Abstract:
A recycling method is disclosed that includes the steps of compacting recyclable material into a fixed bale of recyclable material while concurrently weighing the OCC in the compactor and independently of the force that the compactor applies to the material or to the bale, assigning an individual identifier to the fixed bale in which the identifier includes at least the weight of the bale, and sending the fixed identified bale to a destination selected from the group consisting of shippers, mills, rebalers, or a customers for the baled recyclable material.

Description:
BACKGROUND 
       [0001]    The invention is an improvement in methods of recycling. Recycling is, of course, an activity rather than a composition per se. Thus, almost any item or material is “recyclable” in some fashion. That said, the most commonly recycled materials include old corrugated containers (OCC), paper, plastic, and non-ferrous metals (e.g., aluminum). The invention relates to any (or all) of these materials. 
         [0002]    As an exemplary material, and at recent prices, “used” cardboard is worth approximately US$100-150 per ton. This makes its collection and recycling economically viable. According to some statistics, about 30 million tons of OCC were recovered in the US in 2011; i.e., worth about US$3-4 Billion. Similar statistics exist for other recyclable materials. 
         [0003]    OCC is of interest because commercially, a large percentage (70-90%) of goods is shipped in some form of corrugated containers. Because of that, discarded boxes at retail establishments (e.g., grocery stores and volume retailers) represent a significant amount of OCC. Typically, the discarded boxes are temporarily compacted and baled at the retailer and then hauled away by a commercial waste company to a recycling center. At the recycling center, the cardboard is pressed and wrapped (i.e., rebaled) into bales that are sized for particular requirements such as transport in containers (i.e. container ships, container trailers) or for the input stream of a paper recycling mill. 
         [0004]    Generally, the retailer does not have the capability for such a finalized baling, but instead uses a simpler, but less precise, baler. Because of that, the retailer is at the mercy of the hauler or recycling company in terms of calculating the amount (weight) of the collected cardboard material and the price that the OCC should command. Indeed, in many cases the hauler simply reports an unverified weight to the retailer, a weight that the retailer has no means of confirming. Given that grocery store chains and other retailers can generate huge amounts of discarded cardboard—even within local geographic areas—the total weight can reach thousands of tons per year, that in turn represent millions of dollars. Accordingly, a retailer&#39;s (or a retail chain&#39;s) loss of even a small percentage of the value of the collected discarded cardboard represents a relatively large economic disadvantage. 
         [0005]    Stated positively, a sufficient economic incentive already exists and thus, the reward for recycling OCC (or any other relevant material) is potentially significant. 
         [0006]    As another factor, because OCC material must be hauled from retailers to recycling centers, transportation costs and regulations (e.g., weight limits for commercial vehicles) also become an economic factor. An under loaded (or inefficiently loaded) truck wastes fuel resources while overloaded ones create regulatory and legal problems. As a result, the lack of precise information about OCC bales costs the retailer significant amounts, wastes transportation resources (thus effectively increasing transportation costs) and potentially violates state and federal laws. 
         [0007]    In particular, a significant amount of OCC (or other baled recyclable material) is, at some point, hauled in steel intermodal containers (also referred to as “shipping containers,” “sea containers,” and “ISO containers”). A variety of such containers exist, and a common size is 40 feet long, 8 feet wide and 8½ feet high. The maximum load for this size container is typically about 30,000 kg (about 66000 pounds; about 33 tons). As those in the shipping business are aware, however, the exact sizes and weight capacities (or allowances) can differ from container to container and in some cases from shipper to shipper. 
         [0008]    Regardless of exact sizes, using containers in the most efficient fashion requires filling up the volume and carrying the maximum weight. Stated differently, a shipped container that is less than full (either by volume or by weight) represents an inefficient use of resources and a resulting excess cost. 
         [0009]    Currently, compacted OCC bales that (i) have dimensions of about 58×30×45″ and (ii) weigh about 1250 pounds, will fill a standard container most efficiently. In current practice, however, the retailer does not produce such bales and instead relies on the hauler or recycler to produce the desired bales for further shipment or use. 
         [0010]    As a result, bales of consistent size and weight can have more value than bales of random size and weight, particularly when the bales are intended for container shipping or export or both. The retailer loses this value (or a fraction thereof) when the retailer produces an informal bale. 
         [0011]    In a corresponding manner, informal bales will not fill a shipping container by volume, or by weight. Because of that, a container that is shipped at less than full capacity reduces efficiency and increases cost by a factor related to the percentage of unused space or weight. 
