How a baling machine handles cardboard and film

A baling machine compresses loose cardboard, film or paper into compact bales, making handling and recycling easier. This process saves space and helps to organise recycling streams within a warehouse or factory.

For example, with the TONNA E60, open the upper door, load your material and close it; the platen then lowers automatically. Repeat until the machine indicates the bale is full. Tie the straps while the platen is down to keep the bale compact as the platen rises, then remove the bale, standing to the side of the doors.

Each time you load material and close the door, the baler compresses a new layer onto the previous one. For a flat, stable bale, spread cardboard or film evenly across the chamber before closing the door. If material is dropped into one corner, the bale may lean and be more difficult to stack.

Large boxes do not need to be cut up; simply fold or flatten them. Film tends to spring back more than cardboard, so tie a film bale tightly while the platen holds it. A film bale is also heavier for the same size: on the TONNA E60, 40–60 kg for film compared to 30–50 kg for cardboard.

The HSM V-Press 605 eco features a bale ejector that pushes the finished bale out of the chamber, reducing manual effort. On balers without a bale ejector, you tip the bale onto a pallet or a pallet truck. In both cases, stand to the side of the doors when removing the bale, as the compressed material will expand.

Selecting a baler machine by pressing force and bale weight

Baler machines are categorised by pressing force and bale weight. Compact vertical balers in the cardboard baler subcategory offer a pressing force of 3–5 t and maximum bale weights of 40–80 kg. Medium vertical balers provide 5.7–12 t and maximum bale weights of 70–100 kg. Large vertical balers, such as the TONNA45 and V-Press 818 plus, deliver 18.5–45 t and maximum bale weights of 150–450 kg.

Begin by considering the amount of waste you generate each week. A small shop or office with a few boxes daily will find a compact baler sufficient; a warehouse or supermarket with daily deliveries will benefit from a medium baler; a distribution centre or production facility with high volumes of cardboard should consider a large baler like the TONNA45 or V-Press 818 plus. Higher pressing force and heavier bales mean fewer bales and less handling for the same amount of waste.

Handling finished bales is another important factor. Bales weighing 40–80 kg can be moved with a hand truck. Heavier bales, such as the 200 kg bales from the V-Press 818 plus or up to 450 kg from the TONNA45, should be placed on a pallet and moved with a pallet truck or forklift. Always plan how you will move and store bales before selecting your machine.

Check your building’s power supply before choosing a baler. The TONNA E60 operates from a standard 230 V socket; the HSM V-Press 605 eco requires 400 V, which is a three-phase socket. A bale ejector, as found on the HSM V-Press 605 eco, reduces manual handling where staff process many bales each week.

Summary table of recycling equipment types

The table below shows the main types of recycling equipment in this category, listing models, pressing force and bale weight for each type.

To use the table, first match the equipment type to your waste. Waste already collected in bins suggests a bin press, while sorted cardboard or film for recycling is suited to a vertical baler. If you require packing material, consider the cardboard shredder models. Compare pressing force and maximum bale weight with your waste volume and the equipment you have for moving bales. For instance, if your team uses a hand truck, compact balers with lighter bales are practical; if you have a pallet truck or forklift, larger balers with heavier bales may be more suitable.

Bin presses as waste compactors for standard bins

Bin presses such as the TONNA bin press 240L and TONNA1100 are waste compactors for standard 240-litre and 1100-litre bins. They apply a pressing force of 2 t or 3 t to reduce the volume of waste in the bin.

A waste compactor is suitable for small quantities of cardboard or mixed packaging in bins. For larger amounts or when bales are needed for recycling, a baler machine is the better option.

With a bin press, waste is compacted inside the bin itself: a plate descends into the bin, so you can continue using your standard bins and each holds more before emptying. This arrangement is ideal for workplaces where waste is already collected in these bins, such as small warehouses or retail stockrooms.

The collection company empties the same bins as before, so your waste handling routine remains unchanged. A bin filled with compacted waste is much heavier than one with loose waste. Always check the bin’s weight limit and confirm with the collection company if they accept compacted bins: the truck’s lifting mechanism has a weight limit, and tightly compacted waste may not fall out when the bin is tipped.

Unlike a baling machine, a bin press does not produce bales to tie or store. The waste stays in the bin and is collected as usual. You do not get tied, sorted bales for a recycler to collect or pay for, but each bin holds more, so it needs emptying less often.

What to put in a baler machine and what to keep out

A baler machine is intended for clean, dry cardboard, film and paper. Only one type of material should be loaded per bale for recycling.

