Duracell – Case Study

Challenge: Duracell, the well-known battery maker, was using a vertical baler to crush industrial Super Sacks at its South Carolina location. The Sacks came to Duracell containing a black dust ingredient for producing their batteries. The Sacks no longer had a use so they were being baled to reduce the cost of hauling for disposal. However, as the bags were crushed in the baling process the black dust was being dispersed into the surrounding area. This caused a serious hazard problem to the workers. Duracell needed a cost effective way of containing the dust and keeping the bales from creating a black trail as they were transported to an outside dumpster.

Solution: Through an internal search of their parent company Procter&Gamble, the KenBay RotoPac industrial compactor was found to be used for compacting waste in polyethylene bulk bags in another location. Duracell learned that by merely placing a steel hood over the RotoPac, the dust could be contained as the Super Sacks were compacted into the bulk bags. Since the polyethylene bags could be easily sealed when filled, they could be transported without the dust causing a problem.

The RotoPac compacted approximately 80 dusty Sacks into a single bulk bag forming an approximate one meter cube, ideal for ease of transport. No longer did the compacting of the Sacks have to be performed in a separate room. Since the RotoPac has a footprint slightly larger than a standard pallet, the compacting of the bags could be done in the corner of a storage room. Another benefit achieved using the RotoPac was by customizing its input and extraction of the filled bag, making the process much safer.

Benefits: Increased safety, reduced hauling costs, and the elimination of the need for a separate room to compact Sacks. In all, a cleaner working environment.

Wardcraft – Case Study

Challenge: Matrix left from the manufacturing of labels is sticky and needs to be compacted without sticking to machinery in the process. Reduce compacting and labor costs of disposing of sticky matrix left from producing labels.
Solution: The RotoPac with Teflon® coated drum was installed to compact matrix being blown into it from two label making machines.
Result: The client, a maker of pressure sensitive adhesive (PSA) material for making labels, primarily for the pharmaceutical industry, was blowing the matrix material through plasma coated 12” pipes to a RotoPac.. The compacted materials produced about 750 lb bags of waste for disposal.

Statesman Journal – Case Study

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

Old Trail Printing – Case Study

Challenge/Solution: Paper trim coming off a Muller-Martini saddle stitcher is compacted into KenBay bags weighing approximately 1,000 lbs. when filled.

Maytex Mills – Case Study

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.

Konica/Minolta – Case Study

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.

Kidde Safety – Case Study

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.

General Bearing – Case Study

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.

Excelsior Medical – Case Study

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.

Bostik – Case Study

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.