In-Facility Can Depalletizing and Baling for Scrap Volume Reduction
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Solution Overview
Problem
Existing methods for handling and transporting unfilled aluminum cans are inefficient and costly due to the need for separate equipment and lack of cost-effective means to compact and reuse plastic sheets between layers, resulting in high transportation costs and low scrap value.
Innovation Solution
Combining a depalletizer with a recycling baler to directly transfer cans from pallets to a baler, which compacts the cans and separates plastic sheets for reuse, forming dense bales for efficient transportation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If cans are transported on pallets with plastic sheets between layers, then the cans can be stacked and transported, but the volume is large and transportation cost is high
Solution Approach 1:
The patent combines the depalletizer and baler into a single integrated system where the depalletizer feeds cans directly into the baler. This merging eliminates the need for separate handling steps and intermediate storage, allowing continuous processing that compacts cans into dense bales immediately after depalletizing, thereby reducing the volume that needs to be transported and lowering transportation costs.
Solution Approach 2:
The baler changes the physical state of the cans by compressing them under high pressure into dense bales. This parameter change from loose stacked cans to compacted bales dramatically reduces volume while maintaining the same mass, directly addressing the transportation efficiency problem.
2Ease of operation
If recycler dumps cans and plastic sheets to unload pallets, then unloading is simple, but plastic sheets are damaged or rendered useless and cannot be reused
Solution Approach 1:
The integrated depalletizer-baler system combines the unloading and plastic sheet recovery functions into a single coordinated process. The depalletizer carefully separates cans from plastic sheets and feeds them to the baler, while the plastic sheets are simultaneously collected and stacked for reuse. This merging maintains operational simplicity while preserving plastic sheet integrity.
Solution Approach 2:
The depalletizer is designed to automatically separate and stack plastic sheets without requiring additional manual intervention or separate equipment. The system serves itself by incorporating plastic sheet recovery as an inherent function of the depalletizing process, eliminating the need for separate plastic sheet handling operations.
3Productivity
If depalletizer is used separately from baler, then cans can be unloaded from pallets, but the plastic sheets cannot be efficiently removed and reused
Solution Approach 1:
The patent merges the depalletizer and baler into a single integrated unit where the depalletizer discharge chute feeds directly into the baler hopper. This configuration allows the depalletizer to maintain high unloading productivity while the integrated baler immediately compacts the cans. The plastic sheet recovery function is incorporated into the depalletizer design, eliminating the need for separate equipment and reducing overall system complexity.
Solution Approach 2:
The integrated system performs multiple functions simultaneously: the depalletizer unloads cans from pallets, separates and stacks plastic sheets for reuse, and feeds cans to the baler. The baler compacts cans into dense bales for efficient transportation. This multi-functionality eliminates the need for separate equipment for each operation, reducing device complexity while maintaining high productivity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Reduces transportation costs and increases scrap value by effectively compacting cans and reusing plastic sheets, making the process more cost-effective and efficient.
Implementation Method 1
The baler is operable to crush the aluminum cans and thus compress the cans to form a dense bale of crushed aluminum cans
Data Source
AI summary
A recycling apparatus for positioning within a canning facility receives pallets of damaged or otherwise unusable unfilled aluminum cans, and discharges the layers of cans within a depalletizer into a discharge chute which communicates with the hopper of a baler which compresses the cans and forms a compact bale which is then shipped to a recycled metal processor. The apparatus may be operated as a service to the canner charged on a per pound recovered basis.