Ecogen is one of the UK’s fastest growing recycling companies; with throughput increasing by as much as 10% month-on-month, it was clear that new plant was needed to maintain momentum.
With the focus placed firmly on ongoing expansion, the Ecogen team specified a Presona LP 65 VH K2 cross tie baler to increase material processing speeds and bale density, adding an essential degree of futureproofing for this forward-thinking company.
The new baler has increased Ecogen’s processing capacity from 8 tonnes to 22 tonnes an hour, an improvement which the company says will enable them to become even more competitive when it comes to commercial waste purchasing.
Founded in 2010 by managing director William Nicholls, Ecogen moved to its current location in Alresford, Hampshire in 2015. The company regularly processes up to 3,000 tonnes of paper, card and plastic a month, all from commercial sources.
Ecogen takes post-manufacturing material from customers located throughout the UK, working with organisations in a range of sectors including automotive and food packaging.
It also works with waste management companies of all sizes and often processes, aggregates and trades material from smaller organisations to optimise quality and maximise value.
In addition, Ecogen provides a shredding service, an area which is experiencing huge volume growth and is being extended as a result of the plant’s expansion.
‘We needed a new baler to increase capacity’
Ecogen bought its first Presona baler when it moved to the Alresford site two years ago. The LP50 prepress baler was used to bale cardboard, paper, plastic and shredded paper.
“It was reliable and worked well – in fact it still does,” said Ecogen operations manager Toby Mottram, “but we always had an eye on increasing throughput speeds to allow us to expand on this site.”
The Ecogen team started to look for a new baler which would increase throughput and bale density. The Presona LP 65’s vital statistics proved impressive. (See baler information at the bottom of the page.)
“We wanted the new baler to deliver even better compaction rates, provide increased cross ties to accommodate densely packed plastic film, and give us faster throughput rates,” explained Toby.
Average bale weight up 20%
“Our original LP 50 prepress baler produced a standard bale weight of 350-400 kg with plastic film. The new Presona LP 65 baler has increased this up by 35% to an average of 550 kg.
“In fact, we have processed a bale of cupcake skeletal waste at 860 kg and our average cardboard bale is now between 600 and 700 kg.
“We’re now running tests to see just how far we can increase our bale tonnage,” he said.
Denser bales increase container rate
Based on an average 500 kg plastic bale, Ecogen has increased its container rate from 18-20 tonnes up to 24 tonnes, reducing logistics costs and making the company’s whole process more profitable.
“In addition, we are now able to process material much quicker. As we operate on a small site this is critical. We do up to 20 containers of cardboard a week,” said Toby.
A new life for the old LP 50 baler
Initially, Ecogen had planned to trade in its old LP 50, but the team was reluctant to let go of this trusty baler which, in reality, still has many, many years of operation to come.
“With the help of Presona’s engineering team, we’re moving the LP 50 prepress baler to a new building where it will become part of a dedicated paper and shredding line,” explained Toby.
Why did we choose Presona?
Ecogen MD Will Nicholls said: “We had a Presona previously and we knew they performed well. We looked at all of the other options such as a twin ram or a shear baler, but the Presona prepress baler was the best machine to provide the level of compaction required.
“The new baler will facilitate our ongoing rapid growth, giving us the capacity to increase tonnage further.
“We also know that the Presona team will work hard for us, ensuring that everything is working as it should be week in, week out.”
About the LP 65 VH K2 baler
There’s no disputing that this is a baling beast ideally suited to high volume recycling, waste management and logistics/retail locations.
The details below provide typical minimum and maximum specifications for the LP 65 VH K2
Actual capacity (max m3/h): 370
Theoretical capacity (max m3/h): 940
Motor size (kW): 45
Output (tonnes/h): up to 22t
Feed opening (mm): 1500 x 1100
Press force (tonnes): 65t main press / 25t prepress
Bale size (mm): 1100 x 750 x variable length
Bale density, paper (kg/m3): 575
Weight (tonnes): 21
- Energy Efficient operation
- 5 vertical needles and 3 horizontal needles
- PREMI HMI system for operational control and monitoring