Abstract:
Improved bales may be formed using methods that include baling equipment with multi-component bolster assemblies that may ease installation and removal, reduce wear and tear and maintenance, and/or improve efficiency by reducing material waste, imperfections, and/or contamination. The bolster assemblies may include a plurality of coupling portions that engage a hydraulic rod and may enable the bolster assembly to self-center within a press chamber during normal baling operations. The bolster assemblies also may include an island portion that may be attached to the coupling portions and to a bolster cap, and the latter may be attached using retainer bolts having substantially flat, non-circular heads. The bolts may reduce irregularities in the bale and/or prevent material seepage into the bolster assemblies. During maintenance, an operator may remove only the bolster cap island assembly for cleaning, substantially reducing the time and strength needed to clean and/or repair the baler and reduce downtime.

Description:
BACKGROUND OF THE INVENTION 
     1. Technical Field 
       [0001]    The present invention relates to rubber bales and baling equipment, and more particularly to a reduced-maintenance rubber baler having a multi-component bolster cap. 
       2. Related Art 
       [0002]    Rubber is a notoriously difficult material to handle. It also must be handled with care, taking into consideration its various intended uses, some of which are for food or pharmaceutical grade rubber. Especially for the latter purpose, contamination must be avoided. A change of product may require complete cleaning of equipment, sometimes requiring disassembly, particularly of balers. 
         [0003]    Color, which may be white or transparent, must be considered. 
         [0004]    Irregularities such as “teats” remaining on the outer surfaces of bales after forming at high pressure—the teats corresponding to small holes or crevices in the baling machine—are undesirable but inevitable as artifacts of the baling process. Sometimes teats break off in the machine and remain lodged there for several cycles, transforming in color from white to gray, and then sometimes coming loose and being molded into a bale which is then ejected with a discolored teat, which can result in rejection of the bale, especially in pharmaceutical grades and the like. Maintenance is demanding. Heavy pieces of equipment must be maneuvered in tight, crowded spaces. Each second of downtime is lost profit. 
         [0005]    After synthetic rubber is dried in large sheets, it is crumbled and baled. The pieces are larger—some of them becoming fused together—or smaller with a great deal of dust—all of which is desired to be formed into bales. The crumbles may vary in size depending on their Mooney rating. For example, dry, low Mooney crumbles may be between about the size of talcum powder or dust to about the size of a walnut, while wet, sticky, high Mooney crumbles may be between about the size of a walnut to about the size of an orange. The mess of dust can fall back in, contaminating the next batch in the run and forming irregularities. Irregularities and material waste are another concern that may be caused, for example, by misalignment of a bolster. Material seeps out of the compression zone, clogging the press chamber, creating a bind for the ram, increasing service time, decreasing profits. 
         [0006]    Prior art assemblies also use large, heavy ram head assemblies (typically exceeding 550 lbs.) to compress the compressible materials during bale formation. These ram head assemblies include large base portions placed over the end of a hydraulic rod that are held in place by a large pin placed through apertures in the base, the rod, and opposite side of the base (similar to the pins used to keep outdoor/table umbrellas open). Those pins are susceptible to breaking, causing damage to the ram as well as scarring of the hydraulic cylinder shaft surface which may cause premature seal failure of the hydraulic cylinder and/or misalignment. Misalignment creates greater side pressure on one side of the ram head as compared to the other side. The uneven side pressure causes excessive wear on the side seeing the most pressure, reducing the useful life of the ram head. Additionally, the heavy assemblies are difficult to change in the cramped quarters, often requiring a crane or other equipment. 
         [0007]    Finally, the bolts used in prior art ram assemblies to secure a bolster cap include center indentions. These indentations can cause bale deformation and/or contamination when remnants of prior batches get stuck in the indentation. For example, black rubber used for tires may contaminate clear or white rubber used in pharmaceuticals. 
         [0008]    Improvements such as the bolster or bolster assembly described in commonly assigned U.S. Pat. No. 5,870,951, the entire disclosure of which is hereby incorporated by reference, have helped to reduce material waste from about 600-1000 lbs. of waste per 24 hours to about 40-80 lbs. of waste per day. However, a need has long existed for even further improved systems and methods for rubber baling. 
