1. GLASSWRAPBALER PROJECT
Problem:
The Glasswrap O.D.wrapshop producesexcess paper wasteduring production,itis notonly
costly dueto the frequent trips to the waste facility but is also a risk foremployees workingin the plant
due to trippingand other injuries that canoccurduringproduction.
Solution:
Inmy opinion a baler offersthe adequate solution to this issue. A trash compactorwas
originally thoughtupas a solution but dueto higher costs,and a lower income dueto the current
economic downturn.A baler is a muchbetter fit forcurrentconditions.A baler has a higher compaction
ratio (6:1 vs.5:1 or4:1) than a standardram style compactor.This fact,the lower costof a baler, and the
simplicity ofit make it a perfect choiceforwhat is needed currentlyin the Glasswrapfacility
ComparisonChart:
The following chartshowsdifferent compactorandbaler choicesshownforcomparison. The
compactorsolutionwas notpursueddue to the currenteconomic conditionsbut also for the reasons
previously stated.
Compactors Total Cost Type Warranty Cycle Time Crushing
Force
Compaction
Ration
Installation
Costs
Sani-Tech 63,130$ Electric
Auger
2 year
warranty
Continuous 295000
lbf
5:1 2725$
Nedland
Industries
22,460$ Hydraulic
Ram
-3 year
structure
-5 yr
power
unit
-6 month
labor
50 sec 65000
lbf
4:1 --------
Ram Force 37,810$ Hydraulic
Ram
5 year
frame
5 year
ram
57 sec 76,960
lbf
4:1 ----------
Sebright
Products
Inc.
25,069$ Electric
Auger
5 year
frame
5 year
ram
Continuous 76,960
lbf
4:1 2000$
2. Baler
Company/
(New or
Refurb.)/
Model
Bale
Dimensions/
Bale Weight
Type Cycle
Time
Crushing
Force
Opening
Size
Unit Cost Shipping
Costs
Installation
Costs/
Training
Costs
Warranty
Brute /
(New)
/
30X30X30
15.625 cu.
ft.
1250lbs
Horizontal 46
sec
220,000
lbf
26x24 25,000$ -------- ---------- -----------
Harmony
Itnl/
New
/M60STD)
30x60x51
53.1 cu. ft.
1,100lbs
Vertical 45
sec
56,550
lbf
60X24 9,995$ 1350$ 1200$ 1 year labor/
2 year parts /
3 year
structural
Harmony
Intl /
Refurb. /
CEB-602
60x30x44
45.83 cu. ft.
900-1100
Vertical 45 62,202
Lbf.
60x21 7,500$ -------- -------- 1 year
equipment /
6 months
Labor
PTR
/ New /
3400 HD)
60X30X48
50 cu. ft.
up to
1100lbs
Vertical 56
sec
84,822
Lbf.
60x27 10,250$ 2750$ Included
w/
shipping
quote
-1 year
parts and
labor
-3 year
major
components
PTR
/ Refurb.
/
3400 HD)
60X30X48
50 cu. ft.
up to
1100lbs
Vertical 56
sec
84,822
Lbf.
60x27 7,450$ 2750$ Included
w/shipping
quote
-3 months
on Cylinder
-3 months
on Parts
IDS
/ New /
V60-30HD
60x30X44
45.83 cu. ft.
700-1050 lbs
Vertical 45
sec.
56,520
lbf
60 X 28 12,494$ 1400$ -------- ---------
Cram-A-
Lot /
Refurb. /
DBR-72H)
72x30x48
60 cu. ft.
1600 lbs
Vertical 77
sec
92,350
lbf
72x24 6,400 1050$ 1850$ As is/No
Warranty
Harris /
New /
VS-HD-15
60”x30”x48”
50 cu. ft
Vertical 50
sec
56,550 60x27 8,950$ ----- ----------- -----------
3. 900-1000
lbs.
Calculations:
Currently the waste containeroutside the GlassWrap plant measures roughly5’ x 7’ x 22’.This
gives us a total volume of 924 cubic feetor 34.22 cubic yards.Inorder tocalculate roughly how much
waste is being producedper day; the followingcalculations/observations weremade. Goinginto the
cureroom many piles ofwaste paper wasseen onthe floor. Fromthis an average pile was selected for
measurement. This pile looked to be the waste from3-4processed joints.This canonly be observed
from personal experience workingwith the waste. I believe that this is a fairly accurateestimate. The
pile gave the followingmeasurements 5’ x 5’ x 2.5’.The pile formed roughlyin a pyramid shape.
