Berry Global maximises efficiency & throughput with a new Twin Ram Baler.

Aug 23, 2023

Berry Global, a worldwide plastics packaging manufacturer, required a fast and efficient way to bale mixed PET and HDPE plastics in one of their UK recycling plants. Working closely with their plant builder McDonald International and REP-TEC Automated Recycling Solutions, they were able to maximise their efficiency and throughput...

Berry Global took receipt of the new REP-TEC fully automatic twin ram baler last year and are putting it to work, producing high density bales of PET and HDPE plastics. The Samson model, which was designed and manufactured at REP-TEC's headquarters in Northern Ireland, has an 80T compaction force and is powered by a very efficient 37kW hydraulic power unit. The two-ram baler comes with wire tie and machine data reporting which has helps improve efficiency and make better business decisions based on these reports.

Garrett Loughran, Sales Manager at REP-TEC explains, "Berry required a fully automatic baler for one of their UK recycling plants and we were more than happy to offer a solution. It was clear from the start that a twin ram baler was the best option for baling the plastics. The twin ram baler clears out the baler chamber each time, so Berry can easily switch between the various plastic types without risk of contaminating subsequent bales. That coupled with the high press force the machine offers and the flexibility to add as many ties as they required, made it the perfect choice. The project ran smoothly. As the plant was being built at the same time, we coordinated and worked well with McDonald International and other contractors to ensure smooth delivery and installation."

Cost Savings

Since installing the Samson twin ram baler, Berry Global has experienced significant improvements in efficiency and throughput. The bales are of an extremely high density, making them easier to handle and transport, thus reducing costs. The reason the twin ram baler produces such high-density bales is due to the fact that it comes with a separation door, so expansive materials such as PET can be baled with full force. The baler is also processing more materials in a shorter amount of time due to its large capacity and high compaction force. As the baler is fully automatic, it allows for unattended operation which greatly reduces labour costs.

Remote Monitoring and Smart System

The remote monitoring system on the twin ram baler enables REP-TEC engineers to login and troubleshoot any issues. This helps decrease downtime. The baler also comes with a smart system which calculates the bale size and provides Berry with information on the amount of material they require for each bale. This gives them a consistent bale size each time which is ideal for transportation.

The smart system also enables them to program in their preferred wire tie option to suit their bale type. The number and spacing of each wire tie can be modified and double straps are also possible.

Working Closely with the Plant Builder and Other Contractors

REP-TEC worked closely with McDonald International, throughout the project to ensure that the baler was designed to efficiently handle the mixed PET and HDPE plastics coming into the plant through a chain conveyor system. REP-TEC were able to make several customisations to the baler to ensure that it suited Berry's facilities. On-site testing and training were conducted, and REP-TEC ensured that the customer was completely satisfied before concluding their work.

Darryl Roadnight, Strategic Projects Director at Berry Global says, "We are extremely satisfied with our new baler's performance. The baler is consistently delivering excellent results. We were really impressed with the hassle-free installation process. The REP-TEC team was very professional and efficient during the installation process. They made sure to adhere to all health and safety regulations, which was reassuring as we had a lot of contractors on site at the time. They were in and out of the site quickly, leaving the place clean and tidy. They have provided us with all the necessary support and guidance, and I would highly recommend a REP-TEC baler to anyone looking for reliable and high-quality baling equipment."