       SUMMARY 
       [0009]    Improved bales may be formed using methods that include baling equipment with multi-component bolster assemblies that may ease installation and removal, reduce wear and tear and maintenance, and/or improve efficiency by reducing material waste, imperfections, and/or contamination. The bolster assemblies may include a plurality of coupling portions that engage a hydraulic rod and may enable the bolster assembly to self-center within a press chamber during normal baling operations. The bolster assemblies also may include an island portion that may be attached to the coupling portions and to a bolster cap, and the latter may be attached using retainer bolts having substantially flat, non-circular heads. The bolts may reduce irregularities in the bale and/or prevent material seepage into the bolster assemblies. During maintenance, an operator may remove only the bolster cap island assembly for cleaning, substantially reducing the time and strength needed to clean and/or repair the baler and reduce downtime. 
         [0010]    Other systems, methods, features and technical advantages of the invention will be, or will become apparent to one with skill in the art, upon examination of the figures and detailed description. It is intended that all such additional systems, methods, features and technical advantages be included within this summary and be protected by the claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    The invention can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. 
           [0012]      FIG. 1  shows a side cross-sectional view an exemplary baler press assembly; 
           [0013]      FIG. 2  shows an exploded view of an exemplary bolster assembly for use in a rubber baler; 
           [0014]      FIG. 3  shows a side cross-sectional view the exemplary bolster assembly of  FIG. 2  mounted on an exemplary hydraulic rod; 
           [0015]      FIGS. 4A-B  show a perspective view and a bottom view of an exemplary island portion of the exemplary bolster assembly of  FIG. 2 ; 
           [0016]      FIGS. 5A-B  show a perspective view and a cross-sectional view of an exemplary bolster cap of the exemplary bolster assembly of  FIG. 2 ; 
           [0017]      FIGS. 6A-B  show a side view and a top view of an exemplary retainer bolt for use with the exemplary bolster assembly of  FIG. 2 ; 
           [0018]      FIGS. 6C-D  show a cross-sectional view and a top view of an exemplary lifting retainer bolt for use with the exemplary bolster assembly of  FIG. 2 ; 
           [0019]      FIG. 6E  shows a perspective view of an exemplary retainer bolt for use with the exemplary bolster assembly of  FIG. 2 ; 
           [0020]      FIGS. 7A-C  show top, side and bottom views of the exemplary bolster assembly of  FIG. 2  in an assembled configuration; 
           [0021]      FIGS. 8A-B  show perspective views of exemplary rubber bales formed using the exemplary bolster assembly of  FIG. 2 ; 
           [0022]      FIGS. 9-12  show side and perspective views of the exemplary baler press assembly of  FIG. 1  at various stages of a bale forming process; and 
           [0023]      FIG. 13  shows a perspective view of an exemplary crumb box and cover assembly for use in the exemplary baler press assembly of  FIG. 1 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0024]    The elements illustrated in the figures interoperate as explained in more detail below. Before setting forth the detailed explanation, however, it is noted that all of the discussion below, regardless of the particular implementation being described, is exemplary in nature, rather than limiting. 
       1.0 Baler Assembly Overview 
       [0025]    Referring to the drawings, and initially to  FIG. 1 , a side view of an exemplary upstroke baler press assembly  10  is shown. Only relevant portions of the baler press assembly  10  are shown; other portions are well known to those skilled in the art and are not discussed herein for sake of clarity. In the illustrated embodiment, the baler press assembly  10  may include a press chamber  100 , a bale ejector assembly  200  and a ram assembly  300 . The press chamber  100  may include press walls  110  that function to provide a rigid support capable of withstanding at least the compression forces necessary to form the bale (described below in Section 3.0). Press wall liners  120  may be secured to the inside of the press walls  110 , such as by means of socket cap screws. Other types of securing mechanisms also may be used in place of the socket cap screws. 
         [0026]    The ram assembly  300  may include a hydraulic rod  302  positioned within a rod housing and scraper  304 . A bolster assembly  308  may be secured to the end of the hydraulic rod  302 . Hydraulic power from the power unit may be supplied to the baler press assembly  10  at a number of power connection points. 
