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  • The Benefits of Using an OEM Service Provider for Maintenance on Your Landfill Compactor

    The Benefits of Using an OEM Service Provider for Maintenance on Your Landfill Compactor

    Compactors are the workhorses of any sizable landfill operation. As a result, Aljon has specialized in the production of several different weight classes of landfill compactors in order to meet the demand of companies that desire the best. A significant benefit of purchasing Aljon compactors is that you’ll have access to reliable maintenance and service when you take advantage of our network of dealers, who possess intimate knowledge of the machines and their OEM parts.

    1. Network Technician Attributes

    The benefits of such a network are numerous. You can expect to receive the exact machine parts necessary for optimal landfill compactor maintenance, as well as the handiwork of well-trained and certified technicians, providing peace of mind that your equipment is in the best possible hands. Because it is an interwoven chain of experts, each technician has a large foundation of support from which to draw if they run into any questions or concerns.

    2. Timely Landfill Compactor Maintenance

    Machine downtime equals lost money – the equation is straightforward. One of the chief benefits of going straight to Aljon’s network of OEM service providers for landfill compactor maintenance is the built-in timeliness of it all; this is pervasive throughout the process. As a result of having such well-trained experts, problems are more likely to be discovered during routine maintenance, allowing for timely repairs that help you stay ahead of major issues.

    Scheduled routine maintenance has obvious benefits for any large scale machinery; this rings even truer for landfill compactors that keep your landfill operations going. These machines compact hundreds of tons daily. Eventually, even the toughest parts will wear down, and maintenance prolongs the operational lifetime of your equipment.

    Early identification of small issues is one of the biggest arguments in favor of routine landfill compactor maintenance, helping you tackle an issue before it balloons into something more costly or operation-stifling.

    3. The Expertise of Network Dealer Technicians

    Our goal is to ensure each technician has the specialized knowledge and equipment necessary to service all of the components of our landfill compactors. Aljon technicians complete intensive training to familiarize them with all the OEM parts and aspects of landfill compactor maintenance. Technicians gain a thorough understanding of the equipment, as well as the big picture importance of efficiency, timeliness, and proper diagnosing and repairing.

    This contributes to the robust after-sales support service we provide for all of our customers and their essential equipment, giving you the confidence and expectation that any future downtime will be minimized. The factory service experts ensure that the field techs are always equipped to optimize maintenance with continued training. These technicians already have decades’ worth of experience with the machinery, and keep up with manufacturer amendments and market trends related to their fields of expertise.

    4. Parts Availability

    Whether you have the Aljon ADV 500 landfill compactor, the ADV 525, or the ADV 600, you can rest assured that the OEM parts required for any replacements are accessible by an Aljon network service technician. Because we focus on optimizing your uptime, these spare parts are often on site or quickly available through the streamlined Aljon acquisition process.

    Landfill compactor service and repairs are big business, and although parts may be available at other dealerships, nothing is more reliable than the OEM part for optimal function. Having a technician from Aljon’s service network can further solidify your confidence that a repair and/or replacement will be completed quickly and correctly.

    Another aspect of Aljon’s part availability that reassures users in North America is that machines are all manufactured at company facilities on the United States mainland. This helps expedite the acquisition of equipment and parts, and offers the confidence in American craftsmanship, many owners appreciate. Parts availability is one of the two chief attributes of the Aljon service technician network, with the other being unrivaled expertise.

    5. The Aljon Commitment

    With well over 60+ years of service in the scrap and landfill equipment industry, we’ve built a reputation for reliability. Your Aljon equipment comes with helpful documentation, and you have access to a network of qualified technicians and service providers.

  • 5 Simple Features That Make Owning an Aljon Landfill Compactor Easy

    5 Simple Features That Make Owning an Aljon Landfill Compactor Easy

    When it comes to heavy machinery, landfill compactors form the backbone of a landfill fleet. Because of that, Aljon, one of the world’s top manufacturers of these types of machines, specializes in several variations of the landfill compactor, specifically, ensuring that you can find one that best suits your daily requirements.

    For such an important and robust piece of equipment, you need to take into account the specific features that facilitate its usage, prolong its operational lifetime, and meet or exceed your performance expectations. In this article, we’ll give you just five reasons that present the Aljon landfill compactor as a top choice for your landfill compactor purchasing.

    1. Optimized Cab Design

    One of the first things that you’ll notice about the cab in an Aljon compactor is the straightforward accessibility. With other designs, due to the necessarily high placement of the cab on heavy machinery of this sort, a ladder is essential for access. On the Aljon design, convenient stairs are built into the sides as a part of the overall design.

    In addition to giving your operator easy access to the cab at a moment’s notice, this design facilitates both service calls and training operations. The dual stair system for the two-door cab also bolsters safety, since it eliminates the need for external ladders in the high-traffic area surrounding cab access.

    Another important aspect of cab design is, of course, visibility. To this end, the Aljon series of compactors all possess sizable windows that enable full views from the front, sides, and back of the operator compartment; the front-facing direction, in particular, is unobstructed. The rear part of the cab has a window that is higher up, of course, and so the cab design incorporates a rear-view camera to make up the difference of the smaller rear window size.

    2. General Service Accessibility

    Whether you choose general servicing or have opted to use the extensive network of service technicians available through the OEM manufacturer of your Aljon compactor, ease of accessibility is essential for a variety of reasons, including minimizing machine downtime for repairs. To this end, Aljon prioritizes the accessibility of service points during the manufacturing process. This design consideration isn’t limited to the 100% American-made Aljon ADV 500 landfill compactor; it’s a feature of all their heavy machinery.

    Another key benefit of easily-accessible service points is the cost savings; this goes hand-in-hand with the reduced downtime that occurs when service points are unobstructed and can be identified, reached, and perhaps fixed in a single visit. In suboptimal designs, there are sometimes things that need to be unscrewed just to get to the service panel, which, of course, is a time and resource-draining complication. Obstructions can also make it more difficult to identify the offending component.

    During the manufacturing process, Aljon optimized the placement of the electrical harness, brakes, hose, pressure switches, and pumps in a convenient pump house that can be reached at the rear of the compactor from a panel.

    3. Platform Design: Ease of Service

    The geometry of the service platform is the most obvious design choice geared towards ease of maintenance. For starters, the platform itself is constructed to facilitate both safety and effectiveness. In old cabs, service techs often had to lean at awkward angles just to open panels and remove components; there was even a need to navigate tight squeezes and corridors to reach these parts. Aljon compactor design eliminates these issues with the installation of a more expansive service platform.

    4. Maintenance Optimization: Removal of Cleaner Bars

    Cleaner bars on landfill compactors are used to reduce the buildup of grit and wire as your machine trudges through the landfill terrain. Although they are generally useful in the reduction of wheel-packing, cleaner bars can themselves become a hassle for a variety of reasons:

    • They tend to wear down quickly, and thus have to be maintained and eventually replaced
    • Even before they eventually fail, cleaner bars become filled with dirt and wiring as they work to protect the compactor’s wheels from this, and therefore require regular maintenance
    • Because of the nature of their operation, cleaner bars don’t always prevent wire wrap on the compactor wheels

    Although cleaner bars do serve some function, overall, Aljon design has removed them in favor of a specialized compactor cleat design that mitigates the need for cleaner bars. This eliminates the added burden to the maintenance schedule, as well as the eventual replacement costs associated with cleaner bars and wire wrap on cleats/wheels.

    5. The Reliability of US Parts and Craftsmanship

    At Aljon, nearly every part used in the landfill compactors is sourced in America. In fact, the Aljon ADV 500 is 100% American-made, and the parts for it are readily accessible directly from our Iowa facility or from our North American dealers throughout the continental United States. This aligns perfectly in the event you opt for the help of OEM manufacturer service technicians, as one of our biggest goals is to minimize downtime for our customers.

    There are many more features that make it profitable to own an Aljon landfill compactor; when combined with more than half a century’s worth of operational experience in the industry, you are certain to get heavy machinery that meets or exceeds your rigorous expectations at Aljon.

  • Improving Landfill Airspace with Aljon Landfill Compactors

    Improving Landfill Airspace with Aljon Landfill Compactors

    Landfills provide a lot of services to their communities, but to stay in business, they have to manage one primary asset: airspace. New landfill cells are expensive to build and require extensive permitting and collaboration with many different stakeholders, but once the area is approved, it can be filled with an unlimited amount of material until its maximum height is reached.

    Because airspace is the most valuable asset of any landfill operation, increasing compaction ratios is a high priority. If even slightly more material can be stored safely in the same volume, it benefits both the landfill business and the surrounding community, potentially for multiple generations. This makes landfill compactors one of the most important pieces of equipment for the operation, and the one that makes the most sense to invest in. For over 60 years, Aljon has carefully designed and improved its landfill compactors with this one goal in mind: improving landfill airspace.

