Triple the Output, Half the Effort: Polpure’s Automation Success Story
- CEMAC
- Jun 4
- 4 min read
At Polpure, a commitment to continuous improvement drives every operational decision. Serving regional businesses with efficient recycling solutions, the team is constantly seeking ways to handle growing waste volumes with fewer risks and lower labour demands. The drive for better efficiency, safety, and throughput led them to a turning point in 2024—at IFAT, where they discovered a machine that would reshape their recycling workflow: the Strautmann BaleTainer®.
What sets the BaleTainer® apart
The BaleTainer® stands apart from conventional baling systems with its ability to operate fully automatically—without the need for permanent operating staff. Material can be fed manually or automatically into the machine [1], where it is conveyed into the press chamber [2] and compacted in segments [3] to form bales [4]. These bales are then automatically tied and discharged, with no pre-crushing required—keeping manual handling to an absolute minimum.
A large feed opening allows for continuous material input and seamless integration into existing waste streams. The unit’s fully enclosed roof design ensures safe, all-weather operation, while its compact footprint makes it ideal for tight spaces without sacrificing capacity. Engineered for continuous 24/7 use, the BaleTainer® produces mill-size bales that maximise truck load efficiency (100% utilisation) and reduce shipping costs—including compatibility with 40 ft. high cube containers. What’s more, the BaleTainer can be used across multiple materials at one site including cardboard, film and PET. For businesses like Polpure, these features translate into reduced labour requirements, streamlined logistics, and strong returns per bale.
Before the BaleTainer®: Slow, Manual, and Staff-Intensive
Before the BaleTainer® arrived on site, Polpure used sheep skin presses to compact materials like LDPE, PP bulk bags, and pet food packets. The process was intensely manual—two staff members spent over an hour to produce a single 400 kg bale. The operation was not only slow but physically demanding, with safety risks and inconsistent output.
A Leap in Productivity and Safety
Installing the BaleTainer® completely changed the game. With 156 t/m2 pressing force and fully automatic operation, the machine now produces 3 bales per hour - with just one staff member feeding and another pre-sorting to ensure the bales are clean and free of contamination. Cardboard, film, and other materials are compacted efficiently and safely, with minimal manual handling and no pre-shredding required. For the team, the change has been palpable.
"The machine is set and forget for our cardboard and significantly safer and far less labour intensive for our plastics," says Polpure Operations Manager, Mark Monaghan.
"The BaleTainer® has provided an automated outcome which has been extremely beneficial to our business."
Beyond the impressive numbers, staff satisfaction has increased. Freed from physically strenuous baling, employees now focus on higher-value tasks. The safer, cleaner environment has also led to tidier site conditions and fewer interruptions to daily operations.
Precision Support from CEMAC technologies and Strautmann
Early in the rollout, Polpure identified a small issue: their cardboard bales were hitting 350 kg, shy of the 400 kg transport target. The team turned to the CEMAC technologies service and support team who swiftly coordinated with Strautmann engineers to fine-tune the system. Within a short time, bale weight was optimised to meet the target—an outcome that has remained consistent ever since.
“We have been pleased with the support from CEMAC and their knowledge base with complex machinery. Polpure are well informed due to the vast experience CEMAC provide in the recycling industry. We are already looking at other opportunities where CEMAC can support us so we can continuously grow our businesses, fuelled by best in market technology” says Mark.
Compact Machine, Big Impact
The BaleTainer’s small footprint allowed Polpure to install it in a tight area away from vehicle and foot traffic. This efficient use of space has contributed to improved material flow and operational safety—without the need to expand the facility or interrupt existing processes.
Polpure estimates a weekly savings of four hours of labour and around $950 in other costs. The combination of reduced manual work and optimised bale weight means less time spent per load and more material per truck—bringing the company closer to markets, faster. With that, return on investment is well underway.
By automating a core part of their recycling workflow, Polpure is now able to take on more customers across the region. With higher throughput, faster turnaround, and scalable operations, the BaleTainer® has become a cornerstone of their expansion plans.
"We have achieved higher capacity and throughput and can service more customers in our region as a result," company owner Nick Farrell shared.
From the first time they saw it at IFAT 2024, Polpure was intrigued. The BaleTainer® was unlike any other baler they'd encountered—automated, compact, and robust enough for continuous 24/7 use. Now integrated into their facility, it has become a symbol of Polpure’s forward-thinking approach. In an industry where time, safety, and consistency matter, Polpure’s journey shows what’s possible when the right technology and the right support come together.
For more information on the BaleTainer or Strautmann balers, contact:
Denis Holtgrefe
CEMAC technologies
0493 466 589
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