Creative Labels, located in Gilroy, CA, has been in the business of producing high-quality labels for more than 35 years. The labels they produce are primarily for prime foods and beverages.
Label making generates a great deal of trim waste consisting of paper and plastic. When the label producing machines operate for what are generally 12 hour-days during busy seasons, considerable waste is produced. Prior to 2004, Creative Labels had to wind up the waste from their machines, stop the presses to remove the rolls and try to stomp down the waste to compact it somewhat before putting it into containers. That made it difficult, costly, and time-consuming to dispose of this waste. However, in 2004 when the KenBay RotoPac compactor became available in the US, Creative Labels installed one because it offered significant uptime on the printing presses, which saved time, labor and money.
Designed more than 20 years ago in Europe, the RotoPac was created to offer maximum waste compaction with a minimal footprint. This development was crucial to manufacturing facilities in Europe that were starved for space.
The RotoPac can provide 6-to-1 compaction in a 51-inch by 61-inch space thanks to its unique design: a distributor providing hydraulic power to a drum that is continuously rotated and swept.
The result is a commercial trash compactor designed for both simplicity and longevity, one that applies continuous waste compaction through higher-than-expected torque. It’s what we like to think of as the workhorse of the industrial waste compaction field. (more…)
You’re looking to save money in 2019. You’ve looked at seemingly every aspect of your business. But have you looked in the trash?
Improving your waste management practices can be a valuable way of cutting business costs and one way to do this is by investing in a commercial trash compactor.
Here are five ways installing one of these devices can save you money or even help generate revenue. (more…)
Improvements in the RotoPac
KenBay has recently made a number of significant enhancements and improvements to their worldwide workhorse industrial waste rotary compactor, the RotoPac to keep pace with changes in the marketplace. With increase demand over the last year, KenBay found it necessary to upgrade to a manufacturing partner who could meet the demand while continuing to upgrade, improve and enhance our compactors to achieve customer’s zero waste objectives.
The RotoPac was designed over 20 years ago in Ireland to provide maximum waste compaction (6 to 1) with a small footprint (51” x 61”) in the space-starved manufacturing facilities of Europe. This was achieved through the unique design of a distributor that provided hydraulic power to a drum that continually rotated and swept, ultimately applying continuous compaction to waste through higher than expected torque. The waste is compacted in polyethylene bags on average weighing over 500 lbs. Its design was made simple to use and maintain, delivering longevity of use.
Since its inception, thousands of RotoPac Industrial Waste Compactors have been installed worldwide, usually by repeat customers in various facilities and warehouse location because of the machine’s ability to deliver on it promises — achieving and exceeding its design goals. Many enhancements and improvements have been made over the years resulting in a range of compactors for many different applications and different environments. Our compactors are now made exclusively in North America for the global market.
Not all the enhancements and improvements made to the RotoPac over the past year can be shown in pictures. However, the following pictures show just one simple improvement where the electronic controls were separated from the hydraulics to reduce maintenance and improve accessibility to each.
Enhancements to the RotoPac
Many enhancements made to the RotoPac this past year that improve ease of use, longevity and operational integrity are listed below:
- Increased chrome hardening of distributor shaft and significantly improved seals
- PLC provides relay that allows the RotoPac to automatically synch up with other equipment such as a trim system or conveyor.
- UL Listed Panels to exceed standards
- 24 Volt DC control voltage
- PLC with HMI touch screen provides increased functionality
- User friendly simplified controls
- Powder coated paint throughout
- Category 2 Safety Circuit
- Interior 90 degree angles have been changed to eliminate dust gathering
- New push button station, which is now a PLC, is integrated into the main cabinet.
- Rear tower now descends to the floor for greater strength and stability.
- Rear cabinet doors have been redesigned for greater structural integrity.
Loading door hinges are behind walls to remove dust gathering on them.
Online shopping has exploded in the last decade. The instant gratification coming from purchasing products at home or at work has its consequences though. The ubiquitous cardboard boxes that appear on front steps throughout the country have to go somewhere when no longer needed. And with the economic downturn as of late in the value of recycled paper materials, cardboard recyclers have to get creative to improve their bottom line. Chinese buyers are getting pickier when it comes to contaminates in bales of cardboard, pressboard and general paper. The dilemma for manufacturing companies across the globe is to efficiently remove cardboard from their waste stream, economically compact it and provide recyclers with a clean product.
