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- Case Study: Halter Recycling
Efficient, sustainable and quiet at Halter Rohstoff AG
“We now have one of the most powerful machines on the market.” Hans-Peter Kremer, Technical Developer at Thommen AG, is convinced that after an extensive selection process, choosing the fully automatic channel baling press HSM VK 12018 R-FU was the right decision. The machine from HSM is unbeatable in terms of robustness, efficiency and safety. However, during the search for a successor to a 20‑year‑old pre‑press flap baling press, Thommen AG encountered a number of surprises.
Thommen AG, with eleven locations, is one of Switzerland’s leading recycling companies. Its subsidiary, Halter Rohstoff AG in Biel, collects and presses pre‑compacted cardboard and loose plastic films. Annual volume: 25,000 tonnes. After 20 years in service, the large-format baling press at Halter was increasingly causing concern. Maintenance and spare parts costs had risen significantly, says Hans-Peter Kremer, so it was time for Thommen to look for a new baling press for the Biel site. Important criteria in the selection included machine robustness (static load, wear), occupational safety, energy consumption, wire consumption, noise level and maintenance effort – in addition to the technical competence of the future supplier and, of course, the price. After an intensive pre-selection, Technical Developer Hans-Peter Kremer had two suppliers on the shortlist and planned site visits. However, he reports that the first hurdles appeared even at this early stage. One supplier offered only very distant reference sites, while the second reference customer wanted to get rid of the machine and offered to sell it to Kremer during the visit. “None of this was ideal,” concludes Kremer today.
Company
Halter Rohstoff AG in Biel specialises in metal and paper recycling. It is a wholly owned subsidiary of Thommen AG. With around 80 employees, Thommen is one of the leading recycling companies in Switzerland.
Solution
Following a selection process, Halter and Thommen chose the HSM VK 12018 R-FU channel baling press from HSM.
Task
The central channel baling press with pre‑press flap at Halter had reached the end of its service life, and the company needed to find a replacement. The criteria for a new machine: machine robustness, occupational safety, energy consumption, wire consumption, noise level and maintenance effort, as well as the technical competence of the supplier and price.
Advantages:
- High in-house production depth at HSM with maximum
“Made in Germany” content - On-site presence – both during the project phase and for service
- Convincing reference customers, high technical competence during the project phase
- Cutting-edge technology offering operational advantages
- Product promises are contractually guaranteed
- Frequency-controlled drive saves energy and reduces wear
- Wire consumption reduced by 20 %
- Long service life of the machine
- Heavy bales optimise warehouse logistics
Convincing reference customers
Kremer became aware of HSM through an article in a recycling trade magazine and got in touch. He found a visit to the factory in Salem on Lake Constance “very impressive” – it clearly showed the high proportion of in-house production at HSM. “Made in Germany” is extremely important to the recycler and, above all, to his manager Dr. Tobias Thommen. Kremer also returned satisfied from several reference visits to HSM customers in southern Germany. At one site, he observed a large-format channel baling press from HSM that had been reliably pressing a constantly changing mix of materials for seven years. “I could see how well the machine performs under high everyday loads.”
Kremer was also able to “debunk some sales talk”. Market participants had told him that pre‑press flap machines were indispensable, but the reference visits demonstrated that HSM’s cutting-edge technology “works extremely well” and that the higher cost of a pre‑press flap machine could be avoided. Kremer’s verdict: “There is a lot of nonsense talked in the market.” He is convinced of the cutting-edge technology because it saves time and is cheaper to purchase.
“Based on our detailed market observations, the machine from HSM is unbeatable in terms of robustness, efficiency and safety.”
Hans-Peter Kremer
Technical Developer, Thommen AG
“HSM stands by its product”
Thommen insisted on setting clear contractual requirements for the new machine supplier. It wanted written agreements stating that the machine would be returned and penalties imposed if product promises (throughput capacity, bale weight, electricity consumption, etc.) were not met. Only HSM was willing to agree to these guarantees in writing. This confirmed to Kremer that “HSM stands by its product and the performance it advertises.”
These product features were precisely why Thommen ultimately ordered the HSM VK 12018 R-FU (120 tonnes of pressing force, 180 cm filling opening length). Kremer describes the system as durable, robust and efficient. The HSM press has low operating costs (energy, wire) and runs smoothly. It also meets all current occupational safety regulations. Overall, this results in “excellent value for money”.
Savings in wire and energy costs
Previously, bales at Halter were tied vertically with five wires, but now only four wires are used – with the same wire thickness. Saving: 20%. A fifth wire can be added easily and quickly for certain materials. The Swiss operators also opted for a stepless frequency-controlled drive for the HSM VK 12018. Combined with HSM’s pump concept, this results in significant energy savings of around 50,000 kWh/year under continuous operation compared to the old uncontrolled drive. With this combination, the HSM machine already meets energy efficiency class IE4, says Kremer – even though IE3 only becomes legally required in 2017. Kremer: “The HSM press is essentially one step ahead of legal requirements.” Thommen calculates that energy savings over a 20‑year machine lifetime correspond to one third of the purchase price of the new press. “For a major energy consumer, the savings achieved with this machine are remarkable,” says Kremer.
He also appreciates that the HSM product is consistently designed for longevity. Its stress-free cardan suspension of the press cylinder prevents tension and misalignment, making expensive cylinder replacements unlikely. Additional wear plates made from high-strength XAR500 steel allow for plate replacement only – though Kremer does not expect this to be necessary: “For our materials, the plates will last 30 years.” Nevertheless, he values the fact that Halter is equipped for heavier wear should the material mix change in future. Logistics also benefit: with the same bale dimensions, the new bales are around 150 kg heavier than the previous ones, meaning lorries can be loaded more quickly. Kremer: “This reduces storage volume, loading time and overall handling effort.”
More space in the hall
The collaboration with HSM during the project phase through to acceptance is described by the Swiss recycling company as “professional and passionate”. HSM approaches its work “with great dedication” and with creativity. For example, HSM proposed relocating the machine within the hall when switching to the HSM VK 12018, allowing Halter to gain additional space.
In the months following commissioning, the HSM customer in Biel has experienced no significant disruptions. Minor issues were “sorted out in no time”, says Kremer. And if a problem does occur, it can be resolved quickly – either through the remote maintenance function via the internet or through HSM’s extensive on-site service network. This reassures Kremer: “It is very important for us that the supplier guarantees short response times.”
11/2016
1200 kn
1100 kg