Therefore; we canestimate the followingvolume by getting the volume of that shape withthe
mentioned dimensions. The volume wascalculated to a total of 20.83cubic feetor.7716cubic yards.
This gives us a total of.7716 cubic yardsevery 4 joints. Now the average number of9 5/8joints ran per
day varies from 60-70 per run.We will use65 joints as the average number ofjoints ranper day to
continuethe calculation. The next step is to divide the number ofjoints by four,sincethis is the
number ofjointsto whichthe volume was calculated. In doingthis we will get an approximate value of
16.25.Thenit is a matter of multiplying the result by .7716 cu. as this will give usthe total estimated
volume per run.Oncethis part was done,the next calculation to be made was findingthe weight of the
paper waste being generated. Forthis calculation the following wasdone. Onefoot ofepoxy
embedded waste was cutoffand weighed throughasmall scale w/a+/- .01 gram tolerance. The 1ft
section weighed 11.5grams. Then this weight per footwas multiplied by the total length in feet used in
craftpaper per month. To find the total length ofpaper used the followinglogic was. First ofall, the
advanceof the wrapwas measured with a tape measure; the length was3.75 inches.Then this number
was convertedto feet and then divided by the total length of a joint. The mostcommon jointsize
coated at Glasswrapis the 95-8, range 3,joint.Its length was usedin this calculation. The approximate
length is 42 ft. Bothends ofthe jointhave 4.625inchesof thread area so the wrappedsurfacelength is
actually 32.75 ft. By dividing the surfacewraplength by the wrap advanceof3.75”. We get to 104.8
wrapsfor the 95-8 ODsection. This means each jointhas 86.528 feet ofcraftpaper used to coverit.
This number is now multiplied by 65, whichis the average number ofjoints in a day. Then wescale the
number ofrunsin the whole month andwith this we get the final number of112,486.4 ft. Theweight
cannow be calculated, by multiplying the total length by the weight per footmeasured at 11.5grams
and convertingthat weight topounds.With this calculation we get 2851.53lbspoundsor1.42 tons.
Fromhere the final calculations are those associated with costsmade by waste management. These are
the coststhat S.O.S., the waste facility currently in use,charges us.Their chargesadd upas follows.
S.O.S.charges 175$ per trip, 36$ per ton,and charge19 percentof the total waste shipping charges.
This is every time ourwaste is hauled offand disposed of.Fromthis calculationa final evaluation canbe
finally made and an adequate baler canbe selected fromthe now present data obtained. Below are the
formulas andfigures used in this process.
Formulas,Figures/Calculations
6. 1250lbs
Bale toNon-Bale Waste Comparison
2,851.53/1250lbs
2.28 bales to cover1 month’suse
= 34.23 (containersize in cu.yds.) / (30x
= 59.149bales fit in container
= 59.149/2.281
=25.931 months’worthofbales, before waste haul
Waste Trip Charges
2*269.0828
538.1656
3*269.0828
807.2484
538.1656-807.2484perweek
2152.6624-3228.9936permonth
25831.9488-38747.9232peryear
Savings
25.931 monthsbetweenwastetrip
55,820.626$-83,731.033 $ savedbetweenwastetrip
Time to Break Even Point
2.322-3.48 Months
Up to4 monthsfor Break even
Harmony Intl (New)
M60STD
7. Bale Weight
1100lbs
Bale toNon-Bale Waste Comparison
2,851.53/1100
2.5923 bales for1 month’swaste
= 34.23/(30*60*51)
= 34.23/(2.5*5*4.25)
=34.23/(1.967)