       2.0 Exemplary Bolster Assemblies  308   
       [0027]    Referring now to  FIG. 2 , an exploded view of an exemplary bolster assembly  308  is shown. The bolster assembly  308  may include a first coupling portion  310   a  and a second coupling portion  310   b  that couple to one another, the hydraulic rod  302  and an island portion  320 . In turn, the island portion  320  may couple to a bolster cap  330 . 
         [0028]    The various components of the bolster assembly  308  may be made of any suitably hard material, such as metal, a thermoplastic polymer, or the like. As used herein, the term “thermoplastic polymer” is defined to encompass the DuPont materials Delrin® and Delrin AF® and any other materials having similar relevant properties. Delrin® is an acetal resin thermoplastic polymer (or acetal homopolymer) manufactured by the polymerization of formaldehyde. Delrin AF® contains high tensile strength fibers of Teflon® fluoroplastic resin. Similar wear resistant materials having low static and dynamic coefficients of friction (as compared to steel) and capable of being formed into or bonded to press wall liners and bolster caps are considered to fall within the scope of the term thermoplastic polymer as used in the claimed invention. Other materials also may be used. In some embodiments, each component is made of the same material. Alternatively or additionally, one or more of the components of the bolster assembly  308  may be made of different material than others of the components. 
         [0029]    2.1 Exemplary Coupling Portions  310   
         [0030]    Referring also to  FIG. 3 , each of the coupling portions  310   a  and  310   b  may include a lower portion  311  and an upper portion  312 . When the coupling portions  310   a  and  310   b  are coupled to one another, their respective lower portions  311   a  and  311   b  and upper portions  312   a  and  312   b  may defines cavities for receiving corresponding portions  305  and  306  of the hydraulic rod  302 . This unique configuration provides several benefits over the prior art assemblies, such as increased machine reliability, reduced maintenance, and/or an extended machine life. 
         [0031]    In some embodiments, the cavities defined by the lower portions  311   a  and  311   b  and upper portions  312   a  and  312   b  may be about the same size as the corresponding portions  305  and  306  of the hydraulic rod  302 . Preferably, the cavities defined by the lower portions  311  and upper portions  312   a  and  312   b  may be larger than the corresponding portions  305  and  306  of the hydraulic rod  302 . For example, in a horizontal direction, the cavities defined by the lower portions  311   a  and  311   b  and upper portions  312   a  and  312   b  may be between about 0.025 inches and about 0.040 inches larger than the corresponding portions  305  and  306  of the hydraulic rod  302 , preferably between about 0.030 inches and about 0.035 inches larger than the corresponding portions  305  and  306  of the hydraulic rod  302 . Similarly, in a vertical direction, the cavities defined by the lower portions  311   a  and  311   b  and upper portions  312   a  and  312   b  may be between about 0.002 inches and about 0.010 inches larger than the corresponding portions  305  and  306  of the hydraulic rod  302 , preferably between about 0.005 inches and about 0.007 inches larger than the corresponding portions  305  and  306  of the hydraulic rod  302 . By providing a larger cavity, the coupling portions  310   a  and  310   b  may allow the bolster assembly  308  to self-center in the pressure chamber during operation. As a result of the coupling portions  310   a  and  310   b , preferably no portion of the bolster cap  330  comes into frictional contact with the press wall liners  120  during a baling cycle. 
         [0032]    Self-centering of bolster assembly  308  may reduce and/or eliminate any or all misalignment problems and provide at least one or more of a variety of benefits. For example, self-centering may result in extended life of those components of the hydraulic cylinder that may experience wear from frictional engagement between a bolster and a press chamber wall or liner. Because of the self-centering action of the bolster assembly  308 , the amount of side pressure exerted on the hydraulic rod  302  packing and seals may be reduced. As a result, the baler press assembly  10  may have improved reliability when compared to the prior art. The unique design also may improve the useful life of the bolster cap  330  due to potential misalignment of the hydraulic rod  302 . 