Whether it’s helping prepare cardboard for the recycling station or giving other great tips, KenBay is committed to providing key recycling solutions. We offer a wide range of compactors to you for cardboard and other kinds of waste. For more information, visit our website.
Let’s Witness Proper Cardboard Recycling
Saving Space in the Production Area
One of the world’s largest producers of medicine and vaccinations for pets and livestock recently started using the KenBay Industrial Trash Compactor and recycling unit for compacting their waste. As shipments come into the facility, boxes in which they come, are emptied before the incoming items are moved to the production area. Packaging is not permitted in the production area where animal medicines are made.
Reducing Packaging Collecting Costs
Prior to installing the RotoPac the cardboard boxes were broken down and placed on a pallet. At the end of each day the pallet was moved to the recycler’s truck by forklift. With the RotoPac, most of the boxes are thrown into it without having to be broken down manually; they are compacted into polyethylene bags.
Making it Cost Effective
Now the compacted cardboard, on average weighing 550 lbs. per bag, is moved to the recycler’s truck not having to break down most boxes and reducing the times the cardboard is moved to the truck, significantly reduces labor costs and improves safety in two ways.
Reducing Accidents and Forklift Traffic
Accidents are prevented by not having to use a knife for breaking down the majority of boxes and forklift traffic is reduced.
KenBay Helps Your Cardboard Get There
One of the best ways to recycle your cardboard is through our RotoPacs. RotoPacs not only are safe, easy, and offer continuous compaction, they deliver even more! They’re portable and very easy to move around your facility. You can put them right at the source of your cardboard waste. That way, you reduce clutter and improve overall safety even further. If you would like to try out a KenBay RotoPac for yourself, you can try one before you buy one. Simply pay a small fee and we’ll send one to your location. Best of all, there’s no complicated process if you want to keep it for life. Simply pay the rest of the full price, and it’s yours!
Do you have facility costs that you haven’t factored into your bottom line? Every production facility has waste. It’s unavoidable. But knowing how to adequately reduce its footprint, its hauling cost and potential for possible injuries can make all the difference in the world. If you have cardboard boxes coming into your production area filled with components or supplies and you are still breaking them down by hand, you have room for improvement. Cardboard is recyclable. It’s also messy if not properly dealt with at the point of taking out components. If you’re chasing after savings in your facility by parring down production costs, it might make sense to first examine how you are dealing with excess cardboard.
It’s Simple…Reduce Costs That Are Adding Up
Does dispersing components/supplies received add to the problem of disposing of the packaging materials in your plant? Some areas may be in foods or medicines processing areas where disposing of the packaging there is not permitted. Many locations that receive components/supplies may not have the space there, especially if it is expected to separate the trash from the packaging that can be recycled. In addition, unpacking on the production line may have an effect upon production.
What You Can Do to Reduce Facility Costs
An effective way to solve these problems may be to consider unpacking components where they are received. This can have a number of the following benefits:
- Save space in the production area
- Reduce the cost of collecting the packaging material
- Make it more cost effective in compacting for disposal of the packaging material
- Reduce traffic of persons and/or forklifts in the plant
KenBay has been providing companies with the ability to package the materials more cost effectively by reducing labor and achieving much higher compaction.
Turn to KenBay for a Better Compactor
There’s a lot of compactor options out there to reduce your facility costs. It may be tempting to think that bigger is better. But buying a large bulky compactor is no guarantee of power. Instead, why not try one of KenBay’s RotoPacs? The RotoPac is portable, so you can transport it easily across the floor to wherever you need. Put it right at the source of your waste for maximum effect. And you can bet that the RotoPac has a fantastic compaction rate! If you want to try out a RotoPac for yourself, visit our website to try one out for yourself. You’ll be impressed at it’s power . . . and your savings!
It All Started with a Cubic Yard Box
It won’t come as any surprise to most folks that bulk waste has high associated disposal costs. We’d like to share a story about a West Coast Aircraft Service Facility client of ours who serves the aircraft industry and the waste they produce is considered hazardous, which adds a whole additional level of complexity to the situation! The story begins with the switch to a Cubic Yard Box!
