How a vertical cardboard baler makes a bale

To create a bale in a vertical baler such as the TONNA E60, open the top door and load in cardboard or film. Close the door and the press will start automatically, as it does on the TONNA E80 and HSM V-Press 503 eco, 605 eco and 610 eco. Continue loading and pressing until the machine indicates the bale is full (TONNA E60 and TONNA E80).

Tie the straps while the press plate is down. Open the doors from the side and remove the bale. The TONNA E60 produces bales measuring 70 × 50 × 70 cm and weighing up to 50 kg for cardboard or 60 kg for film.

Each time you load the chamber and close the door, the press plate compacts the new material onto the previous layer, so the bale forms in layers. Distribute each load evenly across the chamber. The TONNA manuals advise that uneven loading can tilt or damage the press plate. On the HSM V-Press 504, 605 eco, 610 eco and 818 plus, the HSM TCS system monitors the plate’s tilt for this reason.

Begin every bale with a large, flat sheet of cardboard on the chamber floor. This helps catch the straps and small pieces, giving the bale a solid base. Load material as it is generated during the day, rather than all at once at the end of a shift, to avoid loose boxes piling up beside the baler.

On models with retaining claws, such as the HSM V-Press 605 eco, 610 eco and the TONNA20, the claws keep the compressed material down when the press plate rises, so the next load is added on top rather than the material springing back. If you tie a bale after the plate is raised, it will expand and the straps will be loose. Stand to the side when opening the doors, as a compressed bale can push a door open as it expands.

Finish the bale in the same way you started. The HSM manuals for the V-Press 503 eco, 504 and 818 plus recommend using a large piece of cardboard for both the first and last pressing. This prevents small pieces from falling off the top or bottom of the bale.

Uneven loading has a direct impact on HSM balers with TCS. On the HSM V-Press 818 plus, if the press ram descends at an angle several times, the machine stops and signals that the bale is ready. This means you must tie and remove a smaller bale than intended. On the HSM V-Press 504, a fault message appears on the display requesting even loading.

Selecting a vertical baler by pressing force and bale weight

Cardboard balers are categorised by pressing force: compact 3–5 t (TONNA E60 3 t, HSM V-Press 503 eco 3 t, HSM V-Press 504 4 t, TONNA E80 up to 4 t, TONNA5 5 t), medium 5.7–12 t (HSM V-Press 605 eco 5.7 t, TONNA10 10 t, HSM V-Press 610 eco 12 t), and large 18.5–45 t (HSM V-Press 818 plus 18.5 t, TONNA20 20 t, TONNA25 25 t, TONNA45 45 t). Bale weights range from 30–50 kg on TONNA E60 and HSM V-Press 503 eco up to 450 kg on TONNA45.

A small cardboard baler produces lighter bales that can be moved with a trolley. An industrial cardboard baler creates bales up to 450 kg, which require a pallet truck or forklift. Heavier bales mean fewer bales for the same amount of waste.

Begin by measuring the weekly waste you generate and the bale weight your staff can safely handle. For example, the HSM V-Press 503 eco and 504 produce bales up to 50 kg and 60 kg, which are removed using a discharge trolley. In contrast, the TONNA20, TONNA25, TONNA45 and HSM V-Press 818 plus make bales up to 150–450 kg, which are managed on pallets.

A greater pressing force allows more material to be compacted into each bale. This reduces the number of bales you need to tie, store and hand over to the recycler, and also means fewer collections.

Compare the models by their pressing force and the bale weights they produce. The HSM V-Press 605 eco, with 5.7 t of force, produces bales up to 70 kg. The HSM V-Press 610 eco, at 12 t, produces bales up to 100 kg. The HSM V-Press 818 plus, with 18.5 t, makes bales up to 200 kg. The TONNA45, at 45 t, produces bales up to 450 kg.

The TONNA45 produces bales with a base of 1200 × 800 mm, matching the size of a EUR pallet. The HSM V-Press 818 plus produces bales with a 1200 × 780 mm base. This means the bales can be handled like any other pallet load in your warehouse.