    Landfill compaction is a relatively straightforward process, so improving compaction performance requires a multi-pronged strategy:

    • Increasing equipment uptime
    • Improving PLI
    • Implementing state-of-the-art wheel design
    • Integrating mechanical and drive train advancements

    Aljon’s singular focus on creating effective, purpose-built landfill compactors means that every one of these design aspects has been honed to provide top-of-the-line performance and reliability. Alongside these top-performing machines, Aljon has also created a legacy of exceptional customer service to keep machines running in less-than-ideal conditions and minimize wait and repair times when problems do arise.

    Why Uptime Matters

    There are many features and design choices (self-cleaning wheels, overall weight distribution, wheel size, cab technology, etc.) that impact the amount of waste a compactor can process in a day and how densely it can pack the material. Regardless of how efficient and effective it is while running, however, all of those gains disappear if the landfill compactor suffers from excessive (or, worse, unexpected) downtime. Proper compaction takes multiple coordinated passes over thin layers of material, and rushing this process will result in worse ratios of solid waste compaction and inefficient use of airspace, raising operational costs over time. Improving landfill compactor uptime by finding one that is low maintenance is arguably the easiest and most important way to optimize a landfill’s airspace and profitability.

    Low-maintenance machines need to have two features: minimal, straightforward routine maintenance needs and uncomplicated, easy-to-repair systems. All landfill compactors come with manufacturer recommendations for service timelines and maintenance schedules to keep machines at their most efficient (and long-lived). In the real world, however, even tight operations will face days with frigid weather, excessive rain, or blistering heat that make crawling under or over a 100,000 lb machine to reapply grease or clean debris seem unbearable. Easy-access maintenance points may seem like a luxury, but they both speed up maintenance (reducing downtime immediately) and make it more likely that operators and techs will adhere to the prescribed schedule (reducing downtime in the future).

    In addition to ease of access, simple designs with fewer moving parts (e.g. hydrostatic drive trains vs. powershift transmission drive trains) have fewer maintenance points to attend to (greasing, cleaning, etc.) – and they create fewer opportunities for things to break down. Fewer friction points mean less strain and wear-and-tear and fewer components to keep track of or replace. When something does break, whether due to age, mishandling, or just the wear-and-tear of the job, having to repair or replace fewer parts keeps costs down as well as reducing the time it takes to install new components. Certified technician time is expensive, and the easier the repairs are, the more quickly and inexpensively they can be completed. Low-maintenance landfill compactors continue to pay dividends the longer they stay in service, making them an excellent long-term investment.

    Improve PLI

    Compaction depends on two things: the weight of the compactor and the width of the wheels. More weight translates to more pressure being exerted on the compressible material below the wheels. Narrow wheels channel that pressure into a smaller area. While PSI (Pounds per Square Inch) is a common measurement in many other fields, landfill compactors are rated by PLI (Pounds per Linear Inch) for easier comparison. To calculate PLI, simply divide the weight of the compactor by the total combined width of all 4 wheels. PLI directly translates to how well the compactor will remove air from the working face of a cell.

    Improving PLI requires maintaining a delicate balance. Narrower wheels will increase the amount of pressure on the material under the wheels, but if they are too narrow, they will leave a wide channel of uncompressed material between them, requiring extra passes by the compactor to even things out. They are also more likely to get stuck in uneven material. On the other hand, if the wheels are too wide, they will start to “float” over the material instead of compressing it down, similar to the tracks on a dozer.

    Weight can be increased in a number of ways. Larger compactors obviously weigh more, especially when built with solid steel frames and components. As a bonus, larger compactors like Aljon’s ADV 600 also have higher-power engines and can process more material in a day (up to 1300 tons per day compared to 1200 and 950 tons for smaller models). Some manufacturers also put ballast in their wheels to increase weight, but this can create major maintenance headaches down the road if leaks form and the ballast needs to be replaced.

    The key to getting the most out of a given amount of airspace is to increase the density of compacted waste. Many smaller landfills find that even if they don’t need the higher processing capacity of larger machines, the increased PLI saves them money by preserving airspace and increasing compaction ratios. Aljon compactors have the highest PLI by class in the industry, making them a top choice for improving landfill airspace.

    Elite Wheel Design For Better Performance

    Although overall weight and wheel width determine PLI, landfill compactor wheels do much more than just translate force onto the surface of the working face. Wheels must provide stability, steering, and motion as well as act as cutters and crushers, thanks to the cleats covering the surface. Ineffective wheels can dramatically reduce compaction ratios and leave dangerous and wasteful air pockets scattered throughout the cell by not spreading and compacting evenly. This can introduce the risk of water penetration and runoff into the neighboring soil as well as increase the fire risks present when air remains trapped inside a cell. If a fire breaks out, the cell must often be dismantled to put it out, as landfill fires are difficult to completely extinguish from the outside. Smoke and other toxic fumes can wreak havoc on both the surrounding environment and on working conditions inside the landfill – a worst-case scenario for everyone involved.

    Landfill compactor cleats are vital components to the function of compactor wheels. Rather than just crushing material as flat wheels (like steamrollers) would, they actually spread the material out thanks to their angled design. They also cut and shred material as they puncture through new layers of waste. Smaller pieces of material are much easier to spread evenly, preventing awkward dips or protrusions that can compound as more material is added. Without this shredding action, larger objects would only be crushed to a certain point, and any air inside would remain a vacant pocket rather than being returned to the landfill airspace. Air pockets are both dangerous and costly to the operation.

    Cleat design consists of the shape of the cleat itself (most are shaped like wedges, with varying shapes on the end, such as truncated edges or angled “W” teeth). They can also be manufactured out of different materials and have abrasion-resistant coatings – something that matters a lot with materials that are constantly experiencing friction as well as the impact of weather, corrosive fluids, etc. Aljon uses MacPactor cleats with a long wear-life guarantee to improve durability and extend the lifespan of compactor wheels.

    While the cleats help puncture and shred material, they are not the primary compacting agent: the flat surface of the wheel itself is what delivers the crushing force needed for even, high-density compaction. This means the whole wheel must contact the surface. If too many cleats are used, the wheel may ride on the surface of the cleats instead of making contact with the material under it, causing uneven compaction and poor shredding of the layer. Too few cleats, on the other hand, won’t provide enough shredding and won’t spread cut material across the surface well enough for maximum compaction on a large scale. At Aljon, cleat configuration has been carefully designed to maximize compaction and increase the life of all compactor wheels and cleats.

    Finally, poorly designed wheels and cleats are a major source of maintenance woes. If material gets jammed in between cleats because they are too close together or wire gets wrapped around the axle, work must be stopped so that the wheels will function as intended (or compaction ratios may be reduced until the maintenance takes place). Even if the cleat designs work exceptionally well, if they require constant cleaning, overall efficiency will suffer. Some compactors come with add-ons like wire cutters and guards that help prevent buildup, but these extra parts must be maintained and replaced, increasing downtime as well as costs. Aljon’s self-cleaning wheels maximize contact with the working face and limit maintenance downtime, resulting in better compaction ratios.

    Mechanical and Drive Train Enhancements

    There are a few mechanical features, such as an I-Beam chassis that prevents buildup, that can take compactors from effective to elite. One key feature is the addition of a frame design with rear-axle oscillation. On rugged terrain or large slopes, one or more wheels can lift off the ground, causing uneven compaction (and decreasing the stability of the compactor). A landfill compactor oscillating frame design allows the rear axle to shift with the terrain, keeping all four wheels in contact with the surface. This makes the compactor safer and more effective on even the most difficult slopes and has been proven to assist in its overall goal of removing air from a landfill’s working face.

    Additionally, upgrading from a powershift transmission drive train to a hydrostatic drive train can dramatically improve the compactor’s efficiency. Widely renowned for its ease of use, hydrostatic drives operate without the need of a clutch or complex transmission. This lowers the learning curve and increases safety for new operators. This lowers the learning curve and increases safety for new operators. It also allows for quick reversing and excellent maneuverability in difficult spaces. All four wheels are powered individually via a hydraulic fluid system and individual motor, so it is always in four-wheel drive, improving gradeability. Coupled with the oscillating frame system, Aljon compactors have 100% gradeability.

    Together, all of these factors make Aljon landfill compactors a desirable choice for improved compaction ratios and better use of landfill airspace. With stringent standards for maintenance and uptime, the highest PLIs in their class, state-of-the-art wheel design, and thoughtful mechanical and drive train improvements, these landfill compactors were designed for a single purpose: to return air in the working face to the landfill airspace, extending the life of every landfill cell.

  • How a Landfill Compactor’s Hydrostatic Drive Leads to Better Compaction

    How a Landfill Compactor’s Hydrostatic Drive Leads to Better Compaction

    Landfill compactors today, much like all types of heavy equipment, are designed with two different powertrain designs: hydrostatic drive and powershift transmissions. In the world of heavy equipment, both have value in a variety of applications, but here we want to talk about the landfill application and the value of a hydrostatic drive powertrain on landfill compactors.

    Hydrostatic drive powertrain systems improve machine performance values in landfill compactors, such as better compactability, gradeability, maintainability, and overall performance. All three Aljon landfill models are designed with a highly efficient hydrostatic drive powertrain, resulting in full-time all-wheel drive as each wheel is powered by a single hydraulic pump and motor at each planetary.