=17.40 bales will fit beforecontainer is full
=17.40/2.5923
=6.7121 months’worthofbales before wastehaul
Waste Trip Charges
2*269.0828
538.1656
3*269.0828
807.2484
538.1656-807.2484perweek
2152.6624-3228.9936permonth
25831.9488-38747.9232peryear
Savings
6.7121 monthsbefore waste trip
14,449-21668.32$savedinbetween waste trip
Time to Break Even Point
3.09-4.64monthstoBreak Even
Up to5 months to break even
8. Harmony Intl (Refurb.)
M60STD
Bale Weight
1100lbs
Bale toNon-Bale Waste Comparison
2,851.53/1100
2.5923bales for1 month’swaste
= 34.23/(30*60*44)
= 34.23/(2.5*5*3.66)
=34.23/(1.694)
=20.206 baleswill fit before container is full
=20.206/2.5923
=7.794 months’ worthofbales before waste haul
Waste Trip Charges
2*269.0828
538.1656
3*269.0828
807.2484
538.1656-807.2484perweek
2152.6624-3228.9936permonth
25831.9488-38747.9232peryear
Savings
7.794 monthsbefore waste trip
16,779$-25,166$ savedin between waste trip
Time to Break Even Point
2.32-3.48 months
10. Time to Break Even Point
3.17-4.76Months
Up To5 months forBreak Even
PTR Baler (Refurbished) 3400HD
Bale Weight
1100lbs
Bale toNon-Bale Waste Comparison
2,851.53/1100
2.5923bales for1 month’swaste
= 34.23/(60*30*48)
= 34.23/(5*2.5*4)
=34.23/(1.851)
=18.492 baleswill fit beforecontainer is full
=18.492 /2.5923
=7.133 months’worthof bales before waste haul
Waste Trip Charges
2*269.0828
538.1656
3*269.0828
807.2484
538.1656-807.2484perweek
2152.6624-3228.9936permonth
25831.9488-38747.9232peryear
Savings
11. 1401.1-2521.98$ permonth
Up to30236.76$ peryear
Time to Break Even Point
2.30-3.462months
upto 4 monthsfor breakeven point
IDS Baler V-60-30HD
Bale Weight
1050 lbs
Bale toNon-Bale Waste Comparison
= 2,851.53/1050
= 2.715 bales for 1months waster
= 34.23/(60*30*44)
= 34.23/(5*2.5*3.66)
=34.23/(1.694)
=20.206/2.715
= 7.44 months’worthof bales before container is full
Waste Trip Charges
2*269.0828
538.1656
3*269.0828
807.2484
538.1656-807.2484perweek
2152.6624-3228.9936permonth
25831.9488-38747.9232peryear
12. Savings
Up to7.44 monthsbetween trip
16,015-24,016perwastetrip
Time to Break Even Point
3.869-5.80 months
upto 6 monthsfor breakeven point
Cram-A-Lot DBR-72H
Bale Weight
1600lbs
Bale toNon-Bale Waste Comparison
2,851.53/1600
1.78bales for1 monthswaste’
= 34.23/(72*30*48)
= 34.23/(6*2.5*4)
=34.23/(2.222)
=14.50
= 8.146months’worthof bales before container is full
Waste Trip Charges
2*269.0828
538.1656
3*269.0828
807.2484
538.1656-807.2484perweek
13. 2152.6624-3228.9936permonth
25831.9488-38747.9232peryear
Savings
Up to8.146monthsbetween waste trip
17,535$-26,303pertrip
Time to Break Even Point
1.98-2.97monthstobreakeven point
upto 3 monthsfor breakeven point
Harris
Bale Weight
1000lbs
Bale toNon-Bale Waste Comparison
2,851.53/1000
2.85bales for1 months waste’
= 34.23/(60*30*48)
= 34.23/(5*2.5*4)
=34.23/(1.851)
=18.492
= 6.488 months’worthof bales before container is full
Waste Trip Charges
2*269.0828
538.1656
3*269.0828
807.2484
538.1656-807.2484perweek
14. 2152.6624-3228.9936permonth
25831.9488-38747.9232peryear
Savings
Up to6.488 monthsbetween waste trip
13,967-20,949.336$perwastetrip
Time to Break Even Point
2.77-4.15monthsto break even
upto 4 monthsfor breakeven point
FinalSelection
Aftercareful comparisonsandexaminations. The baler that wouldworkthe best in the current
situation woulda Cram-a-lot model DBR-72-BHbaler. This baler has the following characteristics that
surpassthe competition. First of all, the pricing is the lowest ofall the currentbaler options. With the
currenteconomic conditionsthis makes it attractive. The baler is also rated at the secondhighest
compressive forceof92,350 lbf;making bales of 1600 lbs. This has the heaviest bales made fromall the
other balers. This means it cancompactmaterial tighter and more time canbe spent w/outhaving
S.O.S.services making trips and addingto costs. The low price ofthe baler will lead to a faster
breakeven point and will start generating revenue faster. This baler also has the biggest opening for
waste at 72 incheswide. With the large amount ofvolume that the paper waste takes inside the plant,
the larger openingwill workmore efficiently in these circumstances. These reasons put the DBR-72-BH
baler ahead ofthe other baler models and in this selection processmakes it the best choice.