Before making your choice, check with your recycler which bale sizes and weights they accept. The requirements for bale size and weight will determine both the machine you need and the equipment for moving the bales. For example, if your recycler only accepts bales on pallets and above a certain weight, a smaller baler may not be suitable.

Overview table: cardboard balers and presses

The table below lists all cardboard balers and presses in this category, showing their type, pressing force, bale weight and power supply.

To use the table, first check the power supply available at your location: single-phase 230 V, three-phase 400 V, or no electricity for manual balers. Next, confirm the bale weight you can move and that your recycler will accept. Then compare the pressing force for each model. The type column indicates which machines have a discharge trolley or bale ejector, and which compact waste inside a bin. Where the table refers to the product page, the figure is provided there.

Cardboard compactor or baler: bin presses for waste in bins

The TONNA bin press 240L (up to 2 t, for 240-litre bins) and TONNA1100 (3 t, for 1100-litre containers, pressing plate 660 × 1000 mm) compress waste directly inside the bin. Hold the ON button and move the lever down to press, and up to lift the plate.

A bin press is suitable when waste is already collected in bins and the aim is to reduce the number of collections. If you have enough clean cardboard or film to make sorted bales for recycling, a vertical cardboard baler is more appropriate. A cardboard shredder converts boxes into packing material instead of compacting them.

The pressing plate descends into the bin, compressing the contents. The waste collection company empties the bin as usual, so there are no bales to tie, store or hand over to a recycler. This is useful where waste is mixed or where the aim is to maximise the amount in each bin before collection.

The TONNA bin press 240L is designed for standard 240-litre bins. The arms are adjusted to fit the bin width, and each pressing cycle takes 20 seconds.

A pressed bin is much heavier than a bin filled with loose waste. Always check the bin’s weight limit and confirm with your collection company that it will accept pressed bins. The TONNA bin press 240L can compact cardboard, paper, plastic, film, foam, soft materials and food waste, but not pressurised containers, cans, metal, wood, glass or other hard materials.

The TONNA bin press 240L can reduce the volume of waste in the bin by up to 80 percent. To operate, place the bin on the platform with the lid facing outwards, then hold the ON button and press the lever down until the plate stops. Add more waste and repeat until the bin is full.

With the TONNA1100, always secure the wheels of the 1100-litre container on the platform before pressing. If the pressing plate is already down, raise it first. The manufacturer’s manual recommends keeping the plate down as long as possible between loads for better compaction. The TONNA1100 is for indoor use only, in a dry area, so plan a suitable location and bring containers to it. If the TONNA bin press 240L does not start, pressing the OFF button resets it. Slow or weak pressing on either bin press may be due to low hydraulic oil, a blocked filter or a leak. The TONNA bin press 240L is fixed to a wall or concrete floor and levelled so that it does not rock during use.

Cardboard and plastic baler: one material per bale

TONNA E60 and TONNA E80 offer separate operating modes for cardboard and plastic film. HSM V-Press 504 and HSM V-Press 818 plus have a programme for each material. Each bale contains only one type of material.

The manual balers, TONNA T-Portable and HSM V-Press 60, require no electricity. A lever compresses the material by a ratio of 5:1 or more. Each bale weighs up to 40 kg and is tied three times with twine. These bales can be further compacted in a hydraulic baler if needed.

A cardboard and plastic baler can press both cardboard and film, but not together in the same bale. For example, after pressing a cardboard bale, you must empty the chamber before switching to film.

Film expands more than cardboard, so it is essential to use the correct programme or mode. On the TONNA E60, a cardboard bale weighs 30–50 kg, while a film bale of the same size weighs 40–60 kg. Keep stretch film and shrink film separate from cardboard at the unpacking area.

Bales from the TONNA T-Portable and HSM V-Press 60 measure 800 × 600 mm and up to 800 mm high. As they do not require a power socket, these manual balers can be placed directly at the unpacking point.

On the HSM V-Press 504 and 818 plus, the film programme has two options. The press ram can return to the top after each cycle, or remain down on the pressed film, which is useful for materials that expand. In the second mode, the ram is raised before the next load. Both models allow you to tie a bale before the display indicates completion, for example if you need to change material during a shift.