    Compactability / Gradeability

    With each wheel being powered by a dedicated hydraulic pump and motor, coupled with an oscillating frame, all wheels having contact with the material at all times, (all-wheel drive capability and landfill compactor oscillation). Aljon produces 100% gradeability, which results in better compaction ratios when compacting on slopes, ultimately improving landfill airspace.

    Maintainability

    A hydrostatic powertrain system has fewer major components, which means fewer moving parts that can potentially fail. This primarily consists of a gearbox on the back of the engine, which drives four hydraulic pumps, providing fluid power to each drive motor at the planetaries. Routine maintenance is much simpler as well, having fewer components that need to be serviced when performing scheduled preventative maintenance.

    Overall performance 

    Aljon’s hydrostatic powertrain performs best when operated at high RPM, using only the FNR (Forward & Reverse) selector to change directions and the speed selector to change the travel speed. This reduces the need for the operator to accelerate or decelerate during operation and focus primarily on best practices, compaction methods, the operator’s surroundings, and the safety of other machinery/personnel operating on the working face.

  • Why a Compactor Oscillating Frame Design Benefits Performance at a Landfill

    Why a Compactor Oscillating Frame Design Benefits Performance at a Landfill

    There are many factors to consider when choosing the right landfill compactor for your landfill. There are many differences in methodology for compacting waste, and the same can be said for machine designs. Here, we want to talk about landfill compactor oscillation, the compactor’s ability to rotate with uneven terrain.

    Oscillation effect on compaction

    The impact that oscillation has on achieving optimal compaction ratios is significant. Oscillation enables the compactor to navigate the uneven terrain of the working face much more efficiently, keeping all four wheels in full contact with the material, with a balanced distribution of weight, so that each wheel is applying maximum compaction in every pass.

    Oscillation effect on gradeability

    Oscillation offers a significant performance value with gradeability as well, especially with a hydrostatic powertrain. Keeping all four wheels in full contact with the material, with an even weight distribution, coupled with each wheel being powered by an individual hydrostatic drive circuit, increases the gradeability of the compactor. This results in better gradeability AND compaction when compacting on a slope and grade. All three models of Aljon landfill compactors are built with a hydrostatic powertrain and rear axle oscillation to maximize gradeability and compaction anywhere on the working face.

    Oscillation effect on PLI

    One way of measuring a landfill compactor’s capability of achieving optimal compaction ratios with the least number of passes is to calculate PLI (Pounds per linear inch of compaction) by dividing the weight of the machine by the total combined surface area in which the wheels are in contact with the material. PLI is most realized when all four wheels are applying energy to the material with an even distribution of weight. If a compactor does not oscillate, the uneven terrain of the working face will result in some portion of the machine being lighter on the material as the high spots will create lift, resulting in less weight applied to the material.

    Landfill Compactor Stability

    While landfill compactor oscillation is helpful at all times, it’s crucial on uneven terrain, slope, and grade. Not only does the oscillation improve weight distribution, but it also maximizes traction by stabilizing the compactor across the working face. The design of the wheel cleats and the wheels themselves also play a major role in traction and stability, but if all four wheels are not fully stabilized on the material, those aspects cannot come into play.

    Oscillation ensures full weight distribution, and hydrostatic drive trains provide constant all-wheel drive. Aljon compactors boast 100% gradeability, leading to strong compaction ratios, stability on rough terrain, and the capacity to handle challenging materials on slope and grade while maximizing efficiency. These components work together to improve your landfill’s airspace.

  • Improve Landfill Airspace With The Right Landfill Compactor Wheel Design

    Improve Landfill Airspace With The Right Landfill Compactor Wheel Design

    A landfill compactor’s primary purpose is to compact as much waste into the landfill to preserve airspace and maximize the life of the landfill while maintaining an optimal compaction ratio, while still being able to control moisture levels. At Aljon, our machines are designed with a very high PLI rating, which leads to better compaction ratios. Our wheels are self-cleaning, low-maintenance, have an optimized number of cleats for maximum compaction, and are built with durable cleats that have a long wear-life guarantee.

    1. Cleat Design

    While compactor wheel cleats on a landfill compactor play an important role in the overall compaction process, the most important role is crushing, shredding, and manipulating waste material to make it more compactable. A higher number of cleats does not necessarily equate to better compaction, and often leads to the requirement for additional features such as cleaner bars and wire cutters, resulting in more maintenance, periodic replacement, and a higher cost of ownership. Having the right number of cleats, with a cleat pattern to match the demand of each application, specifically leads to less maintenance and better performance from the wheel.

    There are many different cleat patterns. Too few cleats won’t provide sufficient shredding and crushing of the waste, and too many can cause material to clog up the wheels, resulting in the necessity of cleaner bars. With over 60 years of experience in the industry, Aljon has combined design expertise with a superior cleat to create a self-cleaning wheel with the optimum number of cleats to produce maximum compaction.

    2. Self-Cleaning Wheels Lead to Lower Maintenance

    Aljon wheels are self-cleaning, requiring no cleaner bars or wire cutters in most applications. This is accomplished with proper cleat spacing, cleat quantity, and a machine design whereby the wheels are spaced far enough away from the chassis to allow waste and wire room to exit the wheel space naturally. Cleaner bars and wire cutters are high-maintenance items that require routine adjustments, are very expensive to replace, and subsequently have a negative impact on the cost of ownership.

    If your goal is improving landfill airspace, choose a compactor with a wheel configuration that will stay clean, allowing the cleats to penetrate the material. All Aljon landfill compactors come with a standard 5-year or 10,000-hour wire wrap warranty and cleat wear guarantee.

  • How Weight Contributes to Improved PLI (Pounds Per Linear Inch)

    How Weight Contributes to Improved PLI (Pounds Per Linear Inch)

    Maximizing density in landfill cells increases safety, efficiency, and profits. Because cells have limited square footage and are expensive to build, packing more material into each layer (increasing solid waste compaction) extends the lifespan of the cell while also reducing the risk of air and water penetration or the possibility of contaminant leaks into the surrounding soil. Improving landfill compaction protects nearby land, wildlife, and communities while also minimizing expenses. The secret to increasing landfill cell density lies in the chosen landfill compactor and its PLI (Pounds per Linear Inch) rating.

    1. What is PLI?

    To calculate PLI, divide the weight of the machine by the total width of all wheels that stay in contact with the ground. PLI is what makes a landfill compactor more fit-for-purpose than something like a bulldozer. Bulldozers typically rest on long, wide tracks that spread the weight of the machine across a larger area, helping them “float” above the surface rather than sinking in or crushing the material below it. Thus, a bulldozer on tracks that weighs the same as a compactor resting on four relatively narrow wheels will result in much less compaction, and its PLI will be significantly less than the PLI of a landfill compactor.

    Increasing the weight of the compactor or reducing the width of its wheels will improve PLI. However, if the wheels become too narrow, they are more likely to get stuck or leave a large gap of uncompacted material between them, requiring more passes and reducing productivity. Increasing the weight is a reliable method for increasing PLI and thus for improving landfill airspace.

    2. Aljon’s Landfill Compactors Have the Highest Weight Per Class

    For machines in the same class with similar wheel designs, landfill compactor weight makes all the difference. Additionally, higher-weight compactors can process more waste each day. Aljon landfill compactors demonstrate that as the weight increases, PLI (and thus compaction efficiency) also increases:

    • ADV500: 86,718 lbs to 95,450 lbs; PLI = 450 to 490; processes up to 950 tons per day
    • ADV525: 108,000 lbs – 117,602 lbs; PLI = 572 – 598; processes up to 1200 tons per day
    • ADV600: 126,160 lbs – 127,500 lbs; PLI = 600 – 613; processes up to 1300 tons per day

    In order to make the most of landfill airspace, aim to use the heaviest (and highest PLI) landfill compactor the operation can support. Even if the higher production limits of a larger machine are unnecessary at first, over time, the extra weight will pay for itself by increasing the lifespan of the landfill through higher compaction ratios.

  • How Important is Landfill Compactor Uptime to Your Landfill Compaction

    How Important is Landfill Compactor Uptime to Your Landfill Compaction

    Landfill operations require equipment that is designed with efficiency and productivity in mind for the operation to run smoothly and maximize profitability, and none is more important than the landfill compactor. We understand the importance of producing a product that offers these features, as well as a machine designed to maximize your uptime.

    Excellence in wheel design, fuel efficiency, weight, and horsepower are all key features of Aljon Landfill Compactors, and while these features improve compaction and overall efficiency for the operation if your machine is down waiting on repairs, those features become a little less important, and that is why we also make reliability and ease of maintenance a top priority to keep your landfill compactor running and maximizing your compaction ratios with less downtime.