Do not place food, wood or metal in the baler. Keep a separate bin next to the baler for items that must not go in, so no one is tempted to press them with the cardboard.

Before loading cardboard into the chamber, remove anything that is not cardboard: wooden pieces, metal, foam and plastic strapping bands. These can damage the baler or reduce the bale’s value for recycling. For film, keep stretch film and shrink film separate from cardboard. Some recyclers also require clear and printed film to be kept apart, so check with your recycler before mixing them in a bale.

Keep cardboard dry before baling: a wet bale is heavier, may begin to rot and could be rejected by the recycler. For example, if boxes have been stored outside and become wet, allow them to dry before loading them into the baler.

Bale size, tying and handling from a recycling baler

A recycling baler such as the TONNA E60 produces a bale measuring 70 × 50 × 70 cm, weighing 30–50 kg for cardboard or 40–60 kg for film. The shop supplies textile strap for tying bales, 16 mm wide and 340 m per roll.

Bales can be stacked and stored ready for collection by a recycler. When placed upright, a TONNA E60 bale of 70 × 50 × 70 cm fits twice on a EUR pallet of 120 × 80 cm. This makes it easy to move bales around the warehouse with a pallet truck. When stacking, always place the heaviest bales at the bottom and do not stack higher than is stable. Keep a brief record of the bales produced, noting the material and date, so you know how many are ready when arranging a collection.

Always store bales in a dry area, away from sources of heat. Compacted cardboard is flammable, so do not keep bales near heaters or electrical panels. Label each bale or stack with its material, such as cardboard or film. This helps the recycler load them quickly without sorting and prevents mistakes that could lower the bale’s value.

Cardboard shredders for producing shipping padding

Cardboard shredders are used to convert used boxes into padding material for shipping. The cardboard shredders subcategory includes four models: GREE XS, GREE ES, HSM ProfiPack C400 and ProfiPack P425.

To create shipping padding, flatten used boxes and feed them into the shredder’s slot. The machine processes the cardboard into padding that fills gaps and wraps goods in shipping cartons. The working width is 420 mm on the GREE XS and 422 mm on the GREE ES, and both machines trim wider board, so you do not need to cut larger boxes to size before shredding.

Always use clean, dry corrugated cardboard and remove any metal or plastic parts before shredding. Position the shredder where incoming boxes are unpacked and outgoing goods are packed, so boxes do not need to be moved twice. Each box reused as padding is one less in the waste, and you save on buying new packing materials for shipping.

When recycling equipment is cost-effective

Recycling equipment is cost-effective when your business generates cardboard or film daily and bins fill up quickly. If you pay for frequent bin collections, a baler machine or a waste compactor reduces the number of collections, as compacted waste, whether baled or in the bin, takes up much less space.

Loose boxes and film also occupy valuable storage space in the warehouse. With waste recycling equipment, clean, sorted bales are kept together until a recycler collects them.

To assess whether recycling equipment is worthwhile for your business, calculate your current costs. Add up the number of bin collections per month and their cost, the floor space taken by loose boxes, and the time staff spend flattening and moving cardboard. Compare this total with the price of the machine and strapping, and with the value of the bales if a recycler pays for them.

Clean, sorted bales are valuable because recyclers often collect them free of charge or pay for them, depending on the market price for cardboard or film. This is different from mixed waste, where you pay for every collection. For example, a business producing bales of clean cardboard can arrange regular collections and may receive payment per metric ton collected.

Loose cardboard around the premises is not just a space issue: it is a fire risk and a trip hazard. When baled and stored in one place, away from heat sources, the same cardboard is controlled and the floor remains clear.

Space, height and electrical requirements

Before installing recycling equipment, check there is enough space in front of the machine for loading and bale removal. A vertical baler such as the TONNA E60 requires room in front and above the doors for safe use. The machine itself measures 83 × 70 × 193 cm and must be installed in a closed, dry area.

The correct power supply must be available where the machine will be located: 230 V for the TONNA E60, 400 V for models like the HSM V-Press 605 eco. If there is no three-phase socket, an electrician will need to install one before the machine is set up.

When planning installation, check the ceiling above the machine for beams, pipes and sprinklers, not just the total height. Make sure nothing obstructs the baler’s doors when they open. For example, in a warehouse with low-hanging pipes, you may need to choose a location where the doors can open fully.