For the TONNA E60 and TONNA E80, the manufacturer’s manual advises leaving the platen down between loads for as long as possible to achieve better compaction. The HSM manuals for the V-Press 503 eco, 504 and 818 plus specify only empty cardboard, dry paper free from solvents and single-ply film. Strongly expanding materials, such as bubble wrap or foam, should only be loaded after consulting HSM. On the HSM V-Press 60, apply the foot brakes, load a large piece of film first, spread the material evenly and pre-compress it by hand. Operate the lever with both hands: release the safety lever with your left hand and pull the handle down gradually. Keep the press closed. The HSM V-Press 60 is suitable for plastic film, corrugated board and heavy paper sacks, but not for household waste, newspapers, tins or bottles.

Power supply and bale removal on cardboard balers

Models that operate on single-phase 230 V (220–240 V) include TONNA E60, TONNA E80, HSM V-Press 503 eco, HSM V-Press 504, TONNA5, TONNA10, TONNA20, TONNA25, TONNA bin press 240L and TONNA1100. HSM V-Press 605 eco, 610 eco and 818 plus require three-phase 400 V, while the TONNA45 uses three-phase 380–400 V.

Bale removal methods: HSM V-Press 503 eco and 504 use a discharge trolley. HSM V-Press 605 eco and 610 eco have a mechanical bale ejector that tips the bale onto a pallet or pallet truck. TONNA20, TONNA25 and TONNA45 feature an automatic bale ejector.

Before installation, ensure that the correct socket is available at the intended location for the machine.

The TONNA manuals state that the baler must be plugged directly into a mains socket, not an extension lead. Using an extension can increase the current and trip the circuit breaker, stopping the machine. If there is no three-phase socket where a 400 V machine will be installed, a qualified electrician must fit one before collection. This is important in production areas with only single-phase power, as it may affect which model is suitable.

Always keep the area in front of the doors clear when a bale is ejected, and ensure that no one stands where the bale will tip out of the machine.

When preparing for installation, inform your electrician of the current drawn by each machine. The single-phase TONNA20 requires 16 A and is fitted with a 2.2 kW motor. The TONNA E80 draws 11 A, and its technical documentation recommends a C16 circuit breaker. For three-phase machines, the direction of rotation must be checked at first start-up. The TONNA45 manual specifies that the motor should rotate clockwise; if it does not, the phase sequence must be altered. The HSM V-Press 818 plus displays a phase fault until an electrician corrects the wiring.

On the TONNA25 and TONNA45, the platen is used to eject the bale. After tying, push the bale tilting lever on the pressure plate forward into the channels at the rear, then press the two-hand button together with the up button to raise the platen and tip the bale out. Pull the lever back afterwards. For the HSM V-Press 503 eco or 504, both the loading door and the bale door must be opened beyond 90 degrees before the bale can be removed onto the discharge trolley. On the HSM V-Press 818 plus, only tighten the hand wheel on the door lightly, as the manual warns that overtightening makes the door difficult to open after pressing.

Tying the bale on a cardboard bale press

The HSM V-Press 503 eco and 504 tie each bale twice with polyester tape, and are supplied with 2 rolls of tape. The HSM V-Press 605 eco ties three times, with 3 rolls included. The HSM V-Press 610 eco also ties three times, while the HSM V-Press 818 plus ties four times. Manual balers use twine, tying each bale three times.

The textile strap in this category is 16 mm wide, 340 m per roll, with 4 rolls per pack, and is tied by hand using a knot. No tool is required.

The TONNA T-Portable and HSM V-Press 60 use twine, tied three times across each bale. A roll of the textile strap has an external diameter of 180 mm.

Before purchasing strap, check the product page for your baler to confirm the correct type and width required. It is important to keep a supply of strap at the baler, so that a full bale is never left untied in the chamber.