Jim Kirby supports a Paint Hangar Operations; the paint masking material contains chrome related primers and requires a Class 1 Fire Protection Unit. Their operations use a RotoPac® they rented from KenBay along with a 40 yard roll-off bin. The first round of compaction was done in 55 gallon metal drums, and shipped to their hazardous waste vendor in Tennessee for fuel blend. In addition, the larger materials would be compacted in the RotoPac and then shipped to a local waste vendor and then repackaged into a cubic yard box and ship to Tennessee for fuel blend. There were several associated costs with this approach, and as you can imagine, those costs quickly added up to a big expense.
One day their hazardous waste vendor made a change that sparked a huge savings for Jim’s company. They started requiring the waste be put into a hazardous waste rated cubic yard box instead of the drums and the cubic yard bags they had used historically. It was important to find the most efficient way to accommodate this change. Since there was already collaborative relationship with KenBay and they were already renting a RotoPac, it made sense to start with KenBay. Don Meis, the founder of KenBay spent time researching the new requirements and he presented a simple solution. There was a way to outfit the RotoPac so that it could compact waste directly into the cubic yard box.
The modification included the following:
- Remove the protection shield
- Stabilize the Unit to ensure the cubic yard box doesn’t move during compaction
- Use a shorter RotoPac drum
- Install guard rails to prevent the boxes from expanding as waste was compacted
That did the trick!
So their old process which required 55 gallon metal drums, a 40 yard roll-off bin, liners, transport to local waste vendor and finally shipping to Tennessee in a cubic yard box to fuel blend, was all reduced to onsite waste compaction indoors without exposing the environment to the hazardous waste, with better logistics, better security and lower costs!
We mentioned 83% savings. Can that be true? Let’s take a look at the numbers:
- For the first 6 months of 2015, the costs utilizing the 40 yard roll off and shipping to TN to fuel blend totaled $86,000
- For the second 6 months of 2015, the costs of using a customized RotoPac, compacting on-site and shipping to TN fuel blend totaled $14, 500
- An annual savings of $71,500!
The great part of this story is how they captured all associated costs and eventual savings as a result of making a few changes to their RotoPac compactor. How many of us pay the bills on a monthly basis without wondering how things could be done smarter and more cost effectively?
The costs for the old process came from various sources:
- 55 gallon metal drums
- The roll-off bin had to be kept outdoors, required a lid and regular maintenance and it took up a lot of physical space.
- Liners for the RotoPac
- Labor of transporting waste from paint operations to the outdoors where the 40 yard roll off was kept
- Pulls from the 40 yard roll-off bin cost $15 per pull and they averaged 10 pulls per year.
- Paying the hazardous waste vendor for the labor, fuel and materials required to put waste in a cubic yard box, blend and ship.
In 2016 Jim decided it was time to stop renting the RotoPac from KenBay and purchase it outright and he hasn’t looked back! Contact us at KenBay. Explain your specific sources of waste and we’ll recommend a process that is safe, efficient and cost effective. It would be our pleasure!
Water is wonderful. After all, we wouldn’t be able to live without it! But there are some places that we just don’t want to see water. Nobody’s happy to stumble upon a flooded basement, for example. Nor is it desirable to see enormous puddles in the yard. And of course, nobody wants to deal with excess water in their waste! Many manufacturers utilize dewatering equipment in order to keep their waste dry and easy to manage. But there are many other great reasons to do it that you may not know about! Here are 5 hidden benefits to employing more dewatering equipment in your waste management process.
For questions about dewatering equipment or anything else to do with your waste compactor, turn to KenBay. We are an experienced company dedicated to proper waste management. Our goal is to lead companies to follow a zero landfill initiative through easy, efficient waste compactors. If you want to know more about KenBay and our zero landfill initiative, visit our website.
Why You Should Use Dewatering Equipment
Ability to Recycle More
At KenBay, we like to talk a lot about reducing the amount of “air” put onto the truck. Well guess what? Water works the same way. The more water is held inside of your waste, the less waste you’re able to fit onto the truck. Use dewatering equipment to save space, allowing you to recycle more when you need to. And you save money as well!
