend, so the council saw immediate benefits. They chose the cloud-based CK Baler Management System, which reports real-time data such as bales produced per hour and wire used per bale. Because this information is instant, the council can track performance and plan maintenance with ease.
Proven Results
Simon Porter, Head of Fleet & Waste Operations, praised the outcome:
“CK International adapted the equipment to our building, which was crucial. Reliability and support have been excellent. We have increased productivity and improved bale weights.”
Cardboard bales now reach 500 kg, while plastic bales reach 550 kg. The baler processes cardboard and paper at 8 tonnes per hour and plastics at 5 tonnes per hour. As a result, lorries carry more material per trip, which reduces forklift movements and saves time. Moreover, the remote management portal lets staff monitor productivity from anywhere—an invaluable feature.