BALER FOR ORVERSIZED CARDBOARD BOXES: custom solution for the automotive sector
In the automotive sector, components are often transported in exceptionally large cardboard boxes. These packages can measure up to 4 meters in length, 2 meters in width and over 1.30 meters in height. Once emptied, they must be handled quickly and safely.
It’s an operational issue affecting industrial plants and recycling centers, particularly when it comes to handling and compacting oversized materials.
Il caso Magna Steyr – Saubermacher: cartone fuori misura, soluzioni su misura
One of the most concrete examples comes from the Magna Steyr plant in Graz (Austria), specialized in vehicle production for major international automotive brands, including Mercedes. Waste flow management is handled by Saubermacher Group, which chose to integrate a dedicated Macpresse solution into its facility to manage oversized cardboard that cannot be processed using standard compaction systems. A traditional baler with a 2,100 X 1,020 hopper is not sufficient: the cardboard gets jammed, slows the process, and increases system downtime.
The Macpresse Solution: Special Setup with Enlarged Hopper and Pre-Compactor Conveyor
To solve the problem, Macpresse designed a dedicated configuration:
- Flared XL hopper, with enlarged conveyor-to-press connection zone (up to 2.1 × 2 m), to easily receive irregularly shaped cardboard.
- Double pre-compactor conveyor: an inclined belt compresses the cardboard before the pressing chamber, allowing the processing of materials taller than 90 cm.
- Hydraulic press flap integrated at the bottom of the hopper: an automatic system that releases any cardboard stuck in the hopper, ensuring continuous operation.
The configuration installed at the Saubermacher site in Graz includes a flared hopper with an expanded loading area, designed to accommodate cardboard up to 4 meters in length. The line is completed by a pre-compaction conveyor system and a hydraulic press flap, which ensures continuous flow even with non-standard materials. In the picture: the MAC 111AS/1 baler in operation — reinforced structure, dedicated automation, and uninterrupted output, even with deformable or oversized packaging.
MAC 111AS/1 Baler: Automation and Flexibility for Bulky Materials
At the heart of the system is the MAC 111AS/1 baler, configured for unmanned operation thanks to its advanced automation. The machine can handle bulky and deformable materials while maintaining high compaction performance and consistent bale quality, reducing handling time and operational costs.
Automatic activation of the press flap: operating logic
The press flap is automatically activated when the system detects a blockage in the loading area.
If the hopper photocells are obscured—indicating the presence of cardboard—but the compaction ram completes two consecutive strokes without the stroke counter wheel registering any bale advancement, the PLC interprets the situation as a material flow interruption between the hopper and the compaction chamber.
In response, the system activates the press flap, which applies a downward force to clear the obstructed area and allow the material to enter the compaction chamber. Once the operation is complete, the compaction cycle resumes automatically.
For Every Oversized Box, a Tailored Response
The example from the automotive sector highlights a key principle of the Macpresse approach: every material requires its own solution. Custom engineering starts by listening to the client and results in actual modifications to hoppers, conveyors, and internal components — to ensure continuous operation even in the most complex cases.
Do you handle oversized packaging or complex waste in your facility? Contact us to evaluate a custom solution together.