Less Trash to Landfill
One of the great things about dewatering is that it opens the door for opportunities to recycle. When waste is dewatered, it is transformed into a dry filter cake. Usually, that cake makes the waste easier to transport and dispose of. But when the cake is non-toxic, it can also be reused for other purposes. Thus, less trash gets sent off to the landfill overall.
Ability to Separate Plastic Cap From Cardboard Container
Plastic and cardboard can work well together, but they’re not the easiest to get rid of. They must be separated first, and recycled separately. Dewatering equipment can handle it easily!
Don’t Pay to Ship Remnant Ingredients
Little bits of leftovers can get annoying. They’re too small to do anything with, but it’s not worth paying to ship them or dispose of them. Dewatering equipment makes it so you won’t have to worry about that problem anymore!
Cleaner Plant Environment
A clean environment is a safe environment. And having wet, nasty waste everywhere definitely does not make for a clean environment. Turn to dewatering equipment to destroy the sludge, keep things dry, and make your workers happy!
KenBay Can Dewater . . . and So Much More
For dewatering applications the SC 2000 and SC 3000 Screw Compactors provide continuous throughput and are configured for de-packaging/de-watering or for foam densifying. These screw compactors can be an integral part of a system that will make your facility landfill free. The SC 2000/3000 is a low maintenance heavy-duty piece of equipment capable of handling large throughputs of material while still maintaining a high compaction rate continuously throughout the operation.
The output from them is ready for delivery to a Waste-To-Energy (WTE) facility having extracted whatever liquids they contain. The Screw Compactors perform well for de-packaging:
- soft drinks
- BBQ Sauces and ketchups
- ice cream
- liquid soaps and detergents
- and much more
To learn more go to “SC 2000 & 3000 Screw Compactors”
Do you ever think about your compaction rate? Probably not. People don’t usually give much thought to handling waste. Most people just toss their waste away, and forget about it. But when it comes to using a waste compactor, it’s important to know your compaction rate. Obviously you want a better compaction rate in order to handle the waste quickly. But are there other benefits as well? Believe it or not, your compaction rate also affects your wallet. A higher one leads to better savings. A lower one could mean wasting more money than you meant to. Here’s what you need to know about saving money with your waste compactor.
For questions about compaction rate or anything else to do with your waste compactor, turn to KenBay. We are an experienced company dedicated to proper waste management. Our goal is to lead companies to follow a zero landfill initiative through easy, efficient waste compactors. If you want to know more about KenBay and our zero landfill initiative, visit our website.
How a Better Compaction Rate Leads to Cost Savings
It’s simple math: the more bags you use, the more money you spend purchasing replacement bags. Some compactors are so inefficient that you need to change out the bags far too frequently. Others cannot handle plastic waste very well. Plastic waste tends to retain its original shape, and resists compacting. But with the right compactor, none of this is a problem. You should simply toss it in and forget about it.
Don’t Ship “Air”
Another side effect of a lower compaction rate is that you end up shipping “air.” If you can’t compact your waste fully, then you’re filling the truck with empty space. It’s would be like if you simply hired a truck to transport only air to another location. A good compactor makes it so that you fill the truck with only waste. That way, you won’t require as many deliveries, and continue to save money!
Less Swapping Out of Bags, Less Foot Traffic
Of course if you are swapping out your bags less often, that means you won’t need to spend productive time moving bags off the plant floor. You also won’t need to spend time moving them around or across the plant floor. In addition to improving overall safety, you will save time because your people can be more productive! They’ll be able to get back to the tasks that really matter, instead of “wasting” it on waste.
Turn to KenBay for a Better Compactor
There’s a lot of compactor options out there. It may be tempting to think that bigger is better. But buying a large bulky compactor is no guarantee of power. Instead, why not try one of KenBay’s RotoPacs? The RotoPac is portable, so you can transport it easily across the floor to wherever you need. Put it right at the source of your waste for maximum effect. And you can bet that the RotoPac has a fantastic compaction rate! If you want to try out a RotoPac for yourself, visit our website to try one out for yourself. You’ll be impressed at it’s power . . . and your savings!