    (Up)Time is Money

    Airspace is the only valuable commodity a landfill has to sell, which is done through tipping fees charged at the scale house. The more material a landfill can process efficiently, the more revenue it can produce throughout its lifetime thanks to increased landfill airspace. For this reason, the landfill compactor is the most important piece of machinery in a solid waste operation. When the landfill compactor is down, the landfill is losing airspace, and a loss of airspace is a loss of revenue. Ease of maintenance is also important. While performing all the manufacturer’s recommended maintenance is an absolute necessity for minimizing downtime, the less time it takes to complete the maintenance intervals, the quicker it can be returned to full production.

    The amount of waste coming into the landfill remains the same regardless of whether the compactor is operational or not. Downtime as a result of overly complicated maintenance requirements or frequent breakdowns will produce lower compaction ratios due to the limitations in the amount of waste that can be processed in a day.

    Ease of Maintenance & Repairs 

    When issues do arise or it’s time for scheduled maintenance, a compactor that is difficult to work on will result in less uptime. Poor access to the maintenance points on the compactor results in more time required to complete the required maintenance. Equipment with easy-to-access maintenance points and a clean, straightforward design encourages operators and technicians to stay on top of routine repairs and makes more extensive repairs faster and less expensive.

    One of the many benefits of an Aljon compactor is the simplicity of its design. From ease of access to all maintenance points to self-cleaning wheels and a hydrostatic drive system, all of Aljon’s compactors are designed to minimize time spent on maintenance and repairs while maximizing landfill compactor uptime.

  • The Benefits of Purchasing Scrap Equipment From a Smaller Niche Company

    The Benefits of Purchasing Scrap Equipment From a Smaller Niche Company

    Niche Companies and Quality Service/Parts

    Specialization and niche, frankly, go hand-in-hand. When dealing with multi-part equipment such as balers and scrap loggers, it is imperative that the parts can be efficiently upgraded or replaced. This includes the time it takes to search for them, the reliability of the provider, and what is actually available. For example, can you obtain the precise OEM part? Or do you have to settle for generic replacement parts from companies that usually sell to big-box markets? Consider the following non-negotiable standards that every piece of scrap equipment must have:

    Compatible Parts: This is where a niche company like Aljon truly shines. The ability to acquire the precise parts for your equipment reaps dividends in all facets of your business. For example, you can replace parts expeditiously without any amendments to the scrap logger/baler (or other heavy equipment); you can also rely more on the estimated lifetime of operation. Sometimes, after-market parts have operational lifetimes that vary wildly.

    You simply can’t put a price on quick installation, confidence, and the expected reliability of an original equipment manufactured part. This same reliability will reduce future complications and set the standard for future replacements.

    Quality Certified by the Manufacturer: If you had to choose a single attribute to prioritize, you’d likely choose quality. OEM parts providers stake almost their entire business on the expectation of quality and applicability, and these attributes are even more important for niche companies than for big box brands. As a result, you can be confident that the parts meet all technical standards. Additionally, industry compliance rules are instantiated into the production cycle of OEM parts, since this is what they specialize in. It also gives them an advantage over generic brands.

    Confidence in the Function and Longevity of Scrap Equipment Parts: One of the biggest differences between OEM parts and generic after-market parts is the specification. After-market parts are not nearly as specific to a particular machine, as they can vary in thickness, girth, and other dimensions. After all, they need to be available to multiple clients – who often have machines that differ slightly in their operation.

    As a result, longevity is usually compromised. Differences in girth between the OEM part and the generic part can reduce the operational lifetime of the heavy equipment; or, at the very least, reduce the lifespan of that part within the heavy equipment. It goes without saying that this will negatively affect performance in the long run. If the generic part is inefficient after installation, other parts of the heavy equipment will be taxed beyond their own specifications.

    Equipment Maintenance and Best Practices

    Scrap logger/balers are some of the heartiest pieces of heavy equipment conventionally available. Braving the elements day in and day out throughout a long operational lifetime, you can expect to replace certain parts a few times.

    When you do need to replace parts, being able to order directly from the company that built your scrap logger/baler is an ideal scenario. Aljon has OEM parts in stock and ready.

    In addition to eschewing generic parts in favor of OEM parts, you should follow best practices for equipment maintenance. Here’s the short of what should be included in a maintenance schedule:

    Regular Oil Changes: The generally accepted interval for changing the oil in your scrap equipment logger/baler is about 500 hours. Such a schedule will stretch the operational lifetime by keeping the engine parts lubricated and resistant to friction damage. It is precisely this wear-and-tear that induces premature breakdowns, as the oil becomes contaminated with grit and becomes more abrasive to the engine parts. Furthermore, you will benefit from improved efficiency of operation when you stick to a consistent schedule of changing the engine oil.

    Consistent Greasing: Every piece of heavy scrap equipment should come with instructions from the manufacturer on greasing the hinges, joints, etc. Metal and steel have a strong capacity to cause damage when grinding against one another, so greasing parts after every shift (assuming about 8 hours) is a great way to extend the lifetime of your heavy machinery. Aljon equipment comes with a manual on the essentials – such as changing hydraulic oil, greasing bearings, and joints, and engine oil-change specifications.

    Experience: The Gold Standard

    You can have all the above, but if you don’t get your scrap equipment from service technicians who know the ropes, then you’re jeopardizing the longevity of your operation. The ins and outs of the heavy equipment, and scrap logger/baler industry are multifaceted, and only providers with decades of experience can point you in the direction that meets the bulk of your needs.

    When it comes to equipment, you want someone with ample experience in the industry. Such a service leader would have seen much of what the industry has to offer and would be well-positioned to provide the best advice on equipment and parts for any current machine. Additionally, your field techs can provide hands-on experience insofar as machine operation is concerned, with a comprehensive knowledge of parts and services. Aljon, specifically, has reps that have been in the business for three decades. You can be very confident that you’re getting the precise parts for your scrap equipment, with information on operator training and device maintenance.

  • Regular Inspections of Your Scrap Logger/Baler Help You Get The Most Out of Your Scrap Logger/Baler

    Regular Inspections of Your Scrap Logger/Baler Help You Get The Most Out of Your Scrap Logger/Baler

    Scrap logger/balers are workhorses that should be built to withstand heavy-duty daily use for extended periods of time. The best way for you to extend your scrap logger/baler’s service life is by consistently performing regular inspections and routine service.

    When you buy a scrap logger/baler, it should come with an operator’s manual that provides photos and diagrams of your machine’s parts, so you’ll know where to find the hoses, filters, and more. The operator’s manual also outlines various maintenance tasks, including when and how to perform service.

    Read this manual from cover to cover. Refer back to the manual regularly to ensure that you stay up to date on the maintenance tasks to limit the downtime of your equipment. In this article, we’ll dive into some steps you can take to prolong the life of your scrap logger/baler.

    Perform a Pre-Check Before Beginning Operation

    Perform a pre-check of your machine each time you begin operation. The pre-check procedure is outlined in your operator’s manual and will help you determine whether your machine needs service before use. These routine inspections can help limit downtime and extend the life of the machine, catching potential issues before they become larger problems.

    When to Perform Routine Service

    Your scrap logger/baler will greatly benefit from pre-established inspection intervals. Regularly monitoring your machine’s operational hours, usually located inside the cab or on the machine, will allow you to know when it’s time to perform routine services.

    • 500 hours: Fresh engine oil is required to reduce friction in the engine and prevent wear on your machine. We recommend filter replacement and engine oil change every 500 operational hours.
    • 2,000 hours: Hydraulic fluid is required to ensure smooth and efficient action of your hydraulic system. We recommend replacing the hydraulic fluid every 2,000 operational hours

    5 Inspection Points For Your Scrap Logger/Baler

    Air Filters

    Air filters allow your engine to “breathe” and operate at peak efficiency. Replace your air filters every 500 operational hours. Replacing the air filters is easy if you have the right type of filter for your machine.

    See your machine’s operator’s manual to determine which filters are right for your model. Keep extra filters on hand to ensure you’ll be ready to change filters every 500 operational hours.

    Engine Coolant

    Low coolant levels can cause your machine’s engine to overheat. During your routine inspections, be sure to check engine coolant levels and add coolant as needed. Monitor your engine temperature throughout the operation of your logger/baler and if signs of overheating are present, immediately stop your equipment and check coolant levels.

    Hydraulic Hoses

    Worn and leaking hoses can result in additional downtime for your machine which is why it is important to inspect your hydraulic hoses regularly. Look for signs of leaks, fray, or wear and check for fluid near your hydraulic hoses, as this could be a sign of a leak. These regular inspections will give you insight into when and if it is time to replace your hydraulic hoses.

    Wire Harnesses

    Wire harnesses control and protect the electrical system of your machine. Inspect your wire harnesses regularly to ensure optimal performance.

    During the check, ensure the wiring is properly protected and functional. Watch for signs that wires are frayed or damaged, or that the wire harness has been compromised. This will help prevent downtime.

    Pumps & Valves

    Pumps and valves are an essential part of your equipment. During normal operation, pumps and valves keep the system functioning and the moving parts of your machine working.

    A good logger/baler operator will have the experience to know when things are not operating normally. Monitor your pumps and valves by listening to your machine while it’s running. Listen for changes in operation, and stop operation as soon as you’ve noticed a problem. Continuing to run your machine when there’s a mechanical problem can lead to bigger issues in the future.

