We recently completed installation, start-up, and full operator training on a fully integrated recycling system engineered for performance, safety, and long-term uptime.
This project wasn’t just about adding new equipment, it was about creating a seamless material flow solution from capture to final bale, integrating new components with the customer’s existing shredder and downstream process.
Turn-key Project Overview
This custom built recycling line includes:
- Air Pickup, Sheeter
- Air Pickup, Die Cutter
- Refurbished American Baler PAC 4029-7T20
- Two Enclosureless Dust Collectors
- Custom Integrated Controls
- 20″ W x 12′ L Infeed Conveyor Feeding
- Existing Shredder
Every component was selected and configured to improve material capture efficiency, reduce airborne dust, and ensure consistent feed into the baler.
Fully Integrated Material Capture, Processing & Baling System
This project was engineered as a complete material flow solution, from trim capture at the production equipment to finished bale output.
Dual air pickup points at the sheeter and die cutter capture scrap directly at the source, pneumatically conveying material into enclosureless dust collectors that efficiently separate recyclable fiber from airflow while maintaining clean plant air. By removing trim immediately, the system reduces housekeeping, protects operators, and ensures valuable material stays in the recovery stream.
From there, a custom 20-inch-wide by 12-foot-long infeed conveyor was engineered to feed the customer’s existing shredder. Rather than replacing operational equipment, REI integrated new components around it, maximizing ROI while improving throughput and overall system efficiency. This approach allows customers to modernize performance without unnecessary capital replacement.
At the end of the line, a refurbished American Baler PAC 4029-7T20 anchors the system with proven durability and consistent bale production. Fully inspected and integrated with custom controls, the baler now operates as part of a synchronized recycling line, not as a standalone machine.
Custom integrated controls tie the entire system together, coordinating air systems, conveyors, shredder feed, and baler operation for smooth material flow and simplified operator interaction. REI’s installation and service department completed the installation, start-up, and operator training to ensure the line was fully dialed in and production-ready before signing off on the completed project.
From material capture to baling, this system delivers measurable efficiency, cleaner operations, and long-term uptime.
Ready to Update Your Recycling Operation?
Whether you need to upgrade air conveyance, integrate new equipment with existing machinery, source reliable preowned recycling equipment, or install a complete turn-key recycling system, REI designs solutions built around your operation, not the other way around.
Our team handles engineering, fabrication, installation, start-up, and operator training nationwide. If your facility needs improved performance, let’s build a system that works.
Contact REI today to discuss your next project.
we're Always Here to Help!
REI offers expert guidance, engineered solutions, and decades of hands-on experience integrating roll shears, conveyors, balers, and complete recycling systems.
Frequently Asked Questions
A turn-key system includes engineering, equipment integration, air conveyance, dust collection, baler installation, custom controls, start-up, and operator training, all managed by one provider.
Yes. REI specializes in integrating new conveyors, air systems, and balers with existing shredders or processing equipment to maximize ROI without unnecessary replacement.
Air pickup systems capture trim at the source, reduce dust, improve housekeeping, protect equipment, and ensure recyclable material is recovered efficiently.
Refurbished balers offer proven durability and performance at a lower capital investment, while still delivering consistent, high-density bale production.
Most of the time. When the customer needs to be brought up to speed quickly, REI provides full installation, start-up support, system calibration, and operator training to ensure every project is production-ready before handoff.