         [0033]    In the illustrated embodiment, the cavities defined by the upper portions  312   a  and  312   b  and lower portions  311   a  and  311   b  of the coupling portions  310   a  and  310   b  may comprise toroids, and specifically, rectangular toroids. In other words, the upper portions  312   a  and  312   b  and lower portions  311   a  and  311   b  each define respective arcs that form cylindrical cavities when the coupling portions  310   a  and  310   b  are attached to one another. Other shapes may also be used. In addition, although two coupling portions  310   a  and  310   b  are shown, more or less coupling portions may be used. 
         [0034]    The coupling portions  310   a  and  310   b  may be coupled to one another via bolts disposed in apertures  316 . Alternatively, or additionally, other methods may be used to secure coupling portions  310   a  and  310   b  to one another. In addition, coupling portions  310   a  and  310   b  may be movably attached to one another. For example, coupling portions  310   a  and  310   b  may be hingedly attached to one another on one end and a single bolt may be used to fix the coupling portions  310   a  and  310   b  about the hydraulic rod  302 . Other variations also may be used. 
         [0035]    2.2 Exemplary Island Portions  320   
         [0036]    Referring to  FIGS. 4A-B , an exemplary island portion  320  is shown in both perspective and bottom views. The island portion  320  may include a reduced section  322  and a base  328 . The reduced section  322  may also include a plurality of bores  326  for receiving bolts that attached the island portion  320  to the coupling portions  310   a  and  310   b . In the illustrated embodiment, six bores  326  are provided to receive the bolts. The island portion  320  also may include a plurality of bolster bores  322  for receiving the retainer bolts  334  and  336  used to attach the bolster cap  330 . The island portion  320  may weigh between about 160 lbs. and about 220 lbs., preferably may be between about 175 lbs. and about 205 lbs., and even more preferably between about 190 lbs. and about 195 lbs. This is a significant reduction in weight from the prior art, resulting in eased maintenance. 
         [0037]    2.3 Exemplary Bolster Caps  330   
         [0038]    Referring to  FIGS. 5A-B , an exemplary bolster cap  330  is shown in perspective and cross-sectional views. In the illustrated embodiment, the bolster cap  330  may include a recessed portion  337  that may be configured to receive the reduced section  327  of the island portion  320 . The bolster cap  330  may weigh between about 20 lbs. and about 60 lbs., preferably may be between about 30 lbs. and about 50 lbs., and even more preferably between about 40 lbs. and about 45 lbs. In addition, the bolster cap  330  may include a plurality of countersunk bores  332  corresponding to the bores of the reduced section of the bolster  322 . The countersunk bores  332  and bores  322  may be adapted to receive retainer bolts  334  and/or a lifting retainer bolt  336 . 
         [0039]    2.3.1 Exemplary Retainer Bolts  334   
         [0040]    A novel exemplary retainer bolt  334  is shown in a side view, a top view and a perspective view in  FIGS. 6A, 6B and 6E , and an exemplary lifting retainer bolt  336  is shown in a cross-sectional view and a top view in  FIGS. 6C-D . The retainer bolt  334  and the lifting retainer bolt  336  may have generally the same overall shape. For example, the retainer bolt  334  and the lifting retainer bolt  336  may each include substantially flat heads  340  and  350 , frustoconical portions  342  and  352 , unthreaded portions  344  and  354 , and threaded portions  346  and  356 . The bolts  334  and  336  also may include a center drill hole  349  ( FIG. 6E ) that is used to provide a consistent center during machining of the bolts  334  and  336 . The retainer bolts  334  and lifting retainer bolt  336  may be made of any suitable material, such as  316  stainless steel or the like. 
         [0041]    Preferably, retainer bolts  334  and the lifting retainer bolt  336  have a substantially flat head so that the upper surface of the bolster cap  330  is substantially flat and even. The use of flat heads may reduce or eliminate the formation of irregularities such as “teats” from forming during the baling process. In some embodiments, a lifting retainer bolt  336  may be provided, such as in the center of the bolster cap  330 , to facilitate removal of the bolster cap  330  and island  320 . 