For the HSM V-Press 503 eco, each tape is pulled approximately 400 mm over the bale door and cut. The end is then removed from the fixing hook and tied securely to the tape at the top of the bale. Once the bale is removed, the tape ends are placed back on the fixing hooks, ready for the next bale. With the HSM V-Press 60, each of the three cords of twine is cut to 3 m and threaded before loading. After pressing, the upper ends are pulled tight and knotted.

On the TONNA E60 and TONNA E80, the straps are inserted before filling the chamber. With the platen raised and the machine unplugged, the straps are fed down through the guides in the chamber and back through the holes in the door, secured with a loop and tightened using the hook. Once the bale is full, the straps are passed over the top with the hook, cut to length and pulled out through the holes on top of the lower door. For the TONNA25 and TONNA45, the strap is threaded through the slots at the bottom and rear of the chamber before loading. When the bale is large enough, the tying compression button presses it and stops the platen in the tying position, and the lower and upper ends of each strap are tied together. On the HSM V-Press 504, the tape is pulled through the channels in the press ram using the tape insertion needle and the loop is cut. The two cut ends must not be swapped, otherwise the bale cannot be tied.

When a baler pays off and what size to buy

A cardboard baler becomes cost-effective when loose boxes quickly fill bins or occupy too much floor space. If your weekly waste fills several bins or containers, a baler will reduce the number of collections required. For waste that is placed in bins, a TONNA bin press 240L or TONNA1100 compacts it inside the bin. For clean cardboard and film, a vertical baler produces bales suitable for recycling.

The correct size depends on your busiest week. Select a baler that can handle the largest volume you anticipate, not just the average. The chamber size determines the base of the bale, and the pressing force dictates how much material can be compacted.

To determine when a baler is worthwhile, record the amount of waste generated per week by material type: cardboard, film and paper. Note whether this waste is placed in bins or accumulates as loose boxes on the floor.

Work out your current waste handling costs. This includes the number of bin collections per month, the floor space taken up by loose boxes, and the time staff spend flattening and moving cardboard. Both collection costs and the space used for waste are reduced when the waste is baled.

Clean, sorted bales have value for recyclers. Depending on the current market price for cardboard or film, recyclers may collect bales free of charge or may even pay for them.

The busiest week is often immediately after large deliveries or during peak production periods.

The hourly output is seldom the limiting factor for a vertical baler. For example, the TONNA20 is rated for 6 to 8 bales per hour, the HSM V-Press 610 eco for 3 to 6, and even the manual HSM V-Press 60 for around 3 bales per hour. In practice, the speed is determined by how quickly staff can load material by hand, rather than the rated output. Manufacturers position their models for different volumes: the HSM V-Press 503 eco is intended for low material volumes, the 504 is HSM’s entry-level model, and the TONNA20 is a mid-range baler that is easy to load with large boxes.

Measure your waste by weight as well as by volume. Weigh a full bin or roll cage of loose cardboard and note its volume. HSM requests these figures before recommending a press: the quantity of material per year, month or hour, and its weight per cubic metre when loose. Bale weight will vary. The HSM manual explains that this depends on the type, moisture and condition of the material, as well as the bale height, so your bales may be lighter than the figures in the table. The display on the HSM V-Press 504 and 818 plus counts the number of bales, separately for cardboard and film, along with the working hours. This helps you plan collections and monitor output.

Space, ceiling height and access route

Cardboard balers require a solid, level floor to support the machine, the bales and a pallet truck. Allow space in front for loading, for the doors to open fully, and for removing the bale. The ceiling must be higher than the machine. For example, the HSM V-Press 503 eco and 504 require at least 2000 mm. The TONNA20 has a reduced height for transport.

Check the access route: ensure that doors and passages are wide enough for the machine. Placing the machine indoors or under cover will extend its lifespan. Electrical connections must be made by a qualified electrician.

Measure the ceiling height at the intended location, and check for beams, pipes or sprinklers that could reduce the available height. The HSM V-Press 818 plus is 2370 mm tall and the TONNA20 is 2600 mm.

The HSM V-Press 504 requires 1825 mm of depth, including the swing of its door. In a packing area, ensure there is sufficient space for a pallet truck or trolley to move bales away from the machine.

The machine is levelled so it does not rock during operation.

