Challenge: Their production assembly floor was being clogged by large amounts of cardboard dunnage discarded from receiving components. Removal of the waste materials required fourteen trips daily to move and empty the full collection hoppers to the rear of the facility.
Solution: They installed a RotoPac and placed it at the source of the waste, right on their production assembly floor.
Result: Not only have they reduced the amount of trips necessary to remove the cardboard to one a day, but it has also resulted in annual saving of 50% more than the cost of the RotoPac.
Challenge: An outside dumpster took up space used for a shipping bay so the door was left open all year round for removing trash. Most trash came from packaging materials from copier machines from overseas. Much was Styrofoam packaging that had to be removed before the copiers were sent to retail stores.
Solution: Client Warehouse & Facilities Manager brought in a RotoPac, the original rotary arm compactor
Result: Freed up one shipping bay (allowing it to be available for deliveries), reduced labor costs and even cut cooling and heating costs. NOTE: Closer waste disposal allowed them to remove the dumpster from the shipping bay and return it to its intended use. Fork lifts deliver bags of compacted waste to the now-remote dumpster and the overhead door opens only when there is shipping activity in that bay.
Challenge: Dust from two separate facilities compacting 50-pound sacks containing resin. The dust needed to be contained within the compaction process.
Solution: Using the RotoPacs with hoods, during good production times, several people are feeding the 50lb bags into the RotoPac.
Result: It takes about 6 hours to fill one industrial waste compactor RotoPac bag. When full, a 4’x4’x4’ compacted bag weighs 475 lbs holds 800 (empty 50lb) sacks! It takes about 10-12 seconds for the RotoPac to compact 15 -20 sacks. NOTE: These numbers came directly from the customer.
Challenge: Compacting large volumes of waste that is collected 24 hours per day in small plastic bags.
Solution: Client recently purchased two RotoPac commercial trash compactors to replace vertical balers for compacting their waste.
Result: Their maintenance manager says his personnel love of the RotoPacs is because the industrial waste compactors are much less labor intensive and much easier to use. Therefore they compact considerably more waste in much less time.
Challenge: Required an alternative to balers for compacting corrugated paper to be recycled. Client felt vertical balers are too labor intensive to operate and require too much training.
Solution: They purchased two RotoPacs because the rotary arm compactors can sit near the source of the cardboard boxes being discarded. When the compactor bags are filled a forklift is used to move the 600 lb bags to a trailer provided by the hauler.
Result: This process saved labor costs in removing waste since it is compacted at the source. NOTE: They discarded balers in favor of RotoPac.
Challenge: Maker of luxury sea craft needed to reduce the number of workers associated with trash removal to reassign them to other tasks.
Solution: The RotoPac industrial waste compactor is situated at the source of the waste. At the plant they have placed two rotary arm compactors, the RotoPacs directly on the assembly line and one in the distribution center to manage the 60 tons of trash.
Result: Reduced disposal costs, labor hours and workplace accidents. Prior to this dumpsters had to be emptied eight to ten times a day by two forklift operators who emptied the smaller dumpsters into a larger open-top dumpster at a remote location. Now trips to the dumpster have been significantly reduced. Also an added benefit of reducing forklift traffic within the facility is that a safety concern has been alleviated. Client indicates that the RotoPac is easy to install and does not require a full-time operator like a baler does. They were able to reduce staff hours and pay for the RotoPacs within a year.
Challenge: Client had voluminous amount of paper products and improperly made filters. The extra paper accumulation was so bad that it was blocking their distribution docks by constantly transporting dumpsters to be emptied. They had 6 dumpsters throughout the plant that were being dumped 32 times per day.
Solution: Now the RotoPac bags are removed 5 or 6 times per day.
Result: By reducing the forklift travel they reduced the maintenance on their fleet, picked up more plant floor space to use in production and calculated $52,000 annual savings in fork lift operator costs.
Challenge: Removing and compacting their suppliers’ waste materials.
Solution: Client placed a RotoPac at “the source” which was along side packaging lines where cardboard boxes are thrown into the compactor.
Result: The boxes don’t need to be transported to the compactor and by placing the RotoPac on the shipping floor, it frees up a loading dock that other compactors would require, thus saving valuable space and person hours hauling waste.
Challenge: Components come into four production lines in cardboard boxes. Client wanted to recycle cardboard with minimum use of manpower.
Solution: Commercial Waste Compactors RotoPacs were placed at the head of each production line. As components come into productions lines, workers remove content and throw empty boxes into RotoPacs. When RotoPac bags are filled, a forklift operator removes bags and loads them into recycler’s truck. The cardboard is sold to a recycler with only labor involved is the forklift operator.
Result: This operation now saves much labor and while increasing the value of used cardboard.
Challenge: Matrix left from the manufacturing of labels is sticky and needs to be compacted without sticking to machinery in the process.
Solution: The client, a maker of pressure sensitive adhesive material for making labels, primarily for the pharmaceutical industry, was blowing the matrix material from two different machines through plasma coated 12” pipes to a RotoPac rotary arm waste compactor.
Result: The compacted materials produced about 750lb bags for disposal. NOTE: RotoPac drum is Teflon coated to address issues caused by pressure sensitive adhesive (PSA).
Challenge/Solution: Paper trim coming off a Muller-Martini saddle stitcher is compacted into KenBay bags weighing approximately 1,000 lbs. when filled.
Challenge: Time wasted using a baler to compact paper trim.
Solution: The RotoPac replaced a complex baler system the client had been using
Result: the process saved space, staff hours and money according to their distribution center manager. “We placed the RotoPac right on the floor by the stitcher-trimmer, which allowed us to eliminate the considerable length of the vacuum system that used to haul the waste to the baler one floor up.” The compactor allowed the client to not only minimize their waste but also permitted the newspaper to redirect the efforts of one worker from waste recovery at the baler to more productive work. NOTE: Part of Gannett