     

    Get the Most Out Of Your Machine

    Following these recommendations will help you identify issues before they become larger problems, limit downtime, and give your machine every opportunity to extend its operational life. At Aljon, some customers who took the time to care for, service, and maintain their equipment have been able to operate their scrap logger/baler far past the traditional “operational life;” some reaching over 30,000+ operating hours!

    Train your operators to perform inspections to ensure your machine is properly maintained. Have each operator read the operator’s manual, and keep the manual within easy reach to ensure that your operators have the resources they need to get the work done.

    The professionals at Aljon can help you throughout the life of your scrap equipment. For more information about performing inspections, buying replacement parts, repairs, or just general maintenance needs for your Aljon scrap equipment, please contact us.

  • 5 Questions To Ask Yourself Before Purchasing A Landfill Compactor

    5 Questions To Ask Yourself Before Purchasing A Landfill Compactor

    Landfill compactors are big investments, even when used or refurbished. They’re also the cornerstone of an efficient landfill operation and one of the biggest determinants of longevity. Without one, compaction ratios will suffer, and the landfill will reach its maximum cell height far ahead of schedule. Given their importance and value, it’s vital to make purchases with your eyes open and put as much time as possible into research to make sure you find the best compactor for your operations. These five questions can save you time and money down the road – time well-spent, given how long the compactor will be working for your operation.

    1. What do Experienced Landfill Operators Prioritize When Buying New Compactors?

    To begin with, ask other operators and owners what they wished they knew before making big purchases. One surprising topic that comes up over and over among experienced operators is the importance of uptime to overall return on investment. Cost of ownership includes both the initial investment and the cost of maintenance, repairs and refurbishment, and unexpected downtime can dramatically increase those costs.

    In addition to raising the operating cost of the machine itself, downtime puts incredible strain on the operation as a whole. Even if a compactor is down for a few days or a week for repairs, the stream of incoming waste still needs to be stored safely. A backup machine can be an organizational lifesaver in these situations, but it also costs money to own and maintain, and it’s usually a less effective compactor, either due to age or build. Temporarily reduced compaction ratios can eventually build up and cause long-term issues.

    Worse, when a landfill doesn’t have a backup option, operators may turn to non-purpose-built machines such as dozers or track loaders. These pieces of equipment are designed to float smoothly over rough terrain, not sink down into it and compact it without getting stuck. As a result, depending on how long it takes to get the primary compactor up and running, a few days of downtime can turn into significant wasted airspace and major costs to the landfill as a whole over time. Regardless of the differentiators that make one machine seem more appealing than another (e.g. fuel efficiency, weight, or wheel design), uptime and reliability make the biggest differences to overall productivity.

    2. What are the Costs of the Current Diesel Emissions Systems to the End User? Is There a Way to Minimize Them?

    While they are vital to meeting regulations and reducing the impact of diesel fuel on the environment and working conditions of operators, filtration systems and regen requirements do increase the cost of ownership for large machinery. Because compactors often stop and start during operation, active regen may be required, adding to maintenance time and reducing productivity.

    Replacing filters and maintaining systems to keep them in compliance all add to the time and financial costs of these systems. The easiest way to reduce those costs is to switch to an engine that integrates a selective catalytic reduction system, such as the Volvo Penta that powers Aljon compactors. These systems do not require DPF or regen, simplifying maintenance and reducing downtime.

    3. What is the Typical Life Expectancy of a Landfill Compactor?

    Compactors trawl through all kinds of unfriendly, abrasive material on a daily basis and are exposed to rain and other corrosive forces. After around 10,000 hours of operation, it’s more likely that systems will begin to fail and need replacement, even with good maintenance and abrasion-resistant wheel cleats. One rule of thumb is when repair costs approach half the cost of a new machine, it’s time to consider a replacement.

    Compactor frames, on the other hand, can last much longer – up to 30,000 hours for Aljon compactors. One way to reduce overall ownership costs is to consider rebuilding rather than replacing your machine. Many companies offer partial rebuilds of the drive train or hydraulics, but the gold standard is an OEM (Original Equipment Manufacturer) Certified Rebuild Program.

    Rather than having a third party rebuild part of the machine, Aljon’s Compactor Certified Remanufacturing program takes place in the factory where expert technicians completely dismantle the compactor down to the frame. Each part is cleaned, refurbished, repaired, or replaced and tested to ensure its longevity. Aljon certifies each rebuilt compactor with six months for the full machine and three years/6,000 hours for the power train. By extending the lifespan another 10,000+ hours, the overall cost of ownership is dramatically reduced.

    4. Is New Technology, Such as a GPS-Powered Machine Guidance System, Worth Investing in Upfront?

    Given that airspace is the most valuable asset of any landfill operation, it makes sense to pursue every possible improvement in compaction ratios, even if the upfront costs are high. Many are turning to new GPS systems that guide compaction routes, reducing the number of passes required to achieve the highest density. However, these systems incur additional installation, maintenance, and training costs to implement effectively, so they may not be right for every operation. Aljon compactors come pre-wired for GPS systems, so you don’t have to decide upfront – it’s possible to add one after the machine has been running for a few years to see if the compaction ratio gains are worth it for your operation.

    5. What Kind of Manufacturing Conditions Should You Look For? How Long Have Aljon Products Been in Production?

    All Aljon machines are built in a factory in Ottumwa, Iowa, where they’ve been built for 60 years. This has several advantages. Onshore manufacturing ensures that spare parts are available for overnight shipping when your machine needs repairs, and expert advice is readily available to solve problems. Aljon has a robust service and support department designed to get machines back up and running as quickly as possible with a high fill rate. Fill rate is the percentage of orders that can be filled with in-stock parts vs. being backordered, and Aljon spare parts has an average fill rate of 95% to reduce the amount of time spent waiting for replacement parts to arrive.

    Big investments require serious thought and research. It’s always worth asking other operators what their main concerns are and considering add-on costs and benefits such as regen-less engines and GPS systems. Additionally, ensuring that the manufacturer offers time and cost-saving benefits such as rebuild programs and exceptional customer service will give you confidence that your operation is in good hands when it comes to your most important equipment.

  • How Important is it to Order Parts Directly From the Manufacturer of My Scrap Equipment?

    How Important is it to Order Parts Directly From the Manufacturer of My Scrap Equipment?

    Maintaining heavy equipment like scrap loggers and balers is critical to ensuring smooth operations in scrap yards and recycling facilities. When parts need replacing, you’re faced with a choice: order directly from the original equipment manufacturer (OEM) or opt for generic, aftermarket parts. While the latter may seem like a cost-saving shortcut, there are significant factors to consider when it comes to the relative quality, reliability, and long-term performance of aftermarket parts compared to OEM parts.

    Using OEM parts is widely regarded as the prudent option for keeping your equipment running optimally, minimizing downtime, and reducing overall operational costs. Here is why ordering parts directly from the manufacturer is essential for maintaining the performance and longevity of your scrap equipment.

    1. Quality

    One of the most compelling reasons to choose OEM parts is quality. When you buy parts directly from the manufacturer of your scrap equipment, you are assured that these parts meet the exact specifications of your machine. OEM parts are crafted to the same technical standards as the components originally installed on your equipment.

    • Precision Fit: Since OEM parts are made with the original design specifications in mind, they will fit perfectly. You won’t have to worry about modifications or adjustments during installation, which reduces the risk of future complications.
    • Compliance with Standards: OEM parts are built according to the manufacturer’s strict production standards, ensuring they perform as expected under the demanding conditions that scrap equipment faces daily.

    The same cannot be said for aftermarket parts, which are often designed to fit a range of equipment models and may not adhere to the same high standards of production. Additionally, the manufacturer of aftermarket parts won’t have the same level of investment in the brand, that the original equipment manufacturer may have spent years or decades building.

    2. Compatibility

    In the world of heavy machinery, compatibility is key. Using parts that are specifically designed for your equipment means seamless operation, minimal downtime, and fewer headaches during installation.

    Benefits of OEM Parts:

    • Flawless Integration: Since OEM parts are designed for your machine, they are installed with confidence, and customers know they will operate smoothly without causing issues. Your machine will function just as it did before, maintaining optimal performance.
    • Avoiding Modifications: Generic parts, on the other hand, often require adjustments to fit correctly, which can lead to unanticipated problems down the road. These modifications may also void warranties or disrupt other machine components.

    Using OEM parts eliminates compatibility concerns and ensures that your equipment will continue to operate safely and efficiently. The risk of incompatibility is especially problematic in scrap equipment, where even small modifications can lead to larger system issues.

    3. Reliability

    When it comes to scrap equipment, reliability is non-negotiable. Your machinery is subject to tough environments, heavy loads, and constant wear. Inferior parts can lead to costly breakdowns and unplanned downtime, which in turn affects your bottom line.

