Flexus Balasystem AB

Flexus Balasystem AB

Flexus BalaSystem AB in Sweden is the pioneer and manufacturer of highly cost effective heavy-duty integrated round baling & wrapping solutions. Flexus brings durable solutions for a wide range of applications, incl MSW, RDF/SRF, landfill management & remediation, Renewable Energy, Waste2Energy, storage & transport of waste and recyclables, wood chips. Flexus is also well established in offering compact solutions to high-value agricultural products, i.e. beet pulp, bone meal, animal feed, biomass. In 2019 we celebrate our 25th anniversary, and we are proud to be well-established in 43 countries across 5 continents.

Company details

Södra Vägen 36 , Nossebro , SE-465 31 Sweden
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Business Type:
Manufacturer
Industry Type:
Recycling Systems
Market Focus:
Globally (various continents)
Year Founded:
1983

With over 30 years of experience in integrated baling & wrapping of challenging materials – Flexus Balasystem is the pioneer and world leader in round baling & wrapping solutions.

We started in 1985, manufacturing machines for handling and storage of agricultural materials. In 1991 Flexus was the first company worldwide to patent an integrated bale pressing & wrapping technology specifically designed and engineered to handle the considerable and uniqe challenges of MSW.

Since 1995, Flexus has delivered round baling & wrapping solutions to 43 countries across 5 continents.  We manufacture heavy-duty industrial-scale machines, designed – engineered – manufactured to operate in all climatic conditions, even in the most remote parts of the world. Flexus baling & wrapping systems have a well-deserved reputation for reliability and ease-of-use.

Flexus Balasystem AB shall produce, sell and maintain systems and equipment for large scale compression, storage and handling of valuable materials for a more sustainable environment.

With regards to environment, quality and economy, our products and services shall provide added-value to our clients.

The Flexus round-baling unit is at the heart of this unique system. 

MSW, RDF, recyclables, pulp, biomass etc are transformed into compacted and foil-wrapped cyclindrical bales.  The wrap & seal method stabilizes the organic bale contents and renders the bale anerobe. 

Particular attention has been paid to making this baler easy-to-use.The Flexus system can be mobile, stationary or integrated into existing waste treatment plants. Mobility means, the baler can be easily moved by truck from site to site; this provides ample flexibility to handle both large and small baling commissions. Stationary and/or fully integrated Flexus systems are designed to meet the demands and conditions of each specific case.

Flexus integrated baling & wrapping systems can produce up to 40 bales/hour, which can equate to a processing capacity of 50 tons/hour (depending on material and infeed)

The Flexus method is synonymous with the classic concept of bale wrapping; Flexus bales can be stored indoors and outdoors, in all weather seasons. Flexus bales are easy to handlel and to transport, guaranteeing optimum load capacities. Stacking of Flexus bales can double space and life span capacities of landfills. Flexus bales can be stacked high and safely.

  • Waste Management & Recycling

  • RDF / SDF

  • MSW, Transfer Station

  • Landfills and landfill remediation

  • Commercial & Industrial waste

  • Biomass, wood chips etc.

  • Renewable Energy projects

  • Waste2Energy facilities, incineration plants

  • Touristic waste, seasonal volumes

  • Islands, remote locations

  • Cost effective transport by truck, rail and sea

  • Agricultural materials i.e. rice hull, Napier grass, pulp, bone meal, animal feed

  • Significant volume reduction (compaction ratio up to 1:4)

  • Almost zero methanogenic activities

  • Zero fire risks due to spontaneous combustion

  • Significant reduction of mal odours

  • No birdfly and windfly

  • Significant reduction of leachate issues

  • Water resistant outdoor storage

  • Retaining calorific value of bale contents

  • Integrated baling & wrapping function

  • Small footprint /layout

  • 5 hour installation time

  • No major civil works are required

  • Mobility of the system

  • Significantly lower operating and & maintenance costs

  • Heavy-duty design for long service life

  • High quality components

  • Hardox steel plates

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Pressing

The material is fed into the baling chamber via a feed conveyor, and is force fed between the chains of the baling unit. The uncompressed material is rotated around the axis of the chamber and as more material enters, the chamber compression of the material increases.

The bale compression increases as more material is force fed into the chamber and the bale becomes evenly firm and stable. Only relatively low power is required to compress material in this way. Softer and smaller material fragments surrenders and embeds larger and harder objects during the compression process.

The computer system monitors the com­pression, by measuring the hydraulic pressure in the system.

The operator sets the compression level required for the baled material via the computerized system.

Netting

When full chamber pressure is reached, a net is wound around the bale. The net is fed into the chamber by means of jet air nozzles.

The net wound around the surface of the bale maintains its form and prevents the compressed material from expanding when the chamber is opened as well as increasing the mechanical strength of the bale.

The net is made of environmental friendly polythene. A roll of net is sufficient for more than 100 bales, and is easily changed by the operator.

The operator sets the required number of windings of the net and the computer system checks continuously that the net is properly fed.

Transfer to the wrapping unit

The baling chamber opens up and the heads of the chamber are pressed towards each circular end of the bale to hold it firmly during the transfer to the wrapping unit. The net wrapping and the high bale compression minimises material loss.

Wrapping

The bale is wrapped with a thin, strong and stretchable plastic film which is air tight and water resistant.

