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Baling cardboard and RDF efficiently

Updated: May 2, 2023



Doyle Bros is a family-owned Sydney-based waste and recycling company that has been servicing the city’s commercial and industrial sector since 1989. The company has over 30 years of experience and is committed to preserving the environment through efficient recycling.

Since 2009, Doyle Bros has been diverting material from landfill into their materials recovery facility (MRF) to recycle old corrugated cardboard (OCC) and refuse derived fuel (RDF). RDF is an especially valuable recycling product in Doyle Bros’ environmentally responsible approach to managing waste. Non-recyclable residuals, waste that would otherwise be destined for landfill, is turned into efficient fuel. It has a lower-emission rate than coal and reduces harmful landfill emissions.

To process both incoming waste streams, Doyle Bros uses state-of-the-art European sorting and separation technology. An integral part of Doyle Bros’ recycling process is the MAC 108 baler from the Italian company Macpresse.

Macpresse is one of the world’s leading companies in the field of plants for waste and recyclables treatment. The company was set up in 1875 and has over 50 years of experience in the production of high-volume baling presses. Over 1500 of their balers are installed worldwide and Macpresse is present with service centres in over 60 countries. CEMAC technologies is the distributor for Australia and New Zealand and supports local installations with service and local spare stock holding.

Paul Doyle, Managing Director of Doyle Bros, bought the MAC 108 three years ago after a visit to the factory south of Milan, where all Macpresse machines are designed and manufactured. He was impressed with the expertise and experience of Macpresse.

“Clearly they have been in business for a very long period,” he says. After having used the MAC 108 for three years now, Doyle points out the machine’s reliability. “It’s a strong and solid thing that you can count on,” he explains.

Since he put the machine into operation, Doyle has experienced no downtime. He adds that he maintains it with a simple maintenance routine suggested by Macpresse and ever since the start “it just keeps going.”

To ensure the sturdiness of all Macpresse machines, HARDOX 450 steel liners are fixed to the structure of the frame with a patented bolted application system. This wearresistant material protects the balers from abrasion and corrosion, with replacement liners on the floor, sidewalls and top of the extrusion chamber.

HARDOX steel is 400 per cent longer lasting than normal steel and is resistant to wear and chemical agents. It can be rapidly replaced, thereby minimising baler downtime while increasing the overall lifetime of the machine.

Another feature that improves the lifetime of the MAC 108 are the blades that are used to cut off excess material in the hopper.

These are tempered blades specially designed by Macpresse to guarantee a greater resistance to wear. Besides the sturdiness of the MAC 108, Doyle enjoys the machine’s ability to bale two different products. Doyle Bros bales both OCC and RDF “in different shifts and it handles it.” Due to the input material which is “very light and fluffy”, Doyle also points out the machine’s high processing volume. “Put all the material into the Macpresse and you compact it into these one metre squared bales,” he says.

The MAC 108 can process 16 tonnes of cardboard and 30 tonnes of RDF an hour, and has been specially designed for compacting medium and large quantities of materials.

Macpresse offers a wide range of different balers, from the small-sized MAC 102 to medium-sized balers such as the MAC 108, until large-sized balers like the MAC 112 XL. Due to the variety of machines, Macpresse balers are suitable for a wide range of plants from smaller supermarkets to larger sites such as landfills and transfer stations.

Macpresse balers are renowned for one of the most reliable tying unit in the industry. By tying all wires simultaneously, the tying time for each bale is reduced significantly. The operator also has the option to choose between plastic or steel wires. Additionally, Macpresse offers the option of a mobile tying unit for all their balers. This unit rotates 90 degrees away from the balers frame and returns into position only during the tying and cutting cycle. This allows for even simpler cleaning and maintenance.

The MAC 108 also has notably low energy consumption, mainly due to the hydraulic system, which is comprised of a high-efficiency IE3 motor and a Rexroth variable flow piston pump.

This motor allows for energy savings of 30 per cent compared with traditional motors, with the variable flow piston pump further reducing electrical consumption while also allowing the hydraulic pressure to be regulated on demand. With Macpresse’s MAC 108, Doyle Bros can reliably and efficiently bale recyclable material. Both input streams, OCC and RDF, can then be processed further in an environmentally responsible way.

CEMAC technologies

03 8400 6066


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