The TONNA20 stands 1955 mm high for transport, which is lower than its operating height. Measure all doors, corridors and lifts along the route. Check whether the lorry can reach a loading ramp or if a tail lift is needed, and whether a forklift is available on site. The TONNA E60 is designed for use in a closed, dry room. Outdoors, a waterproof plug and socket are required. Good lighting and ventilation are also necessary.

A baler should only be moved when the platen is fully lowered and the doors are closed and locked, as otherwise there is a risk of tipping. The TONNA25 and TONNA45 feature grooves in the base to accommodate the forks of a forklift or pallet truck. The manuals for the TONNA5 and TONNA10 advise positioning the machine in a corner, with both the side and rear against the walls. If this is not possible, a protective barrier should be installed at the back and sides to keep the baler clear of forklift routes.

Before first use of a TONNA5 or TONNA10, the oil plug used for transport must be replaced with the supplied breather cap. The manual warns that operating the machine without the breather cap will cause damage. The HSM V-Press 503 eco and 504 may only be used outdoors under supervision and must never be left exposed to rain. Maintenance intervals are shorter if used outside, and in cold weather, a suitable hydraulic oil is required. The HSM V-Press 610 eco requires 2 to 3 m² of floor space, allowing it to be placed close to where waste is generated. HSM site checklists also ask whether a vehicle must pass through a gate or pedestrian area, if there are restricted collection hours, and whether the installation site is above a basement, as this affects floor load requirements.

Safe operation of a cardboard baler

Only trained personnel are permitted to operate a cardboard baler. The TONNA manuals specify a 1 m safety zone around both the machine and the finished bale. Do not load glass, aerosol cans, metal, wood, solid items, cardboard cores, or complete bales of newspapers or cardboard. The press will only operate with the door closed.

Stand to the side when opening the doors, as the bale will expand once released. Never attempt to lift bales by hand; always use a trolley, pallet truck or electric pallet stacker. Safety footwear, safety glasses and gloves must be worn. Inspect the machine daily before use and disconnect it from the mains before any maintenance. Do not use the machine if there are damaged cables, hoses or an oil leak until it has been repaired.

Only trained individuals who have read the manual should work at the baler, and only one operator should be at the machine at any time. All others must remain outside the 1 m safety zone during operation and when removing a bale. This helps prevent injuries from moving parts or from a bale expanding as it is ejected.

The TONNA manuals exclude the materials listed above because they pose a risk of injury and can damage the machine.

On the HSM V-Press 503 eco and 610 eco, a safety switch halts pressing if the door is opened. Hearing protection is recommended.

Before every start, check that no persons, children or animals are inside the chamber or bin. Both the TONNA and bin press manuals require this check to avoid accidents. No one under 16 is permitted to operate the TONNA E60, TONNA E80, TONNA1100, HSM V-Press 60, 503 eco, 504 or 818 plus, as stated in their manuals. At the start of each shift, inspect the safety devices as required by the HSM manuals. On the HSM V-Press 504, the press cannot start if either the loading or bale door is open, and the locking lever must engage when the loading door is closed.

Keep the baler doors locked when not in use. At the end of each day, turn off the main switch, secure it, and unplug the machine. On the HSM V-Press 504 and 818 plus, the main switch can be locked in the off position with a padlock. Always open and close the doors slowly to avoid injury. Only lift manageable loads when filling the baler, and remove loose clothing and jewellery before operating the machine. An oil leak is also a fire hazard, as highlighted in the manuals for the TONNA E60 and TONNA E80.

Factors affecting the price when you buy cardboard baler equipment

The price of a cardboard baler is determined by pressing force, bale size, type of bale ejector, and whether there are separate programmes for cardboard and film. Installation may require a three-phase socket and arrangements for collection. Ongoing costs include strap and servicing. The price is displayed on each product card. A cardboard box baler with higher pressing force and automatic ejection will be more expensive.

Installation costs may include fitting a new three-phase socket for a 400 V machine, and larger balers may require a forklift or a truck with a tail lift for collection.