    OEM vs. Aftermarket Reliability:

    • Durability of Materials: Aftermarket parts may seem reliable at first, but they often fail to meet the manufacturer’s requirements in terms of materials and design. Their specifications are frequently altered for the purposes of cost-cutting, which can result in weaker components.
    • Long-Term Reliability: Even the smallest engineering deviations (e.g., part thickness, quality of material) can cause catastrophic failures over time. OEM parts are designed to wear more slowly, providing a higher level of dependability and protecting your equipment from unexpected breakdowns.

    By investing in OEM parts, you safeguard the longevity and reliability of your entire system. Over time, this results in fewer breakdowns and a reduced need for repairs.

    4. Performance

    The performance of your scrap equipment depends not just on the machine as a whole, but on the quality of each individual component as well. Choosing OEM parts ensures that your equipment continues to perform at peak levels.

    Why OEM Parts Protect Performance:

    • Maintaining Operational Integrity: With OEM parts, each replacement part is guaranteed to meet the high standards set by the manufacturer, who has a reputation to consider in the long term. This means that the machine will continue to operate with the same level of efficiency and safety as before.
    • Avoiding Damage: Installing low-quality, generic parts can lead to damage not only to the part itself but to other critical components. Over time, this can cause significant performance issues and may even shorten the life of your equipment.

    To ensure that your scrap logger or baler maintains its operational integrity, OEM parts are the safest choice. By using manufacturer-approved components, you minimize the risk of costly damage and system failures that could compromise the safety and efficiency of your scrap equipment and your business’s operation.

    5. Long-Term Cost Savings

    On the surface, aftermarket parts may seem like a way to save money, but in reality, they often result in greater costs over time. As mentioned earlier, generic parts are typically designed to meet a broader range of applications, so they may not fit or function as well as OEM parts.

    How OEM Parts Save You Money in the Long Run:

    • Reduced Wear on Other Parts: Poorly fitting or subpar components can cause excessive wear and tear on other parts of the machine. OEM parts, on the other hand, are designed to integrate seamlessly, reducing the likelihood of additional damage and minimizing repair costs.
    • Less Frequent Repairs: By investing in high-quality, manufacturer-approved parts, you’ll face fewer repair costs over time. OEM parts last longer, meaning you won’t have to replace them as often.
    • Extended Equipment Lifespan: Regularly using OEM parts can significantly extend the life of your scrap equipment. When your machine is operating at its peak, there’s less need to replace the entire unit prematurely, leading to substantial cost savings over time.

    In the long term, OEM parts provide the best value. While they may have a higher upfront cost, their reliability, performance, and compatibility ensure that you avoid expensive repairs and downtime, leading to a lower total cost of ownership.

    When you’re maintaining heavy-duty scrap equipment like loggers and balers on an ongoing basis, there’s little room for compromise. Upon careful analysis, it becomes clear that ordering parts directly from the manufacturer ensures that your machinery will continue to operate at peak performance with minimal disruptions. OEM parts provide superior quality, reliability, and compatibility, protecting your equipment from unforeseen issues and reducing long-term costs.

    Manufacturer-approved components are the most cost-effective and prudent choice for any operation that relies on scrap equipment to keep things running smoothly. To learn more about specific OEM parts for your scrap equipment or to place an order, contact us today!

  • What is PLI and Why is it Important to Your Landfill Longevity?

    What is PLI and Why is it Important to Your Landfill Longevity?

    In a landfill, space is at a premium. New cells are enormously expensive to clear and build, and they take a lot of time and effort to get approved. The more material that can be compressed into a cell before it reaches its height limit, the longer it can keep working – and stay profitable. This makes “airspace” a key consideration for landfills. By compacting waste more densely, that airspace can be preserved, extends the lifespan of the cell and the landfill as a whole.

    1. What Is PLI?

    PLI (Pounds per Linear Inch) is calculated by dividing the weight of the compactor by the combined width of all four wheels. This corresponds to the amount of pressure the wheels exert on the surface beneath them, and, thus, how well they will compress the material. Some equipment, such as bulldozers, are built with the opposite goal in mind; dozers need to “float” on top of the surface, not sink down into loose dirt, mud, or waste, so they can keep moving without interruption over rough terrain. Thus, most run on wide tracks rather than wheels to spread out the weight of the chassis and attachments.

    Landfill compactors need to do the opposite: sink down onto the layer of loose waste and debris beneath them and compress it without getting stuck. Four optimized, cleat-covered wheels help translate the weight of the compactor directly into the material beneath it. Increasing the weight and reducing the width of the wheels will both increase PLI and thus compaction, but if the wheels get too narrow, they are more likely to get stuck or leave a pile of un-compacted material between them. This makes increasing the weight a more reliable way to improve PLI.

    2. How Do Compaction Ratios Impact Airspace?

    Once a landfill cell is designed, approved, and built, the only limit on the amount of material it can contain is its maximum height. Material can be added to the working face in a variety of ways, ranging from simply running it over with non-purpose-built equipment like bulldozers once or twice to stabilize it to complex, multi-pass pattern, GPS-driven compactor routines. The second may seem like more work, but when you compare the PLI of the two methods, a purpose-built landfill compactor will offer dramatically better compaction ratios, maximizing airspace usage.

    Aljon compactors come in three models: the ADV 500, 525, and 600. They max out at ~95,000, 117,000, and 127,000 lbs respectively, for maximum ratings of 490, 598, and 613 PLI. The largest can process up to 1300 tons of material per day, while even the smallest can handle up to 950 tons per day.

    These PLI numbers are some of the best in their class across the industry. While higher weight translates into higher PLI (for similar machines), bigger compactors have the added bonus of being able to process more material in a day. Even landfills with smaller daily intake amounts often find that bigger machines are worth it in the long run because of the increased compaction they offer. For long-term benefits, it’s wise to invest in the highest PLI compactor an operation can afford to ensure that a cell’s airspace lasts as long as possible and no space is wasted as air pockets inside the cell.

    3. How Can You Improve Landfill Longevity?

    Improving PLI increases the amount of material that can fit into a landfill cell, extending its lifespan, but it also preserves the integrity of the cell itself. Air pockets are more than just wasted space; they can create instability as material decomposes, eventually resulting in dips that reduce the effectiveness of compaction down the road. They can also create opportunities for water to seep between compacted material and intrude deep into the cell. This creates safety hazards such as toxic runoff. Most importantly, when these pockets contain trapped oxygen, they become potential sites of ignition and origin points for landfill fires. Because it is difficult to put out fires burning deep within the cell from the outside, cells often have to be dismantled to extinguish them and stop toxic gases from accumulating. Repairing this damage is time-consuming and costly, in addition to halting normal operations for days or weeks while the problem is resolved.

    Achieving maximum PLI greatly improves the chances of a landfill reaching its longest possible lifespan and increases overall revenue without having to go through a costly expansion process. Every little bit of added density matters, which is why choosing a landfill compactor with high PLI is so important. Small increases in compaction ratios build up over time and can increase a landfill’s lifespan by years, especially if done from the beginning.

  • 3 Important Routine Services You Should Perform On Your Scrap Logger/Baler Regularly

    3 Important Routine Services You Should Perform On Your Scrap Logger/Baler Regularly

    Formidable in appearance but straightforward in function, the scrap logger/baler is a powerful and meticulously engineered machine. Used in scrap metal and recycling industries to compress and bundle large quantities of scrap materials into dense, manageable bales, it reduces the volume of scrap, making it easier to transport, store, and sell for recycling or disposal, enhancing operational efficiency.

    Maintaining your logger/baler is crucial to ensure it continues to reliably operate at peak efficiency. Properly maintaining this equipment can save you time and money, while also helping you avoid unexpected downtime. Here are three essential routine services that will help keep your scrap logger/baler in top shape.

    1. Grease Every 8 Hours

    Regular greasing is one of the most important tasks in maintaining your scrap logger/baler. Heavy equipment like this involves numerous moving parts, including joints, hinges, and bearings, which are prone to metal-on-metal contact. Over time, this friction can cause wear and tear, ultimately leading to costly repairs or even equipment failure.

    • Why it’s essential: Greasing your machine prevents metal components from grinding against each other, minimizing wear and prolonging the life of your equipment.
    • What to grease: Pay special attention to key components like the hinges, joints, and bearings, as these areas see the most motion. Ensuring these parts are properly lubricated reduces friction and prevents unnecessary strain on the machinery.
    • How to do it: The manufacturer will provide a detailed map with every scrap logger/baler, outlining the grease points to simplify this task. Following this guide will ensure you never miss a critical lubrication point.

    By adhering to a consistent greasing schedule every 8 hours of operation, you’ll safeguard the longevity of your scrap logger/baler and limit unnecessary breakdowns.

    2. Change Engine Oil and Filters Every 500 Hours

    Your logger/baler’s engine is its powerhouse, and regular engine maintenance is key to keeping it running smoothly. One of the most important aspects of engine upkeep is changing the oil and filters at recommended intervals.