       SUMMARY 
       [0012]    Accordingly, in one aspect, the invention is a combination of a baler (compactor), a scale that weighs the recyclable material in the compactor at any point from the loading step to the finished compacted bale and independently of the force applied to the bale by the compactor, an identification system, and one or more processors (computers) that will bale to a required size on site (i.e., at the retailer), that will concurrently weigh the bale, that will assign an identifier (e.g. a barcode or RFID) to the bale, and then provide the selling retailer (and potentially other parties) with a highly accurate inventory of discarded, baled, sold, and transported recyclable material. 
         [0013]    In another aspect, the invention is a recycling system that is particularly suitable for old corrugated containers (OCC) generated at a retail location. The system includes a baler for baling multiple pieces of OCC into generally fixed bales, a scale in weighing communication with the baler for weighing baled OCC produced by the baler, an identification system for adding specific identification to each bale produced by the baler, and at least one processor in signal communication with the baler, the scale and the identification system. 
         [0014]    In another aspect, the invention is a weighed, identified bale of recyclable material that is ready for immediate container shipment or for a mill. 
         [0015]    In another aspect, the invention is a recycling method that includes the steps of compacting recyclable material in a compactor into a bale while concurrently weighing the material in the compactor and independently of the force that the compactor applies to the material or to the bale, assigning an individual identifier to each fixed bale in which the identifier includes at least the weight of the bale, and generating an inventory of the baled recyclable material. 
         [0016]    In yet another aspect, the invention is a recycling method that is particularly suitable for old corrugated containers (OCC) generated at retailers, that includes the steps of baling OCC into a fixed bale of OCC, weighing the fixed bale, assigning an individual identifier to the fixed bale in which the identifier includes at least the weight of the bale, and sending the fixed bale to a destination selected from the group consisting of shippers and mills (recycling, paper). 
         [0017]    The foregoing and other objects and advantages of the invention and the manner in which the same are accomplished will become clearer based on the followed detailed description taken in conjunction with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]      FIG. 1  is a flow diagram illustrating the method of the invention. 
           [0019]      FIGS. 2 and 3  are perspective views of a baler according to the invention. 
           [0020]      FIG. 4  is an exploded view of the perspective views of  FIGS. 2 and 3 . 
           [0021]      FIG. 5  is a front elevational view of a baler according to the invention. 
           [0022]      FIG. 6  is a cross-sectional view taken along lines A-A of  FIG. 5 . 
           [0023]      FIG. 7  is a side elevation overview of the baler according to the invention. 
           [0024]      FIG. 8  is a top plan view of the baler of  FIG. 5 . 
           [0025]      FIG. 9  is a perspective view similar to  FIG. 3 , and  FIGS. 10 and 11  are enlarged cutouts of the indicated portions of  FIG. 9 . 
           [0026]      FIG. 12  is another perspective view similar to  FIGS. 3 and 9 , with enlarged cutout portions that form  FIGS. 13 and 14 . 
       
    
    
     DETAILED DESCRIPTION 
       [0027]      FIG. 1  is a schematic diagram illustrating various elements of the invention and the method of the invention. The invention is described in terms of old corrugated containers (“OCC”) that are designated at  15  in the flowchart and that are placed or otherwise delivered to a baler  20 . 
         [0028]    As a point of nomenclature, a device that uses force (e.g., a press or a piston) to reduce the size of waste material such as OCC is typically referred to as a “compactor.” In this specification, the terms “baler” and “compactor” are generally used interchangeably unless the context indicates a different use or distinction. “Baling” refers to the step—manual or automated—of wrapping the compacted waste material in some fashion that maintains its integrity for the most part as a geometric unit. Baling is typically carried out by wrapping the OCC with metal bands, or with high-strength polymer strips, or in some cases polymer wrap, or with some other appropriate material. 
         [0029]    In the flowchart, the OCC  15  and the baler  20  are connected by the line  16 . In actual practice this relationship can be as simple as having an operator deliver the OCC  15  to the baler  20 , or the line  16  can represent a more sophisticated system (e.g. a conveyor) for delivering OCC to the baler  20 . In the expected context of an individual retail location, it is likely that an operator will place the OCC  15  in the baler  20 . 
         [0030]    In most cases, the baling step is selected based upon the preference of the customer that will receive the bale. One typical technique is to hand wrap the compacted bale with 14 gage baling wire. This is typically available in precut lengths (e.g. 10 feet) and is sometimes covered with a protective plastic coating. A 14 gage wire can generally be tied by hand without significant difficulty. 
