A metal recycling operator in Kazakhstan has put a 2000-ton hydraulic metal scrap baler into production after our engineering team completed full on-site installation, commissioning, load testing, and operator training. The project was delivered as a turnkey package — from foundation drawings and cold-climate engineering to final handover of bales ready for steel mill shipment.
| Item | Detail |
|---|---|
| Project | Metal scrap baling line, installation & commissioning |
| Location | Kazakhstan (Central Asia) |
| Equipment | 2000-ton hydraulic metal scrap baler |
| Scope | Site preparation support, mechanical installation, hydraulic & electrical hook-up, commissioning, load test, operator training |
| Status | Commissioned and handed over to the client's production team |
The client collects and processes mixed ferrous and non-ferrous scrap for regional steel mills and foundries. As volumes grew, loose scrap was consuming too much yard space and costing far too much in transport, since trucks were carrying air rather than metal. The customer needed a high-force baling solution capable of compressing heavy, awkward scrap into dense, stackable, mill-ready bales — and needed it running quickly, in a location far from the equipment manufacturer.
- Remote inland location: the plant sits far from any seaport, so the machine had to travel by rail and road, with every module dimensioned to fit standard transport limits.
- Harsh continental climate: winters bring deep sub-zero temperatures, which thicken hydraulic oil and stress electrical components.
- Heavy-duty cycle: continuous handling of thick-walled scrap, engine blocks, and structural steel demands extreme pressing force and a robust frame.
- No local engineering support: the client's maintenance team had no previous experience with machines of this tonnage.
Our engineers travelled to the site and worked alongside the client's team through every stage:
- Verification of the reinforced concrete foundation against our load and anchor drawings.
- Unloading, positioning, and precision levelling of the main frame, pressing chamber, and power unit.
- Assembly of hydraulic piping, cylinders, and valve manifolds, followed by flushing and pressure testing.
- Electrical installation, control panel wiring, and safety interlock verification.
- Cold-climate preparation: low-temperature hydraulic oil, oil pre-heating, and heated control cabinet checks.
- No-load running, then progressive load testing with the client's own scrap material.
Commissioning followed a documented, step-by-step protocol rather than a quick trial. After confirming hydraulic pressure stability and cycle timing, we ran the baler on the customer's mixed scrap stream. Bale formation, ejection, and wire tying were each adjusted on site until the output met the density and handling requirements agreed with the client. Only after a stable production run was the machine formally released to the customer's operators.
Operating and maintenance staff received hands-on training covering daily start-up and shut-down, bale chamber inspection, hydraulic oil monitoring, filter replacement intervals, and safe troubleshooting of common alarms. The client also received a full documentation set, including electrical schematics, hydraulic diagrams, spare parts lists, and a preventive maintenance schedule — so routine service no longer depends on external support.
- Turnkey delivery: installation and commissioning completed on site by our own engineers, with a single point of responsibility.
- Production-ready handover: the baler entered the client's scrap flow with trained operators and full documentation.
- Dense, transportable bales: loose scrap volume reduced dramatically, cutting truck movements and freight cost per ton.
- Climate-ready reliability: cold-weather package protects hydraulic and electrical systems through Kazakhstan's winter.
- Self-sufficient maintenance: local team able to handle daily operation and scheduled service independently.
This Kazakhstan project shows what a properly engineered turnkey programme delivers: a 2000-ton metal scrap baler that was not simply shipped, but installed, commissioned, tested, and handed over in working condition. For recyclers sourcing hydraulic metal balers for remote or cold-climate sites, on-site installation and commissioning support is often the difference between a machine in a yard and a machine making money.