    • Why it’s essential: Clean oil is vital for ensuring your engine’s components remain lubricated and function efficiently. Over time, engine oil accumulates dirt, debris, and metal particles, which reduces its ability to protect engine parts from excessive friction.
    • Signs of dirty oil: As the oil becomes contaminated, it loses its lubricating properties, leading to increased friction within the engine. This can cause parts to wear prematurely, reduce overall performance, and, in severe cases, result in engine failure.
    • How often: We recommend changing the engine oil and filters every 500 hours of operation to maintain optimal performance. Doing so improves engine efficiency, reduces the risk of breakdowns, and extends the lifespan of your equipment.

    Neglecting this critical task can not only reduce your machine’s performance but also lead to expensive repairs and extended downtime.

    3. Change Hydraulic Oil Every 2,000 Hours

    Hydraulic systems are at the heart of a scrap logger/baler’s functionality, enabling powerful, smooth, and precise operations. Just like engine oil, hydraulic fluid needs to be replaced regularly to ensure the machine continues to perform optimally.

    • Why it’s essential: Hydraulic oil transfers power within your machine’s hydraulic system and provides essential lubrication for its moving parts. Over time, this oil can become contaminated with debris and particles, which can reduce its effectiveness.
    • Consequences of neglect: Failing to change your hydraulic fluid when needed can lead to damage of the critical hydraulic components, such as pumps and motors. Hydraulic system failure can cause major operational disruptions and lead to expensive repairs.
    • How often: We advise that you change hydraulic oil every 2,000 hours of operation. This interval ensures that your hydraulic system will continue to function efficiently and mitigate contamination-related issues.

    Hydraulic system issues can significantly impact your scrap logger/baler’s performance, so be sure to stay on top of this maintenance task to avoid costly setbacks!

    Performing these three essential services—greasing every 8 hours, changing engine oil every 500 hours, and replacing hydraulic oil every 2,000 hours—are simple but essential procedures that will keep your scrap logger/baler running at peak efficiency. Routine maintenance not only extends the life of your equipment but also prevents costly repairs and unexpected downtime.

    Routine maintenance is crucial for heavy equipment, particularly in harsh environments like scrap yards. Regular servicing not only ensures optimal performance but also extends the equipment’s lifespan, reducing costly downtime and repairs. In challenging conditions, preventive maintenance helps identify potential issues early, maintaining productivity and safety. Consistent care also enhances efficiency, ensuring that your equipment operates reliably, even in the most demanding settings. For more information about maintaining your equipment or to explore what we offer in logger/balers, don’t hesitate to reach out to us!

  • Keep Your Landfill Compactor Out Of The Trash: Reduce Ownership Costs Through Aljon’s Factory Certified Rebuild Program

    Keep Your Landfill Compactor Out Of The Trash: Reduce Ownership Costs Through Aljon’s Factory Certified Rebuild Program

    If you’ve just purchased a new landfill compactor, it may seem premature to start thinking about what you’ll do when it needs to be replaced. However, making those plans early can help you predict your overall cost of ownership, minimize disruption to your business, and decide how much to set aside for future repairs or your next purchase.

    Even with the best care and maintenance, most landfill compactors have a lifespan of approximately 10,000 – 12,000 operational hours before corrosion and strain begin to take their toll on more sensitive systems and components. At first, many, if not most, of these components can be repaired, but when multiple systems start to fail simultaneously or the cost of repairs approaches 50% of the cost of replacement, it makes sense to invest in equipment with full warranties and brand-new parts.

    If you want to breathe new life into your machine at this point in its life cycle, there’s still a way to extend its lifespan: rebuilding instead of replacing. Many manufacturers offer this service through third parties or for specific systems (e.g. an engine rebuild), but Aljon runs a factory-certified full rebuild program that can give your compactor a second life. This program is so successful that it typically adds up to another 10,000+ hours of operation to equipment like the ADV 500 on the first rebuild. Some machines can even be rebuilt multiple times, always with a factory warranty included.

    Reduce, Reuse, Recycle

    Aljon’s landfill compactors are designed with this rebuild program in mind. Every component can be stripped all the way down to the frame in order to fully rebuild and restore the machine with no loss in quality or performance. This thrifty approach reuses one of the most costly and durable parts of the equipment (the frame) and stretches its lifespan as long as it feasibly can, making the manufacturing process more sustainable and saving you money by not scrapping perfectly good components. Factory rebuilds also make it possible to upgrade parts to satisfy new regulations or take advantage of new technology without having to shell out for a brand-new machine. Newer isn’t always better; if you’ve had a reliable machine for a long time, it makes sense to stick with it and rebuild instead of replacing.

    Factory Certified

    Many rebuild programs focus on components like the engine or hydraulics, as those systems are often the first to break down beyond repair. Aljon’s rebuild program, on the other hand, is much more extensive:

    • The machine is completely disassembled down to the frame at the factory
    • Every single moving part is being rebuilt, reconditioned, or replaced.
    • It’s factory-certified, meaning that the landfill compactor is actually brought back to the manufacturing facility and rebuilt there by highly-trained Aljon experts, not third parties.

    Once the equipment has been disassembled, it is thoroughly cleaned and repainted to protect the underlying metal. It then receives everything from brand-new hydraulic hoses to wiring harnesses and all other moving components to ensure peak performance. New or reconditioned wheels are then inspected and installed. Once everything is tested and the new build is verified, it is certified with the standard full machine warranty (6 months), power train warranty (3 years/6,000 hours), and hydraulic hose warranty (2 years), just like new machines.

    When considering the lifetime ownership cost of a new machine, it’s important to check upfront whether it is eligible for a rebuild program and how comprehensive that program is. How many additional hours of use will it buy you? Does the manufacturer stand behind rebuilt products? An OEM (Original Equipment Manufacturer) rebuild ensures that your equipment is remanufactured by factory-trained technicians to the highest standards. This program reduces waste while still giving you access to a full warranty and the newest upgrades. Eventually, the time may come when even the frame needs to be scrapped, but in the meantime, rebuilding can save an average of 30% on the ownership cost over 10 years – and keep your landfill equipment from costing you landfill space.

  • How Important is Customer Service in Your Scrap Logger/Baler Purchasing Process?

    How Important is Customer Service in Your Scrap Logger/Baler Purchasing Process?

    At the beginning of the purchasing process, customer service is mostly a hypothetical issue, as sales teams are incentivized to make the buying process as easy and hassle-free as possible. But a few years into operation, if something goes wrong, will the company still be there for you?

    Downtime is costly, and every day it takes to get in touch with the service department and wait for parts to ship compounds those losses. To get the most out of your investment, it’s important to evaluate manufacturer service reputations in the following three areas: responsiveness, parts quality, and customer service.

    Responsiveness

    Scrap equipment takes a beating over its lifespan, often working in less-than-ideal weather and in contact with corrosive materials. While a solid maintenance schedule, well-trained operators, and a suitable environment will extend the life of your machines, eventually, something will need repaired. It’s important to know who to contact for diagnostics and replacement parts, as well as how long it will take to get the machine up and running again.

    Building excellent equipment requires a lot of logistical and mechanical experience, while running a service department requires fast-paced customer service, software, and shipping solutions. A manufacturer may be very good at one side of the operation but struggle in the other, even though service is vital to the overall operational quality and longevity of equipment in the field.

    It’s important to ask both the sales team and other owners questions like:

    • How long are average hold times when calling the parts department?
    • Are the phones staffed by people with knowledge of the machinery and replacement parts? Or do they simply take orders?
    • How difficult is it to get in touch with someone to help with more complicated problems or repairs?

    In addition to finding out how communicative the manufacturer’s service department is, it’s important to ask questions about their fill rate and inventory status. “Fill rate” is the percentage of orders that can be fulfilled with current inventory. A low fill rate means the part you need to get your operations back on track may be backordered and take weeks or months to arrive from overseas, unnecessarily extending downtime.

    Our Aljon scrap parts typically have a 95% fill rate or higher, ensuring that you can get the parts you need without long lead times. As a further commitment to customer service, both maintenance and replacement parts are ready for same-day shipment and generally ship within 24 hours of the order being placed.

    Replacement Part Quality

    Once you know you can get replacement parts quickly, it’s also important to check their quality. Third-party and aftermarket competitors often promise to save you money upfront, but they lack the detailed knowledge of the original manufacturer – and have less of an incentive to maintain a good reputation for a particular brand. When purchasing replacement parts from the OEM (Original Equipment Manufacturer), you know that you’re investing in parts every bit as good as the original builds (and, sometimes, upgraded ones, if technology has improved since your purchase).

    All Aljon Scrap Parts components are designed explicitly for Aljon machines and manufactured to the same standards as the original parts, ensuring that performance will not be degraded after installation.

    Furthermore, because the entire manufacturing operation is designed to produce Aljon components, it’s possible to sell the highest-quality parts at competitive prices. Replacement parts are considered part of Aljon’s overall commitment to quality and fair pricing, not an add-on revenue stream, so there’s no reason to gouge customers on replacement costs.

    Customer Service

    With operations stretching back more than 60 years, we have a long – and consistent – history of prioritizing customer service. It’s not enough to build solid equipment; a company needs to stand behind that equipment to the very end of its lifespan (and even extend it through rebuilding when possible) to ensure customer satisfaction and the best possible return on investment. Aljon has a robust pre-owned division, which is a testament to both the durability of machinery and its quality of service over time.