         [0031]    In most circumstances, the compactor essentially forces the memory out of the materials such as plastic or cardboard during the compacting step. If the bale is tied relatively quickly after compacting, the return of the memory will cause the bale to expand against its tie and thus essentially tighten the bale. 
         [0032]    In a first aspect, the method includes the step of baling the OCC  15  into a plurality of generally fixed bales of OCC and then weighing each bale. As will be described in somewhat more detail with respect to  FIGS. 2-11 , the baler includes a scale  21  that is in weight communication with the baler  20  for weighing the bale of OCC  15  produced by the baler  20 . The term “scale” is used broadly to describe any device that weighs the bale, including devices that weigh the bale “in progress.” In the embodiments illustrated in  FIGS. 2-11  the weighing is carried out by one or more load cells  82  that are under the baler (e.g.,  FIG. 11 ) and electronically connected to the processor  25  by the communication line  27 . 
         [0033]    Because the load cells are under the baler (compactor), they can weigh the compactor and its contents while the compactor is compacting recyclable material and independently of the force that the compactor applies (e.g., cylinder  60 ,  FIG. 2 ). Because the weight of the compactor  20  will generally remain constant, the difference in weight measured by the load cells will represent the weight of any added recyclable material. 
         [0034]    An individual identifier is assigned to each fixed bale in which the identifier includes at least the weight of the bale from the scale  21 . As will become clear from the further description herein, any identifier that can carry the required information and from which the required information can be reproduced or harvested is appropriate. In most current embodiments, the individual identifier will be some version of a radio frequency identification device (“RFID”) or a machine readable label such as a barcode. 
         [0035]    The term “barcode” is used in a broad sense and includes variation familiar to hose in the art such as “UPC,” “EAN,” and several others. In addition to individually naming (so to speak) a bale, these codes can include data about dates, measurements, locations, and many other types of information. 
         [0036]    In  FIG. 1 , the identification system is indicated at  23  and an identified bale is indicated at  24 . A processor  25  is in signal communication with the baler  20 , with the scale  21 , and with the identification system  23 . Communication lines  26 ,  27  and  30  help illustrate these relationships. In the context of a plurality of bales, the method includes generating an inventory of the baled OCC material using the processor  25  and appropriate memory. The processor can be any appropriate device that has the calculating and memory sufficient to handle the steps of the invention. Typically, it includes a programmable logic controller (PLC) that can be programmed by the user. Many current types of PLC&#39;s can be programmed through a connection (e.g. Ethernet) to a personal computer and thus PLC&#39;s appropriate for the invention can be selected, programmed and used by those skilled in the art, and without undue experimentation. 
         [0037]    In the method, the OCC is baled into a plurality of bales of similar fixed weight, or of similar geometry, or of both similar weight and similar geometry. Because of the nature of OCC, and of baling and recycling in general, the term “fixed weight” will be understood to include an appropriate tolerance or uncertainty rather than the level of precision that might be expected, for example, in bench top chemistry experiments. In some embodiments, the method comprises adding the OCC  15  to the baler  20  until the baler  20  and it&#39;s scale  21  detect a desired bale wait of OCC, and then producing a bale from that amount of OCC. 
         [0038]    It will be understood, of course, that although the method is particularly advantageous for multiple bales and large amounts of OCC, the method also applies to a single bale. 
         [0039]    In the same manner, the invention can include, either in conjunction with the weight or independently of it, baling the OCC  15  into a plurality of bales of similar fixed shape. The most typical shape is a solid rectangle (again used generally with an understood tolerance) and an advantage of the invention is that it will produce the bale in a size and weight that is considered mill-ready. Although the term “mill-ready” is to some extent subjective, it is understood in the industry to represent a solid rectangle that weighs at least about 800 pounds, or in some cases at least 1000 pounds, and in many cases over 1200 pounds. Similarly, the bale will have dimensions on the order of about 60 inches on at least one of its sides (length width or height). As noted in the background, bales having dimensions of 58×30×45 inches (about 147×76×114 centimeters) are most efficiently-sized for filling typical shipping containers with little or no wasted space. Additionally, if such bales weigh about 1250 pounds (about 568 kilograms) each, they will match (or nearly match) the 30,480 kg (67,056 pound) weight limit. Using the maximum space and weight in turn maximizes the efficient use of a plurality of containers, including the most efficient use of energy to transport the containers and the proportionally lowest cost. 
         [0040]      FIG. 1  also illustrates that one of the advantages of the invention is the use of the baler  20  at the site of the retailer  31  at which the OCC is being generated. As indicated in the background, the general advantage of the invention is to produce bales that can be transported to, and used at, a final destination without any rebaling step.  FIG. 1  illustrates the destination as the mill (or buyer or shipper)  32 , and the transportation to the mill  32  is indicated by the line  38 .  FIG. 1  is, of course, exemplary rather than limiting of the invention, and the destination is not limited by the terminology used herein. 