         [0042]    In some embodiments, the retainer bolts  334  and  336  may be placed in countersunk bores  332  (also referred to as pockets) in the bolter cap  330 , run through the island  320  and be secured by a corresponding nut  360  and locking washer  362 . Optionally, adhesives, such as LOCTITE® adhesives sold be Henkel North America of Rocky Hill, Conn., may be used to further secure the bolts  334  and  336  to the corresponding nuts  360 . 
         [0043]    The countersunk bores  332  may complimentary shapes for receiving the bolts  334  and  336 , such as non-circular openings  333 , frustoconical portions, and the like. In the illustrated embodiment, the heads of the bolt  334  are rounded rectangles, and, in particular, rounded squares. Other non-circular shapes also may be used, such as ovals, triangles, hexagons and the like. The use of non-circular openings  333  may prevent the non-circular heads  340  and  350  of retainer bolts  334  and  336  from rotating while in the bores  332 . They also may allow corresponding nuts  360  (shown in  FIG. 2 ), which may be a Teflon locking nut or the like, to be removed from the bolts  334  and  336  without the need for an additional instruments (such as a screwdriver) to be inserted into the heads  340  and  350  of the bolts  334  and  336 . 
         [0044]    The size of the heads  340  and  350  may vary based on the shape used. 
         [0045]    For example, the rounded rectangular heads  340  and  350  shown in  FIGS. 6A-D  may have sides between about 1¾ inches and about 2¼ inches, preferably about 2 inches, and may have corner radii between about ¼ inches and about ½ inches, preferably about ⅜ inches. The rounded rectangular shape may provide a stronger bolt head  340  over a pure rectangular head. The depth of the heads  340  and  350  may be between about ⅛ inches and about ⅜ inches, preferably about ¼ inches. 
         [0046]    The frustoconical portion of the bolts  334  and  336  may be angled between about 76° and about 88°, preferably between about 79° and about 85°, and even more preferably about 82°. The frustoconical portions  342  and  352  may have heights between about ½ inches and about 1⅛ inches, preferably between about ⅝ inches and about 1 inch and in one embodiment about ⅘ inches. The diameter of the bases of the frustoconical portions  342  and  352  may be about the same size as the sides of the head  340  and  350 , or preferably may be slightly smaller than the sides of the heads  340  and  350  so that the lip  341  provided by the underside of the heads  340  and  350  may run about the perimeter of the base of the frustoconical portions  342  and  352 . For example, for a retainer bolt  334  having a side of about 2 inches, the diameter of the frustoconical portion  342  may be 1 995/1000 inches. 
         [0047]    The combination of the flat heads  340  and  350 , angled frustoconical portions  342  and  352 , and/or the lips  341 , and their complimentary portions in the bores  332 , may reduce and/or substantially prevent any rubber crumbles (or portions thereof) from entering the bores  332  and/or settling between the bolster cap  330  and island portion  320 , gumming up the threads and/or causing bowing between the bolster cap  330  and island portion  320  over time. In some embodiments, the clearance between these components  340 - 42  and their complimentary counterparts in the pockets  332  may be between about 1/1000 inches and about 1/100 inches, preferably about 5/1000 inches. 
         [0048]    The threaded portions  346  and  356  may have a runout of between about 2¼ inches and about 3 inches, preferably about 2½ inches. Various threading may be used. Preferably, the threading is fine threading, such as, for example, ¾ inch 16 UNF threading, ⅞ inch 14 UNF threading, 1 inch 14 UNF threading, 1⅛ inch 12 UNF threading, or the like. The diameter of the threaded portion  346  and  356  may be between about ⅘ inches and about 1⅕ inches, preferably about 995/1000 inches. 
         [0049]    The lifting retainer bolt  336  may include a threaded center bore  338 . During bale forming operations, an insert  338  may be inserted into the threaded center bore  339  to create a substantially flat upper surface. During maintenance (as described below), a handle or other tool may be secured to the threaded portion  339  to allow an operator to lift the bolster cap  330  and island portion  320 . Various fine or course threading may be used for the threaded center bore  338 , such as for example, 7/16 14 UNC threading, 7/16 20 UNF threading, ½ 13 UNC threading, ½ 20 UNF threading, 9/16 12 UNC threading, 9/16 18 UNF threading or the like. 
