Replacement Box Feeder & Baler Feed Conveyor for Casepak

The plant is a 24tph automated MRF built originally by BHS. The main baler feed conveyor that receives material from all the bunkers in the MRF was becoming worn. Casepak were looking to replace the conveyor as downtime for repairs was becoming more frequent.

OKAY has long supplied conveyors to Casepak (and upgrades to other members of the Reconomy group) and so was asked to provide a turn-key proposal to remove the existing chain conveyor and replace with new.

The conveyor in question was a huge machine, running at 46m. However, the removal and installation of new conveyor also presented a challenge, as it was sited deep into the existing MRF plant. During the original install, it was one of the first items to be set in place as it is at the base and heart of the system. Therefore, the existing baler feed conveyor was boxed in by 10 bunker conveyors of each side, plus structures and electrical trunking.

The replacement conveyor that OKAY offered a KC3, which is a heavy-duty chain conveyor with 6” pitch, 200kN breaking strength chain. This connects to cross belt slats which are nicely contained in a rubber conveyor belt carrying medium. The overall length was 46m with a 26m infloor section, which receives the sorted material from the bunkers for baling.

OKAY, working with specialist lifting contractors, surveyed the task and came up with a detailed plan to enact the works.

As downtime to a plant like the Casepak MRF is critical, Casepak then tabled a second project to see if OKAY could undertake both simultaneously. This second project had been planned for a later time but running the two together would mean the overall downtime/cost to Casepak could be halved.

This second project was the replacement of the front-end Box Feeder with a metering drum. This standalone unit is designed to accept loose incoming material and meter it into the Plant.

Whilst OKAY offers a range of Box Feeders, the brief was to replace the existing unit with one dimensionally the same, plus improvements as specified by Casepak.

The OKAY Box Feeder unit is based on the same heavy-duty KC3 chain conveyor and has a 1.8m diameter metering drum. The unit also has wear liner plates on the walls and drum, and the drum is shielded to prevent material becoming entangled. The unit is set within a push wall structure.

After reviewing the two proposals from OKAY , and looking at the planned programme for combined installation, Casepak felt comfortable in ordering the two projects together.

With two installation teams working together to complete the project within the specified window, the two machines went in safely, on time and with some considerable skill.

Ultimately, the project was delivered on time and on budget for Casepak and OKAY .

Project leaders Ben Grundy and Jacob Smith were delighted with the results. Ben commented, “Casepak have used OKAY down the years because we know the kit they build is second to none. Looking at what has been installed here, we made the right decision. It looks great, it went in smoothly and easily, and it’s worked from the off.”

Jake Smith added, ‘The installation did worry us upfront. Given the tonnage we handle, we cannot live without our plant. The baler feed sitting in the middle was hard to imagine coming out, let alone a smooth replacement going in. One error and the critical timeline would be out. Fair play to OKAY , it was planned with us and it went to the minute.”

OKAY MD, Antonia Kay, said, “Casepak and OKAY go back a long way. It’s a matter of great pride to me to continue this relationship. Now Casepak is part of the Reconomy group, OKAY’s sense of duty only deepens as we need to ensure Mark, Ben and Jake remain pleased with their recommendation, and that OKAY delivers on its promises. I am proud to say we have done that. And with good-looking kit too!”