Indian Customer Y81T-630 High-Density Aluminum Scrap Baler Application Case

see how it works:

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I. Market Background: Upgrading Aluminum Scrap Recycling, Loose Materials Become a "Hidden Cost"

In recent years, India has seen rapid growth in the use of aluminum in construction, automobiles, wires and cables, and home appliances. This has led to the emergence of numerous extrusion plants, machining plants, and die-casting plants across the country. Consequently, a continuous stream of aluminum chips, profile scraps, and stamping waste is generated daily.

If these materials are handled in loose form for extended periods, several typical problems arise:

Low bulk density, requiring large storage space, making the factory area look "full of material but unable to fill a truck";

Difficulty in loading containers and trucks to the ideal weight, resulting in either high empty weight ratios or dangerously overloaded trucks;

High levels of dust during loading and unloading, posing significant on-site management and safety risks.

Against the backdrop of steadily increasing aluminum scrap recycling volumes, more and more Indian recycling companies are shifting from "stockpiling" to "baling," hoping to reduce overall logistics costs by using high-density baling machines to transform loose materials into regular, high-density bales.

II. Customer Pain Points: 35 Tons of Aluminum Scrap Daily, Old Equipment Can No Longer Cope

This Indian customer is a regional aluminum scrap recycling and sorting center, primarily processing extruded aluminum profile scraps, aluminum chips, and some stamping scraps. Before the project started, their concerns focused on three points:

Capacity Constraints

The average daily input volume had reached approximately 35 tons, and their existing small-tonnage baler was only suitable for steel scrap or small batches of aluminum;

To "process everything," they had to reduce the compaction ratio, resulting in large piles of loose aluminum scrap still remaining on the site after each shift.

Unstable Bale Density

The material type was mixed (fine aluminum chips, profile segments, and sheet scraps), and the old equipment lacked sufficient pressure, resulting in bales of varying density from the same batch of material;

During furnace charging, the smelting plant complained that "the bales are too loose and unstable for charging," affecting their downstream business relationships. High Labor and Energy Consumption Pressure

Operators need to frequently replenish pressure and repeatedly operate the press head, resulting in high labor intensity;

The hydraulic system is inefficient, with significant power consumption during idle and return strokes, leading to high overall energy consumption per ton of aluminum.

The company manager stated directly:

“We need a high-density baler that can truly withstand 630 tons of pressure,
one machine to solve the problem of 35 tons of scrap aluminum per day.”

III. Solution: Y81T-630 High-Density Metal Baler (2.0×1.75 m Compression Chamber)

After fully understanding the customer's site, feeding method, and downstream smelting requirements, a Y81T-630 high-density scrap aluminum baler machine was finally configured for them, with targeted adjustments made based on the aluminum material conditions. Key aspects of the solution are as follows:

Large Opening Compression Chamber, Adaptable to Various Aluminum Materials

The effective size of the compression chamber is approximately 2.0×1.75 m, with ample height space, allowing for direct feeding of large bundles of profiles, baled aluminum chips, and mixed materials;

The feeding method is compatible with various equipment such as grab cranes and dump trucks, reducing secondary sorting and cutting.

630-Ton Pressure for High-Density Aluminum Bales

The main and side pressure design ensures that even when used for aluminum materials, it can still form highly compact bales;

The weight of each bale is controlled to several hundred kilograms, which is convenient for forklift handling and also facilitates container stacking and furnace charging.

Production Capacity Matches the 35 Tons/Day Requirement

Under reasonable feeding and baling arrangements, the overall cycle time of the machine can meet the customer's daily processing needs of approximately 35 tons of scrap aluminum;

During peak periods, capacity can be further increased by extending shifts or optimizing shift rotations.

Optimized Energy Consumption and Operating Experience

The hydraulic system adopts an energy-saving configuration, reducing unnecessary flow and pressure output during idle and light-load stages;

The control system has multiple preset work programs, allowing operators to select automatic cycles based on the material type, reducing frequent manual intervention. IV. Customer Feedback: Cleaner Floors, More Compact Bales

After the equipment was installed and commissioned on-site in India and ran continuously for a period of time, the customer provided very direct feedback:

Production Capacity Meets Requirements, No Backlog After Compaction

The 35 tons of scrap aluminum per day can be processed during a single shift, and the height and area of ​​stacked materials in the factory have significantly decreased;

Even with increased new orders, there is no longer any concern about the packaging process becoming a bottleneck.

Bale Density and Size Are More Acceptable to Downstream Customers

High-density aluminum bales are neatly arranged in containers and trucks, approaching the target loading weight;

The smelting plant reported that the bales are "heavy, solid, and easy to feed into the furnace," and they are willing to accept goods based on bale weight, leading to more stable cooperation.

Reduced Labor and Electricity Costs

Operators are mainly responsible for feeding and strapping, and the situation of constantly "monitoring the pressure gauge and repeatedly adding pressure" has basically disappeared;

Comparing monthly electricity bills, the overall energy consumption for packaging the same tonnage of scrap aluminum is now more controllable.

The customer summarized it in one sentence:

"Previously, the material was waiting for the machine; now the machine is waiting for the material.
This shows that the equipment's capabilities have surpassed our needs."

V. Summary: Applicable Scenarios for the Y81T-630 High-Density Baler

Based on the performance of this Indian project, the Y81T-630 high-density metal baler is particularly suitable for:

Recycling plants, sorting centers, and upstream facilities of recycled aluminum smelting plants that process 20-40 tons of aluminum chips and scrap per day;

Companies whose downstream customers have specific requirements for bale density and size, and who want to improve efficiency in both container loading and furnace feeding;

Factories with sufficient space to accommodate a medium-to-large horizontal baler and who want to achieve their main production capacity with a single piece of equipment.

For similar customers, a reliable upgrade path is:

First, clearly define the daily processing volume, scrap material type, and downstream transportation methods;

Based on the target production capacity and bale size, select the 630-ton high-density equipment;

In the initial stages of equipment implementation, establish internal standards for bale weight and density to truly make the packaging process an "efficiency amplifier" for the entire scrap aluminum business, rather than a bottleneck.