Ongoing costs include strap or tape for each bale, electricity, and the annual service with oil change recommended in the TONNA manuals. Each product card features a Get offer button for a quotation, for example for a baler with strap, and an Add to inquiry button to combine several products in one request.

Electricity is a minor part of the running costs: the TONNA E60 and TONNA E80 use 0.008 kWh per pressing cycle. For the annual oil change, the TONNA bin press 240L requires 14 litres of hydraulic oil, the TONNA1100 needs 8 litres, and the TONNA E80 also takes 8 litres.

Plan the installation of the HSM V-Press 818 plus in advance. It is supplied with its hydraulic cylinders retracted for transport, and trained personnel must move them into position and secure them before the first bale is produced.

Checklist before ordering a cardboard baler

Check your recycler’s requirements for accepted materials, bale size and bale weight. Measure your weekly waste and compare your largest boxes to the baler’s loading opening. The floor must be level and strong enough to support the machine and a pallet truck. The ceiling must be higher than the machine.

Check the power supply at the installation site. Decide who will load the baler and where bales will be stored before collection. The table above lists the specifications for each model, including pressing force, bale weight and power supply.

Begin by asking your recycler which materials they accept, the required bale size and weight, whether bales must be loose or on pallets, and the minimum quantity per collection.

The HSM V-Press 504 has a loading opening of 700 × 470 mm, the 605 eco and 610 eco offer 800 × 495 mm, and the 818 plus provides a width of 1195 mm. If a box is too large, it must be folded before loading. Ensure a suitable socket—either single-phase 230 V or three-phase 400 V—is available nearby.

Decide where to store the strap. In some cases, a single baler may not be suitable for all materials, so a bin press for mixed waste alongside a baler for cardboard may be the best solution.

When requesting a quotation, describe the material: whether it is dry or wet, loose, stacked, already pressed or shredded, and the size of the smallest and largest pieces. HSM asks these questions before recommending a press. Any material other than cardboard, paper or film must be clarified with the manufacturer first. HSM may request a compression test.

Check the loading height against the height of those who will be using the machine. The HSM V-Press 610 eco has a loading height of 655 mm, while the HSM V-Press 818 plus has a filling height of 958 mm with a fold-down door. Also consider working hours and site conditions: the number of working days per week and shifts, whether the area is sheltered from the weather, and the temperature range.

Questions about cardboard balers

What is the weight of the bales produced by each cardboard baler?

TONNA E60 produces bales weighing 30–50 kg with cardboard and 40–60 kg with film, HSM V-Press 503 eco bales 30–50 kg, and TONNA E80 bales 40–60 kg with cardboard. TONNA5 produces 40 kg bales and TONNA10 produces 80 kg bales. The HSM V-Press 504 makes bales up to 60 kg, HSM V-Press 605 eco up to 70 kg, HSM V-Press 610 eco up to 100 kg, TONNA20 up to 150 kg, HSM V-Press 818 plus up to 200 kg, and TONNA25 up to 250 kg. TONNA45 produces bales up to 450 kg, while TONNA T-Portable and HSM V-Press 60 produce bales up to 40 kg.

Which cardboard balers operate on a standard 230 V supply?

TONNA E60, TONNA E80, HSM V-Press 503 eco, HSM V-Press 504, TONNA5, TONNA10, TONNA20, TONNA25, TONNA bin press 240L and TONNA1100 all operate on single-phase 230 V (220–240 V).

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

Cycle times are as follows: 20 seconds for the TONNA bin press 240L, 27 seconds for both the TONNA E60 and TONNA E80, 21 seconds for the HSM V-Press 605 eco, 22 seconds for the 610 eco, and 27 seconds for the 504 and 818 plus (HSM idle cycle, without material). The TONNA20 has a cycle time of 40 seconds.

What ceiling height is required for a cardboard baler?

The HSM V-Press 503 eco and 504 require a minimum ceiling height of 2,000 mm. The ceiling must be higher than the machine itself: the HSM V-Press 818 plus stands at 2,370 mm tall, while the TONNA20 is 2,600 mm high, though the TONNA20 is lower during transport.