The floor beneath the machine must be level and strong enough to support both the machine and the bales stored nearby. If the floor is uneven, the baler may not operate correctly or could be unsafe. In a packing area, check that the floor does not slope and that there are no drains or steps where the machine will be placed.

Plan two routes before the machine arrives. First, the route in for the baler: measure all doors, lifts and corridors the machine must pass through. Second, the route out for the bales: ensure you can move bales with a pallet truck or forklift from the machine to storage and then to the collection point. For example, if the baler is installed upstairs, check whether the lift can accommodate both the machine and the bales.

The best location for the baler is close to where boxes are unpacked and also near the collection point outside. This minimises the distance staff need to carry waste and move finished bales.

What a recycler requires from a bale

A recycler will accept bales of a single material, clean and dry, and a well-tied bale remains intact during handling and transport.

Heavier bales mean fewer trips to the recycler: the same weight of cardboard leaves as fewer bales and fewer loads. Check which bale weights your recycler accepts before selecting a machine.

Before ordering a baler, ask the recycler about their requirements. Find out which materials they accept, the bale size and weight they require, whether they collect bales loose or on pallets, and the minimum quantity they will pick up. Also ask if they take film and paper as well as cardboard, so one recycler can collect all your bales.

Clean, clear stretch film is generally more valuable than printed film, so keep them separate if your recycler requests it. Ensure the straps are secure before bales are collected, as a bale that bursts during loading causes delays for the recycler.

Agree with your recycler how collections will be arranged: some operate on a fixed schedule, while others collect when you notify them that a set number of bales is ready. This helps you plan how much space you need for storing bales.

Clarify how bales are weighed and paid for: whether by the recycler’s scale or by bale count, and how the price reflects the current market for cardboard and film. Always compare each statement with your own records of the bales handed over.

Safe operation of the baling machine

Only staff who have been trained on the machine and have read the manual should operate the baler. The press operates only when the loading door is closed. Stand to the side when opening the doors, as a compressed bale will expand when released.

Only one person should use the baler at any time, and others must keep clear of the doors during operation. Before clearing a blockage, switch off the baler and unplug it or lock the main switch to prevent anyone starting it while you reach inside. Never climb into the chamber. Keep the area in front of the baler clear to avoid trips when loading or removing a bale.

When cutting the straps on a compressed bale, always stand to the side. The bale will expand rapidly once the straps are cut. Heavy bales should be placed on a pallet and moved with a pallet truck or forklift, not carried by hand.

Checklist before purchasing recycling equipment

Before ordering, assess the type and quantity of packaging waste you generate each week. Confirm the bale weight your recycler accepts, check the available space and ceiling height at your site, and ensure the correct power supply. Decide who will load the machine and where it will be installed.

The comparison table above shows which type of machine is suitable for your requirements.

For instance, a packing line might fill three 240-litre bins with cardboard and one with film each week. If waste is produced in peaks, such as after large deliveries, choose a baler machine sized for your busiest week rather than the average. If your cardboard volume is increasing, select a larger model rather than one that will be full from the start.

Plan how you will move the bales and where they will be stored before collection. Choose a dry storage area near the collection point and clearly mark it for each material. Decide where to put plastic strapping bands, foam and wood removed from goods, as these must not go into the baler. For a waste compactor, check that your bins match the standard size for the press.

Order strapping with your baler; textile strapping for waste bales is supplied in packs of four rolls. Keep a supply at the machine to avoid running out while a bale is in the press. Assign the staff who will load the machine and arrange training before the baler is put into use.

Decide whether one baler is sufficient for all materials, or if you need separate machines for cardboard and film: one baler can process both, but only one material should go into each bale, so mixed waste means more frequent changes between materials.

Questions about recycling equipment

How heavy are the bales produced by these machines?

Bale weight depends on both the machine and the material. For example, the TONNA E60 produces bales weighing 30–50 kg for cardboard and 40–60 kg for film. Larger balers such as the TONNA45 can produce bales up to 450 kg.

Can a baling machine compress plastic film as well as cardboard?

Yes. The TONNA E60, for instance, can bale both and has separate operating modes for cardboard and film. The TONNA T-Portable and HSM V-Press 60 are compact balers designed for film and paper.

How long does a pressing cycle take on a vertical baler?

On the TONNA E60, a single pressing cycle takes 27 seconds. Cycle times for other models are listed on their respective product pages.

What power supply do the balers require?

The TONNA E60 operates on 230 V. Other balers may need different power supplies, such as 400 V for the HSM V-Press 605 eco. The power requirements for each model are detailed on its product page.