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Flexus Balasystem

The world's brand name for integrated round baler wrappers.

Flexus Balasystem “Round Balers” produce cylindrically shaped bales in a fully integrated process of baling & wrapping in one machine. This technology had been used for decades in agriculture around the world.

During the 1990’s Flexus Balasystem pioneered the conversion from agriculture to industrialised versions for heavy duty baling & wrapping applications.

Bales are shaped via a continuous looped, heavy duty steel belt, then at the end of the baling process the bales are wrapped with a net and film.

Key features

  • Available in three different sizes: Breeze Mini, Breeze and Typhoon with increasing power and bale output
  • Fully computerised automated operation
  • High throughput – up to 35 bales/50 tonne per hour
  • High compaction rates – bales up to 2000kg
  • Long service life – 1 million bales/20+ years
  • Less energy usage than alternative wrapping solutions
  • Lowest OPEX of any baler wrapping system
  • Fully mobile for use in or outdoors
  • Small footprint

Since 1995, Swedish manufacturer, Flexus Balasystem have become the world’s brand name for integrated round baler wrappers.

Their industrial machines give high compaction rates, long service life, the lowest OPEX and enviable reliability.

The objective of wrapping bales is to ‘seal’ the bale to prevent decomposition and lowering of the calorific value of its contents.

  • Creating an anaerobe inner bale chemistry
  • Eliminating methanogenic activity – no fires or explosions
  • Significantly reducing odours
  • Reducing bird and wind fly
  • Preventing spillages
  • Ensuring extremely space-efficient stacking, storing and transport.

With increasingly high energy, operating, labour and site costs, there are more reasons than ever to use a Flexus machine:

  • Fully computerised automated operation
  • Use significantly less energy than a channel/twin ram + inline wrapper
  • Installed within just 8 hours, no civil works required – only steel plates under the feet
  • No ‘hidden extra’ costs i.e. roller conveyors, supportive steel frames, expensive power supply/control panel rooms
  • Mounted on 2 roll-on-off frames for easy relocation by hook lift or flatbed vehicles
  • Sits in a fraction of the space needed for a channel/twin ram + inline wrapper
  • Operates in or outdoors 24/7/365
  • Uses no metal wire/strap and less netting and wrap
  • Produces up to 30-35 x typically 1000-1600kg bales per hour – up to 50 tonne per hour!
  • Designed and manufactured to comfortably reach a 1 million bale / 20+ year life span
  • Happy end-users in hundreds of locations in 48 countries on 5 continents
  • Has the lowest OPEX of any system

Flexus Balasystem machines process:

  • ASR, car fluff, SLF (0-7mm/7-12mm)
  • Commercial and Industrial waste (shredded/unshredded)
  • Biomass/woodchips/sawdust
  • Plastics (shredded/unshredded)
  • Car tyres (shredded/unshredded)
  • Wire mesh, Agricultural film, PP bags
  • Paper pulp rejects, Coal ash, Bottom ashes
  • Maise, Silage corn, Rice hull, Bagasse, Beet pulp

Horizonal balers = square balers
Round balers = Flexus Balasystem

Flexus Round baler Horizontal baler + external wrapper
Manufacturer Flexus all-in-one machine = one manufacturer Baler + wrapper = 2 different manufacturers
Operational layout/footprint 17m x 8m for 30+ bales/hour capacity >30m x 26m = >2x operational layout compared to round baler
Operational height Flexus maximum operating height is 5 meters Square balers require a minimum of 10 meters ceiling height
Machine weight/civil works Flexus max weight 13 tons Baler weight >25 tons + weight of wrapper
Civil works No special civil works required Considerable special civil works required: baler + wrapper need to be elevated by 1.5m, requiring extra steel frame for entire process length incl several extra roller conveyors,; square baler may require under-conveyor pit + MSW leachate collection system
Control cabinet On-board control cabinet 2 separate large control cabinets needs, no integration possible
Baler installation Installation within 1 working day Baler + wrapper + frame + roller conveyors need 2 weeks with separate installation teams
Baler operation/ automation Fully automatic, on-board control panel + remote controls Baler + wrapper require at least 3 full time staff, no integrated control
Mobility Flexus = mobility; hook lift frame allows easy moving; suitable for rental options Square baler + wrapper designed for stationary use only
Electric power consumption Total motors 55kW, power consumption 40-60kW >90kW + baler wrapper
Bale size Standard 1.3m3 bale size (1.1 x 1.1 x 1.1m) Length operator controlled
Binding of bales/incinerability Tight wrap 50% overlap with net and foil = fully incinerable Mostly metal wire; organic acids will corrode wires, wires must be removed prior to incineration, wires will puncture foil wrap, known occupational hazard
Bale integrity Air is removed during the round baling process, bale contents are homogenized, calorific value is retained, bale contents anaerobe, zero fire risks Bales consist of several sliced layers; contents not homogenized. Horizontal ram action unable to expel air; compacted layers have air pockets that can accelerate loss of calorific value of baled materials
Bale handling Flexus bales can be handled repeatedly without danger of breakages, drop tests Square bales have sensitive corners, requiring careful handling to avoid damage to wrapping; bale wire tends to puncture foil wrap; broken bale issue is well-known
Bale storage Independent academic studies in Germany, Sweden, France have confirmed storability of round bales with out material decomposition, zero fire risks, and with maintained calorific content No such studies/reports on wrapped square bales
Bale stacking Flexus bale stack height unlimited; numerous examples worldwide. Under pressure, round bales take on honeycomb shape = static stability Limited stack height and unreliable static stability, waste spaces between bales
Bale opening Bales are easily opened via front loader attachment; bale contents fall apart in original size, can be directly sent to the incinerator grate Square balers are ‘springy’ = occupational hazard. Bale contents fall out in large blocks/slices requiring extra handling
Overall operating & maintenance costs Flexus has predictability low O & M costs Square baler + wrapper = higher costs incl extra manual labour required
Service support Designed and engineered for easy service Square baler + wrapper = different manufacturers
  • Each bale can be delivered onto an individual pallet, fed from a cassette stack

Typhoon Breeze Breeze Mini
Capacity (bales) up to 30-35 bales per hour up to 15 bales per hour up to 5 bales per hour
Capacity up to 50 tonnes per hour up to 15 tonnes per hour up to 7 tonnes per hour
Power consumption 40kW 35kW 25kW

Motors total: 60 kW (at 400 V), one connection only, biggest motors 2 x 30 kW,
Generator required: minimum 135 kVA
Energy used per bale: approx 1.3 kW/hr

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Estimated Weekly Volumes

Based on a 50kg per m3 material density
Visual Size Guide
1100L bin
55kg approx.
8 yard skip
300kg approx.
16 yard skip
600kg approx.
40 yard skip
1500kg approx.