Enhanced tyre baler design increases capacity by 25%
Local recycling company reduces distribution journeys by 70% with Dark Red Design
Client’s Main Objective
A recycling firm based in Northern Ireland had created their own tyre baler to compress used and waste tyres into blocks that occupied roughly half their original area. Even so, they were keen to find ways to further improve their equipment to increase the number of tyres that could be compressed, while maintaining the bales at the same size.
Processing the many thousands of tonnes of used tyres generated each year has long been one of the recycling industry’s biggest challenges. It has been illegal to dump tyres in regular landfill sites for some time and the procedures surrounding their disposal are strenuously regulated. Heavy and cumbersome by nature, transporting tyres is also expensive.
Traditionally, they have been shipped as loose items in trucks, leading to massively inefficient use of load space and an increase in weight profile—all adding up to extra journeys, higher fuel costs and an increase in harmful emissions. However, waste tyres are a valuable recyclable commodity. Compacted into bales, they have a host of uses in the building and civil engineering sectors.
Tyre bales are used in ground stabilisation and road construction and they can also be broken down for energy generation. The reduced volume of baled tyres significantly decreases transport costs by maximising the payload on each journey. The client enlisted the help of Dark Red Design to advise on developing their existing equipment and to investigate if it was possible to increase the number of tyres in each bale.
We had the opportunity to evaluate the current machinery’s original 3D CAD files as well as observing the equipment in use. We interviewed and noted the feedback of the baler’s operators to gain an understanding of where improvements could be made and drew up several solutions to show the client. The chosen design fully complied with the current Duty of Care and HSE regulations and we were able to retrofit it onto the existing equipment with very little disruption to the production line.
The enhanced design allows for an increase of up to 25% in the number of tyres that can be compressed into the same space. This has the knock-on effect of reducing transport journeys by a massive 70%, slashing fuel costs and enabling our client to fully realise their environmental obligations.