The baler completes its cycle, but the bales are looser and take up more space during storage or transport. The operator may extend the pressing time or try to compensate for the problem by changing the settings, which, without identifying the cause, may only mask progressive wear. ETMAL services equipment used in land-based industries and has experience in major overhauls of balers used in waste management. The work begins with an assessment of the machine so that the scope of the repair is based on measurements rather than on the assumption that replacing the pump will solve the problem.
A loose bale and an extended cycle indicate reduced machine performance
A decline in performance is not indicated solely by lower bale density. Slower movement of the pressing plate, difficulty maintaining the required compression parameters, an increase in oil temperature and longer operating times of the power unit should also raise concerns. However, the type and moisture content of the material must also be taken into account. Comparing cycles performed under similar conditions helps distinguish the effect of the feedstock from a deterioration in the condition of the machine.
Correct pressure does not rule out losses in the cylinder or valve system
The pressure gauge at the power unit may show a value close to the required level, while the baler still fails to develop sufficient compaction force. The reading does not automatically show what pressure reaches the cylinder during movement or how much oil the system delivers during the successive stages of the cycle. Some of the fluid may flow through an internal leak in the cylinder or return to the tank due to leakage in the directional control valve or incorrect operation of the relief valve. A reduction in pump efficiency after the oil heats up can also be the cause. Therefore, pressure should be assessed together with flow rate, temperature and the plate movement time. Measurements taken at the appropriate points in the system show where the hydraulic circuit is losing performance.
The condition of the components determines whether a repair is sufficient or a major overhaul is needed
A fault involving a single valve, hose or setting can often be rectified on the machine. A worn cylinder or pump may require removal and workshop inspection. A major overhaul of the baler becomes justified when wear affects several key assemblies and repairing just one of them will not ensure stable operation of the entire machine.
The condition of the pressing chamber, plate guides, locking or tying mechanism, supporting structure and control system is also assessed, depending on the machine’s design. The decision should take into account the machine’s failure history, the availability of spare parts and the expected remaining service life.
A loaded test confirms whether the baler has regained the required compaction force
After a repair, simply starting the machine without material is not sufficient. In accordance with the equipment documentation and safety requirements, the baler should complete a full cycle with a representative load. The service team then checks the movement time, oil temperature and pressure behaviour under load. Comparing the dimensions, weight or density of the finished bale with the parameters adopted at the facility confirms whether the machine is once again delivering the required process results.
If your baler is becoming increasingly slow or producing bales that are too loose, provide ETMAL with a description of the symptoms and the machine’s repair history. The team will plan diagnostics and determine the scope of work based on the actual condition of the equipment.