         [0041]    In some circumstance, some (rather than all) of the bales are identified, labeled, and tracked. Stated differently, a method that bypasses one or a few bales from a plurality of bales still falls within the invention. 
         [0042]    Furthermore, because the bales  24  carry the individual identifiers, the method can include reading the location of the bales using the bales&#39; individual identifiers after the bales leave the retail site. This step is illustrated in  FIG. 1  by the detector  33 . The detector  33  is appropriately complementary of or congruent with the type of identification used in the bale  24 . Thus, if the bale is identified with an optical label such as a barcode, the detector  33  will be an optical scanning device that will recognize the barcode and interpret (and store and send) the information provided by the barcode. 
         [0043]    Alternatively, if the identification system is RFID, the detector will either pick up the signal from the RFID or broadcast a signal to which the RFID responds. The relationship between the detector  33  and the identified bale  24  is indicated by the connecting line  34 . 
         [0044]    RFID devices are helpful because in most circumstances they eliminate the need for a data entry step. Their use and operation are generally well understood in the art and can be adopted by those of ordinary skill without undue experimentation. Some RFID tags are “passive” meaning that they have no internal power source, but draw power from the detector. Active tags contain a battery for power and some tags combine both passive and powered features. RFID tags have the advantage of not needing to be within the line of sight of a particular optical reader and thus can be embedded in the bales. 
         [0045]    Bar-code labels or other similar indicators, however, have different advantages. Such labels are typically much less expensive than RFID tags and a plurality of data sources can be placed on the same object. Additionally, barcodes or other optical labels can be generated and distributed electronically; for example by email or to mobile devices. 
         [0046]    In order to provide the relevant information to the interested parties, the information from the detector  33  is sent to the retailer  31 , the mill  32  or both. As illustrated in  FIG. 1 , this is most conveniently carried out using the Internet which in turn is symbolized by the cloud  35 . 
         [0047]    The use of the Internet  35  is, of course, convenient rather than mandatory, but the ubiquitous nature of the Internet and the ease of electronic communications make its use convenient and helpful. Connecting line  36  illustrates the flow of information from the detector  33  to the Internet  35  and line  37  similarly indicates the flow of information from the Internet to the mill  32 . Line  40  indicates the flow of information from the Internet  35  to the retailer  31 . 
         [0048]      FIG. 1  also illustrates that the relevant identification data  41  is generated by the scale  21  and by the identification system  23 . The data  41  arrives from (or its path is symbolized by) the scale  21  through the line  22  and with the identification system by the line  43 . On a periodic basis, information and identification data are produced by the detector  33  as indicated by the line  44  connecting the detector  33  to the data  41 . 
         [0049]    In a similar manner, the relationship between the baler  20  and the identification system  23  is indicated by the line  45  and the relationship between the baler  20  and the identified bale  24  is indicated by the line  46 . The relationship between the scale  21  and the identification data  41  is indicated by the line  42 , and between the data  41  and the Internet  35  by the line  39 . Line  49  represents the relationship between the bale  24  and the identification system  49 . 
         [0050]      FIG. 1  also shows that the processor  25  can also provide information  47  to the retailer early in the process, a relationship indicated by the connecting lines  50  and  51 . 
         [0051]    Although  FIG. 1  illustrates several of these potential communication relationships, it will be understood that  FIG. 1  is exemplary rather than limiting of this capability. Accordingly, the invention can include other paths of communication between and among the retailer, the bale, the mill, the transporter (shipper) and the Internet. 
         [0052]      FIG. 2  is a perspective view of a baler  20  that includes aspects of the present invention. The baler  20  includes a frame broadly designated at  53  that is typically form of an appropriate metal, usually steel. The frame  53  has a number of structural elements such as the girders  54 ,  55 , and  56  at the top. A pair of parallel reinforcing girders  57  helps support a main compaction cylinder  60  which is typically a hydraulic cylinder. The main compaction cylinder  60  is connected to hydraulic fluids through appropriate hydraulic lines (which have been omitted from  FIG. 2  for clarity). The hydraulic cylinder includes a piston  94  ( FIG. 6 ) driven by the motor  61  and obtains fluid from, and is controlled by, a tank and control housing  62 . 
         [0053]    The main compaction cylinder  60  is attached to a press head assembly broadly designated at  63 . In the illustrated embodiment, the press head assembly is formed of a plurality of press head plates  64 . These are connected to the main compaction cylinder  60  by the crosspiece  65  and the plate  66 . 