The wrapping is made by means of a sweep arm which rotates on the wrapping table to give a 50% overlap of film on the bale.

While the bale is being wrapped, the heads of the baling chamber returns to the baling position. The baling chamber closes and new material is fed into the unit. When wrapping is completed, the film is cut and the bale is loaded to the bale conveyor.

The stretch film, although thin, is very tough. This ensures the hermetic enclosure of the material which prevents the escape of litter as well as stops the degradation processes.

The stretch film and the net in which the bales are wrapped consists of polythene which converts to carbon dioxide and water when incinerated. The plastic film is only 25-30 µm and it constitutes of only 0,1-0,2% of the total weight of the bale. A roll of stretch film is sufficient for 15-25 bales depending on the number of layers. Rolls of film is easily replaced by the operator.

Unloading

The wrapped bale is tilted onto a bale conveyor for unloading to further transportation or storage. If the conveyor is equipped with a scale and a marking unit, each bale can for example be marked with weight, material type or with a bar code, depending on the demands of the job.

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Low Energy Consumption

A complete plant with press, bale wrapper and conveyors consumes no more than 10-40 kW/h. Which comes out as low as approximately 1-1,5 kW per finished bale.

The low energy consumption owes to the special patented construction of the press. The functions of the press are electro-hydraulically powered. The press chamber has rotating sides and the feeding mat rests on rollers with ball bearings.

Leakage and Leaching

Thanks to the lack of oxygen inside the round bale there is no fermentation occurring inside. Storage is therefore without risk of build-up of methane gas. Poisonous substances can not be leached, since the stretch film effectively restrain all water from penetrating inside the bale (provided that the bales aren't submerged in water).

Stretch Film and Net

The stretch film and the net in which the bales are wrapped consist of polythene, which converts to carbon dioxide and water when incinerated. The plastic film is thin, only 25-30 µ and it constitutes only 0,1-0,2% of the total weight of the bale. A roll of stretch film weighs approximately 17 kg and is sufficient for approximately 18 bales.

The net is made of environmental friendly polythene. A roll of net weighs approximately 30 kg and is sufficient for approximately 100 bales.

The stretch film, although thin, is very tough. This ensures the hermetic enclosure of the material, which prevents the escape of litter as well as stops the degredation processes. The waste is compressed and wrapped with stretch film, into airtight bales. Without oxygen the processes of fermentation and degredation cannot start.

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Degradation processes in baled waste

Degradation of waste involves two different processes; aerobic and anaerobic. In the aerobic phase the main degradation is oxidation reactions which produce CO2. Combustion and thermal degradation can be the consequence of this phase.

During the anaerobic degradation, three meta­bolically different groups of bacteria become active and result in hydrolytic, aceto­genic and finally methanogenic degradation. This biodegradation process in which the organic substances are acting as a nutrient as well as an oxidation agent is a result of coordinated action of many different bacteria species in sequential reactions.

Any disturbance in such a consecutive system can delay or accelerate some of the biochemical step reactions and this affects the degradation rate and energy/mass losses in the stored material. By preventing oxygen and water from penetrating the waste, Flexus baling system offers such a disturbance, thus more or less halting the biochemical process.

Study of MSW baled & wrapped round bales

Scientific tests of waste stored in round bales were done at:

  • Lund University, Sweden, 1995

  • Dekra Report, Germany 1995

  • Cylergie, France 1995

  • Storage of highly calorific waste, Germany: 1998  

  • Ardlethan Commission of Enquiry, Australia 1999

  • Australian Museum, Sydney, Australia 1999

  • Disposal Plant, Asslar, Germany 1999

  • Storage of MSW in Spain, 2000

In summary, all studies confirm the anerobe and stable inner-bale conditions.

Scientific papers are available upon request.

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The material handling capacity of a bale press is largely dependent on the type and characteristics of materials for baling, as well as the manner of infeed and operational experience.

Flexus has 3 baler models to choose from:

Flexus Typhoon -  up to 40 bales/hour

Flexus Breeze - up to 15 bales/hour

Flexus Breeze Mini - up to   5 bales/hour

Feel free to contact us at Flexus Balasystem for more specific information.

We have in-depth experience in delivering our technology across 5 continents, for different industries and a wide variety of applications.  Flexus is happy to share its worldwide experience with you.

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A single bale has a diameter of approximately 120-135 centimeter, and it is 120 centimeter high.

A normal wheel loader can easily stack 4 bales high (4,8 metres), but with a telescopic stacker we see regular stacks of 8 bales in height. The bale layers are stacked with an offset, so that each bale covers half the area of two bales below, and thus locking them in place. The entire stack is then safer for storage, which is also important from a personal safety view.

On our website at www.flexus.se you can find a storage area calculator to approximate the storage capacity for a given area. You will also get a hunch about the total storage weight, depending on the material that is to be processed.

Flexus integrated baling & wrapping systems are certified and comply with international quality and safety standards.

Flexus cares about each and every baler that leaves our factory; we therefore offer the best possible support to ensure that our clients continue to be satisfied. 

Our in-house competence together with multi-lingual customer support staff are there to assist you.

Over 90% of our business is international …25 years of serving our international customers - worldwide in 43 countries across 5 continents.  
The multi-lingual Flexus team plus our dedicated distributors are just a phone call or an email away from you.
We will be happy to share our considerable application know-how with you.