         [0050]    The unique retainer bolts  334  and  336  described herein may reduce and/or eliminate the marring of the under surface of the rubber bale during the baling operation and/or contamination that may be caused by these prior art bolts. In some embodiments, the bolts  334  and  336  may be tightened to a predetermined torque rating, such as between about 90 ft./lbs. of torque to about 150 ft./lbs. of torque, preferably between about 105 ft./lbs. of torque and about 135 ft./lbs. of torque and in one embodiment about 120 ft./lbs. of torque. Tightening the bolts  334  and  336  in this range further secures the heads  340  and  350 , lips  341  and frustoconical portions  342  and  352  to the pockets  332 , further preventing dust or other compressible materials from infiltrating the bores  332 . 
         [0051]    2.4 Bolster Assembly/Disassembly 
         [0052]      FIGS. 7A, 7B and 7C  show top, side and bottom views, respectively, of an assembled exemplary bolster assembly  308 . To assemble a bolster assembly  308 , an operator may position the first coupling portion  310   a  and the second coupling portion  310   b  about the hydraulic rod  302  and secure the coupling portions  310   a  and  310   b  to one another via bolts. Next, the bolster cap  330  may be positioned atop the island portion  320  and secured thereto using the retainer bolts  334 . Finally, the combined island portion  320  and bolster cap  330  may be positioned atop the coupling portions  310   a  and  310   b  and secured thereto by bolts. 
         [0053]    Preferably, all frictional contact between the ram assembly  12  and the press chamber  100  preferably occurs between the press wall liners  120  and the bolster cap  330 . Thus, the bolster cap  330  receives the brunt of the wear for the bolster assembly  308  during baler operation. The design of the bolster assembly  308  allows for the removal of only the island portion  320  and bolster cap  330  when a bolster cap  330  needs replacement. This significantly reduces the weight of the removable part of the assembly when compared to the prior art. For example, the combined weight of the island portion  320  and the bolster cap  330  may be between about 180 lbs. and about 280 lbs., preferably may be between about 205 lbs. and about 255 lbs., and even more preferably between about 230 lbs. and about 240 lbs. This weight reduction reduces the time and physical effort required of the maintenance crew. 
         [0054]    2.5 Exemplary Ejector Mechanism 
         [0055]    Referring to  FIGS. 1 and 9-11 , the exemplary ejector mechanism  200  may include a crumb box  210 , a cover assembly  220 , a cover rail support  230 , a cover hydraulic cylinder  240  and a support arm  250 . The crumb box  210  may provide a pathway for crumbles to enter the press chamber  100  and also may include an ejection bumper  212  for horizontally ejecting a formed bale  400  (shown in  FIGS. 8A and 8B ), as described below. 
         [0056]    The cover assembly  220  may be attached to the crumb box  210 , as shown in  FIG. 13 . The cover assembly  220  may include a top plate  222 , a cover plate  224  and wheels  226 . The top plate  222  may close off the crumble shoot  500  during a bale forming process to prevent additional crumbles spraying onto the baler assembly  10 . The cover plate  224  may close the press chamber  100  during a bale forming operation. The wheels  226  may allow the cover assembly  220  to move along the cover rail support  230  during a bale forming operation. 
         [0057]    The cover hydraulic cylinder  240  may provide a motive force for moving the crumb box  210  and cover assembly  220  during a bale forming operation. Finally, the support arm  250  may provide a base upon which the other portions of the ejector mechanism  200  may rest. 
       3.0 Bale Forming Methods 
       [0058]    Referring to  FIGS. 1 and 9-11 , during normal operation, rubber crumbles or other compressible materials may be weighed and supplied to the press chamber  100  via a conveyor belt (not shown). As shown in  FIG. 9 , the crumb box  210  may be positioned between the crumb shoot  500  and the press chamber  100  at this time to provide a pathway for crumbles to enter the press chamber  100  to ensure that the full weighed amount of crumbles enters the press chamber  100 . The crumb box  210  also prevents crumbles from spraying onto other components of the baler assembly  10 . 