         [0054]    The compactor  20  includes a vertically oriented gate  70  that reciprocates vertically between two gate guide tube assemblies  71 . The gate  70  includes a smaller portal  72  through which an operator can observe the status of the compaction and of any resulting bale. The gate  70  is typically raised in order to add OCC and lowered (closed) for the compacting step. 
         [0055]    In order to remove the bale from the compactor  20 , a door  73  is included in the lower half of the baler  20 . The door  73  is mounted on a door hinge  74 . When the compactor is in operation the door is closed (e.g.,  FIG. 3 ) and held in place by a door latch  75 . The door latch  75  pivots on a hinge  97  ( FIG. 14 ) and is in turn is opened and closed by the turnbuckle  76  which moves on its own hinge  77 . 
         [0056]    The floor of the baler  20  is broadly designated at  80  and in the illustrated embodiment is formed of a plurality of floor plates  81 . 
         [0057]    Although illustrated in more detail in  FIG. 11 ,  FIG. 2  also illustrates a pair of load cells  82 . In the illustrated embodiment, a total of four load cells are positioned beneath the main frame  53  and are operatively connected to the controller and display  84 . 
         [0058]      FIG. 3  illustrates the same baler  20  and thus the same structural and operational elements as  FIG. 2 , but with the gate  70  lowered and the door  73  closed and latched. 
         [0059]      FIG. 4  is an exploded view of the same baler  20  illustrated in  FIGS. 2 and 3 . Thus, the elements are the same, with  FIG. 4  helping to illustrate a few more structural elements.  FIG. 4  illustrates that in addition to the cross pieces  65  and the plate  66 , the press head assembly  63  includes vertical bars  85  and horizontal bars  86  that are further joined and supported by the crossbars  87 . 
         [0060]      FIG. 4  also illustrates that the frame  53  includes side panels  90  and a rear panel  91 . A pair of control support bars  92  extend from the side panel  90 .  FIG. 4  also illustrates a limit switch  93  (best seen in  FIG. 13 ) that is typically one of several present for monitoring various positions of (for example) the press head assembly  63  as it reciprocates vertically. 
         [0061]      FIGS. 5-8  are additional elevational, plan and cross-sectional views of the baler  20 . These figures illustrate a number of items that have already been described, and thus they carry the same reference numerals.  FIG. 6  illustrates that the main compaction cylinder  60  includes a piston  94  that reciprocates within the cylinder  60 .  FIG. 5  includes a somewhat clearer view of the digital display  95  on the controller  84 .  FIG. 7  illustrates another limit switch  96  positioned lower in the baler  20  than the limit switch  93  illustrated at the top. 
         [0062]      FIG. 9  is identical to  FIG. 3 , but includes the cut out expanded views of  FIGS. 10 and 11 .  FIG. 10  illustrates the controller  84  and its digital display  95 .  FIG. 10  also illustrates the hinge  97  for the door latch  75 . 
         [0063]      FIG. 11  shows the rear load cell  82  and its surrounding structure. The structure includes a side angle iron  100 , a small portion of the floor plate  81 , another angle iron  101  that serves as a load cell cover, and a load cell arm  102  that transfers force from the floor plate  81  to the load cell  82 .  FIG. 11  also illustrates that the side angle iron  100  is fixed to several anchor bolts  103 , two of which are visible in  FIGS. 3 and 9 . As the skilled person will recognize, both the weight of the baler and its reciprocating motion require that the baler be firmly anchored in place, and the anchor bolts  103  are thus typically fixed directly to a structural floor (or equivalent element) that can handle the forces generated when the baler is in operation. 
         [0064]      FIGS. 12 ,  13 , and  14  illustrate several other details.  FIG. 12  is identical to  FIG. 9  and  FIG. 3 . The enlarged view of  FIG. 13  illustrates that the limit switch  93  is an up stop limit switch.  FIG. 13  also illustrates a full bale limit switch  104  and a safety gate limit switch  105 . 
         [0065]      FIG. 14  illustrates a main bale door limit switch  106 . 
         [0066]    Using the invention, a retailer can produce and track a weighed, identified bale which is ready for immediate container shipment or for a mill. As an advantageous result, the retailer no longer needs an intermediate party to collect and resell (or recycle) the discarded cardboard. This in turn means that the retailer can collect more of the value per ton than has been previously available. 
         [0067]    In the drawings and specification there has been set forth a preferred embodiment of the invention, and although specific terms have been employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being defined in the claims.