Japanese Customer Case Study | 315-Ton Side-Push Scrap Metal Baler: Supporting a High-Standard Recycling System with Stable Production Capacity and High Consistency
Customer Background: "Stability and Consistency" Prioritized in the Japanese Recycling Industry

The Japanese scrap steel and recycled metal processing industry has a very distinct characteristic: it not only pursues high output but also emphasizes long-term stability, controllable processes, and consistent finished products.
The customer is a large Japanese recycling company, primarily processing mixed scrap metal, mainly steel scrap, and supplying materials to downstream steel mills/smelting companies. When expanding their processing line, the customer set three key objectives:

Increased output per unit time: Increasing hourly processing volume without significantly increasing labor costs.

More controllable baling consistency: Achieving more stable bale density to reduce secondary losses during transportation and furnace loading.

Equipment requiring "long-term reliable operation": Japanese sites place great importance on low failure rates, ease of maintenance, and responsive remote support.

Based on these objectives, we provided the customer with a complete solution for a 315-ton scrap metal side-push baler, and implemented it through an integrated approach of "process + equipment + operation and maintenance" before, during, and after delivery.

Key Challenges: How to balance compression efficiency and structural stability under mixed scrap steel conditions

Scrap metal baling is not simply a matter of "the more pressure, the better." In conditions where mixed scrap steel, offcuts, thin materials, and short pieces coexist, the factors that truly affect capacity and stability are often:

Uniformity of force distribution within the compression chamber: Uneven force distribution can lead to uneven bales, material jamming, unstable molding, and even increased oil temperature and impact.

Smoothness of side-push bale ejection: The side-push solution offers high capacity, but it is more sensitive to door structure, guidance, cylinder matching, and control logic.

Cycle time and power matching: Simply pursuing speed may lead to high temperatures, impact, and reduced seal life; while prioritizing stability may result in insufficient capacity.

Therefore, our design and service focus was on using a reasonable cylinder combination and control strategy to achieve the customer's goals of "long-term stable capacity + consistent finished products."

Solution: 315-ton main press + side press dual cylinders, combined with PLC automatic control and remote support

The core of this project's equipment lies in: the main press responsible for dense molding, the side press responsible for even material distribution and rapid shaping, and the side push for high-efficiency bale ejection. The specific configuration is as follows (final parameters based on customer selection):

1) Forming System: Main pressure 3150kN, side pressure double cylinders 1600kN×2

Main pressure cylinder: YG400/280, stroke 1250mm, nominal thrust 3150kN (315-ton class), 1 unit

Side pressure cylinders: YG280/200, stroke 1600mm, nominal thrust 1600kN×2 (double cylinders), 2 units

This combination is crucial for mixed scrap metal: the double side cylinders increase the "coverage" of compression within the chamber, reducing uneven compaction and rebound caused by localized accumulation; the main pressure ensures final density and bale stability, thereby improving transportation efficiency and downstream furnace stability.

2) Structure and Door Opening: Door cylinder and bale pushing cylinder ensure continuous side pushing

Door opening cylinder: YG220/160, stroke 1350mm, thrust 1000kN (100-ton class), 1 unit

Bale pushing cylinder: YG160/100, stroke 420mm, thrust 500kN (50-ton class), 1 unit

Bale discharge method: Side push out

The side push solution requires high demands on "door mechanism rigidity, hinge structure, and guiding accuracy". In this project, we focused on: the interlocking logic of the door opening and side pushing actions, the stability of the action under varying bale resistance, and ease of on-site maintenance.

3) Process Window: Chamber size and bale size cover multiple specifications

Compression chamber: 2000×1750×1200mm (L×W×H)

Bale size: (100～800)×600×600mm (L×W×H)

This means that customers can produce short bales to adapt to different transportation and handling conditions, and also produce long bales during peak demand to improve tonnage efficiency, ensuring business flexibility. 4) Capacity and Cycle Time: Approximately 140 seconds per cycle (no load), 5-9 tons/hour (steel scrap)

No-load single cycle time: Approximately 140 seconds

Production efficiency: Approximately 5-9 tons/hour (steel scrap)

During the acceptance phase, we use a multi-scenario verification method (thin materials/short materials/mixed materials) to clearly demonstrate to the customer that the capacity is not based on "ideal single material" specifications, but rather maintains a stable range under actual material fluctuations.

5) Power and Hydraulics: 74kW total power, 31.5MPa system, 3300L oil tank + water cooling

Total power: 74kW

Motor: YX3-225M-4, 37kW × 2, 1470rpm

Hydraulic pump: A7V-160, rated pressure 31.5MPa, displacement 160ml/r × 2

Oil tank capacity: 3300L (approximately 2800L hydraulic oil)

Cooling system: Water cooler with 12㎡ heat dissipation capacity

Power supply: 380V 50Hz 3P (customization supported)

In the Japanese customer's standards, "oil temperature control" and "long-term energy efficiency" are key factors in equipment evaluation. We use a large oil tank capacity and water cooling configuration to reduce temperature fluctuations, improve the lifespan of seals and pumps/valves, and ensure the equipment maintains stable and consistent operation under high-intensity working conditions.

6) Control and Operation & Maintenance: PLC automatic control + remote control, compatible with manual operation

Control method: PLC automatic control (with remote controller) / Manual

We recommend that customers use automatic mode for normal production, and manual mode for material changes, maintenance, and troubleshooting. The control strategy focuses on: action interlocking, abnormal shutdown protection, cycle time optimization, and remote support diagnostics, ensuring the equipment is not only "operational" but also "easy to manage and maintain."

Project Delivery Highlights: Delivering not just a piece of equipment, but a sustainable operating method

Many pieces of equipment "run" on the day of delivery, but the differences become apparent after six months. In this project, we focused on three key aspects of our service:

**Phase 1: Selection and Parameter Confirmation Based on Operating Conditions**
We don't just confirm pressure and dimensions; we also discuss the customer's material structure, target bale type, transportation methods, and on-site operating habits to avoid the problem of "parameters being suitable but the equipment being awkward to use."

**Phase 2: Integrated Debugging Based on "Cycle Time - Temperature Rise - Consistency"**
Instead of simply maximizing speed, we optimize oil temperature, impact, and molding stability within a reasonable range while meeting production requirements. This is the "long-term stability" that Japanese customers value most.

**Phase 3: Remote Support and Spare Parts Strategy**
We reduce downtime through remote control and fault diagnosis; we also provide recommendations for key wear parts and maintenance cycles, helping customers integrate the equipment into a standardized operation and maintenance system.

**Summary of Customer Value:** Stable Production Capacity, Consistent Bale Quality, and Controllable Operation and Maintenance

Through this 315-ton side-push baling solution, the customer gains not just a single improvement, but comprehensive benefits in three areas:

Production capacity is stable in the 5-9 tons/hour range (steel scrap), and can handle fluctuations in different incoming materials;

Bale formation is more consistent, making transportation, stacking, loading and unloading, and downstream furnace feeding more efficient;

The equipment has stronger sustainable operation capabilities: oil temperature control, action interlocking, and remote support make downtime risks more controllable.

**Why Choose Us: We Understand Equipment, and More Importantly, the "Real Operating Conditions" of the Recycling Industry**

The ultimate test for recycling equipment is its long-term performance under real-world material, operation, and maintenance conditions.
We insist on starting from the customer's operating conditions and developing solutions into a systematic engineering approach that is "deliverable, operable, and maintainable." This is especially true for the Japanese market: higher standards, longer cycles, and stricter requirements for reliability and consistency – which are precisely the advantages we have accumulated over the long term.