         [0059]    Next, the cover assembly  220  is positioned between the press chamber  100  and the crumble shoot  500 , as shown in  FIG. 10 . The top plate  222  may close off the crumble shoot  500  at this time to prevent additional rubber crumbles or other compressible materials from spraying onto the baler assembly  10 . The cover plate  230  may close off the top of the press chamber, which prevents rubber crumbles or other compressible materials from exiting the press chamber. In some embodiments, the cover plate  224  is positioned so as to allow a small gap between the cover plate  224  and the top of the press chamber  100 . This gap may allow air to escape from the press chamber  100  during a bale forming operation and prevent the vapor lock and/or the formation of a “fluffy” bale. Preferably, the cover plate  224  is positioned to provide a gap between about 1/100 inches and about 15/1000 inches. 
         [0060]    Next, the ram assembly  300  may be activated. Upon activation, hydraulic power may be applied to the ram assembly  300  such that the hydraulic rod  302  travels in an upward direction, forcing the bolster assembly  308  into the press chamber  100 . The baler press assembly  10  may be powered by a hydraulic power unit (not shown). The compression force applied by the ram assembly  300  may be of sufficient magnitude to form a solid bale of the compressible material contained in the press chamber  100 . For example, the compression force may be between about 1000 pounds per square inch (PSI) and about 1500 PSI and preferably about 1200 PSI for low Mooney crumbles. For high Mooney crumbles, the compression force may be between about 1500 PSI and about 3500 PSI, preferably between about 2000 PSI and about 3000 PSI. The dwell time, or duration of the compression period, may be between about 0.5 seconds and about 3 seconds for low Mooney crumbles, and in some embodiments about 1 second. For high Mooney crumbles, the dwell time may be between about 10 seconds and about 20 seconds, and in some embodiments about 15 seconds. Finally, the temperature of the press chamber may between about 120° F. and about 180° F., preferably between about 130° F. and about 155° F., depending on the type of material. 
         [0061]    Following formation of the bale, the ejector mechanism may be repositioned to allow the formed bale  400  to be vertically ejected from the press chamber  100 , as shown in  FIGS. 11 and 12 . Once the bale  400  is vertically ejected from the bale, the crumb box  210  may be moved horizontally so that the bumper  212  horizontally ejects the bale  400  from the assembly  10 . At that time, the crumb box  210  may be positon between the shoot  500  and the press chamber  100  and the entire process may be repeated to form additional bales. 
       4.0 Exemplary Bales 
       [0062]    Exemplary bales are shown  FIGS. 8A-B , which show a low Mooney bale  400   a  and high Mooney bale  400   b , respectively. As a result of performing the above described method and using the improved baling apparatuses and bolster assemblies  308  described herein, bales  400  of rubber (or other material) substantially free of imperfections and/or irregularities may be manufactured. 
       5.0 Exemplary Embodiment 
       [0063]    In one embodiment, a baling apparatus for compressing rubber materials may be provided. The baling apparatus may include a hydraulic rod and a bolster assembly. The bolster assembly may include a first coupling portion and a second coupling portion removably attached to the first coupling portion. The first coupling portion and the second coupling portion may cooperatively define a cylindrical cavity for receiving the hydraulic rod, and the cavity may be between about 0.030 inches and about 0.035 inches larger than the received portion of the hydraulic rod. The bolster assembly also may include an island portion attached to the first coupling portion and the second coupling portion, and the island portion may include a reduced section. A bolster cap may be attached to the island portion, and the bolster cap may include a recessed section that engages the reduced section of the island portion. The bolster cap including a plurality of countersunk bores for receiving retaining bolts that have substantially flat, rounded rectangular heads. The baler apparatus also may include a press chamber for receiving the bolster assembly and the rubber materials, wherein compression force is provided by movement of the bolster inside the press chamber to form a rubber bale. 
         [0064]    It is contemplated that the novel portions of the baler press assembly  10  could be used in any type of press assembly having a press chamber. Further, the scope of the invention is not considered limited to rubber balers, but instead could be used in the compression of a wide variety of materials. 
         [0065]    While various embodiments of the invention have been described, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible within the scope of the invention. Accordingly, the invention is not to be restricted except in light of the attached claims and their equivalents.