    When service is an afterthought, the entire manufacturing operation suffers. Service requirements must be integrated into every step of the manufacturing process, from design (so that parts are easy to replace and install) to fabrication (ensuring both the quality and quantity of spare parts are made) and sales. A company can only deliver on its promises of long-lasting machinery if it has a commitment to ongoing service and the infrastructure to make it as quick, low-cost, and hassle-free as possible – a standard that our customers have applauded for decades.

  • 4 Surprising Ways Cab Design Can Impact Scrap Logger/Baler Safety

    4 Surprising Ways Cab Design Can Impact Scrap Logger/Baler Safety

    The use of heavy machinery like scrap logger/balers comes with obvious hazards. As we all know, cutting and crushing tools designed to handle cars and other scrap metal sources are particularly dangerous.

    Common safety techniques such as exclusion zones, Lock-Out/Tag-Out systems, and accessible maintenance panels help control access to the most dangerous parts of the machines to keep operators, bystanders, and mechanics out of harm’s way. Other safety tools use maintenance and operational protocols to reduce risk. Regular maintenance schedules and well-trained staff can identify safety problems before they become emergencies. Keeping work spaces clean, abiding by space and ventilation requirements, and double-checking safety features on startup can all help things run safely.

    While it’s important that all workers be trained in both general workplace safety and the particulars of any machinery they will be working with (or near), the first and last lines of defense are always the operators themselves. With experience, they gain deep knowledge of their machine’s normal operations, maintenance needs, and any unique handling requirements (e.g. switching from logging to baling). They have access to emergency stops and are responsible for keeping others safe while their machinery is active.

    Cab design can impact operator visibility, response time, and personal safety, making it a critical (but often overlooked) way to improve safety across your operations. Meeting the needs of your operators, in turn, will empower them to keep others safe.

    1. Safe Cab Access

    While creating a culture of safety and attention to detail is crucial to the well-being of long-term operations, rules and protocols can get overlooked on busy days. This should not be the norm, and violations should be quickly reported so that retraining can take place.

    But one way to minimize corner-cutting or other unsafe behavior even in challenging circumstances is to design processes, pathways, and machinery so that they automatically guide safer behavior. For example, to borrow an idea from urban planning, identifying “desire paths” (natural areas of high foot traffic) can show you where to install machinery to discourage shortcuts through exclusion zones. Workers, like pedestrians in cities, will often consciously or subconsciously identify the shortest path from A to B in order to save time, potentially ignoring marked paths or even barriers.

    Observing habitual behaviors will give you insight as to how spaces and machinery are actually used and will allow you to make changes to improve safety and efficiency. If machinery is positioned so that “desire paths” are kept clear, workers will be less likely to veer into unsafe territory as it will require extra effort.

    Climbing up and down a ladder in a variety of conditions by many different types of operators is not always the easiest way to access a cab. Here at Aljon, we design our logger/balers to use steps with rails and a platform to enter and exit the cab rather than ladders. This makes access, training, etc. extremely safe and easy for all operators.

    2. Cab Controls

    Modern landfill equipment typically uses a control screen in addition to a joystick to control movement. This screen should be both easy to reach and view so that the operator doesn’t have to exert additional effort by stretching or leaning.

    It should also display operational safety information, such as whether baler doors are fully closed, as clearly as possible. Furthermore, hardware and software should be designed so that bale processing cannot take place unless the doors are completely shut to prevent harm to nearby workers as well as the machine itself.

    These built-in safety protocols prevent user error (whether due to fatigue or negligence), reducing potential points of failure during operation. Additionally, a manual emergency stop button should be clearly visible so the operator can halt the machine should something go wrong.

    3. Operator Presence Control (OPC)

    As the system that provides crushing force, the hydraulics are one of the most important parts of a scrap logger/baler when it comes to safety. In addition to shutting off the engine, hydraulic energy must be released on shutdown. If it is left on (e.g. during maintenance when removing a jam), it could suddenly engage and cause an accident.

    Aljon logger/baler cabs require both a key to start and the operator to be fully seated. If the operator leaves the cab (or falls or moves for any reason), the hydraulics will be deactivated and the machine shuts down. Again, automatic systems like these reduce both user error and accidents if the operator were to become incapacitated.

    4. Cab Comfort & Ergonomics

    While arthritis and repetitive strain injuries are not as newsworthy as dramatic accidents, ergonomic injuries can increase employee turnover as well as cause other issues like fatigue, lack of situational awareness, and reduced speed and efficiency. There is no reason for operators to end their workday exhausted, unfocused, and in unnecessary pain when better alternatives will allow you to retain skilled employees for longer.

    Important considerations include:

    • Is the cab seat adjustable and designed for 6+ hours a day of sitting?
    • Are joystick controls easy-to-reach and comfortable?
    • Is the screen easily visible for operators of different heights?
    • Can you see the bale chamber, crane, and surrounding areas from the cab or is visibility limited?
    • Is the cab isolated from sources of noise and vibration such as the air compressor to aid in decision-making? Is it easy to blame an unexpected vibration on the A/C compressor activating rather than investigating the source?

    Heavy equipment safety (especially in challenging environments like landfills and scrap yards) requires an overlapping system of precautions for safe, long-term operations. Robust maintenance programs, leadership that prioritizes safety protocols and PPE, and invested workers as well as operators are just as important as specific tools like Lock-Out/Tag-Out.

    Cab design is just one part of the overall safety picture, but it can enhance every other aspect because it helps operators be alert, aware, and in position to keep others safe. Don’t underestimate its importance. Choose an Aljon scrap logger/baler for efficiency, power, and of couse, safety!

  • Can Wheel Design Affect Landfill Compactor Performance?

    Can Wheel Design Affect Landfill Compactor Performance?

    On landfill compactors, wheels are one of the most critical design features of the machine. They are designed to shred, tear, and break down the waste, to make it more compactable. Landfill compactor performance depends on many factors including overall weight, engine horsepower, and best practices, but the wheels, being directly in contact with the waste, their design directly impacts how well the landfill compactor functions & its ability to obtain optimal compaction ratios. There are many schools of thought on cleat design, centering around three key factors: quantity, placement, and the design of the cleat itself.

    1. How Many Cleats Do You Need Per Wheel?

    It’s easy to think that more wheel cleats will result in better compaction, but the cleats are mainly meant to crush, tear, and breakdown the waste making it more compactable. The overall weight of the wheel then compacts the waste. Too few cleats won’t allow for sufficient manipulation of waste, but if there are too many cleats, this will create the risk of waste building up on the wheel, reducing the effectiveness of the cleats, reducing compaction, and loss of air space. 

    Too many cleats can allow material to get stuck in the narrow spaces between the cleats, creating the need for cleaner bars, and / or wire cutters, both of which are maintenance items that need to be adjusted regularily, and replaced multiple times throughout the life of the machine. As a result, this will also add to the the cost of ownership.

    2. Cleat Placement/Pattern

    Cleats are distributed across the surface of the wheel in a variety of staggered patterns. These vary from design to design and can significantly impact compaction rates, maintenance needs, and stability in different conditions. Aljon’s cleat patterns optimize how many cleats are in contact with the material during the wheel’s rotation while also improving compaction and making the wheels easy to clean.

    3. Cleat Shape, Size, & Material

    In addition to their distribution pattern, wheel cleats today are available with many different geometrical designs. Some cleats are partially hollow or have narrow ridges, which can result in the need for replacement during the life of the machine. This requires more frequent service and replacement, increasing downtime and decreasing your ROI on your equipment. Aljon cleats are both made of a high content abrasion-resistant material and are solid all the way through, creating a longer wear life, and reducing the cost of replacement. 

    The Aljon ADV 600 has a standard 10” cleat compared to our competitors machines who use an 8 inch cleat. These larger cleats increase weight and compaction as well as the shredding and manipulation capabilities of the compactor. They also maximize traction on our heavist machine, which reduces the possibility of wheel spin and improves performance on slopes.

    Wheel Structure

    As important as the cleats are to the compaction process, the design of the wheels also matters. Many compactors have cone wheels, and and some of them ballasted with steel shot to increase the overall weight of the compactor at a lower cost. This shot is retained by a plug, and if the plug fails, the shot will be lost, and it will change the weight distribution and reduce overall weight until it is noticed and repaired, leading to unexpected performance issues during operation. Adding a point of failure to an expensive piece of machinery always runs the risk of increased cost of ownership.

    Aljon’s ADV 500 model has cone wheels, with an operating weight range between 86,718 – 95,450 lbs. (depending on the machine configuration) without using ballast. For landfill operations that need more power, the ADV 525 and 600 both have I-Beam wheels, which offer better overall structural integrity. For these heavier machines (the 525 has an operating weight of 108,000 – 117,602 lbs. and the 600 has a weight of 126,160 – 127,500 lbs.), better structural integrity is necessary to achieve peak performance. These wheels are also easier to clean with fewer opportunities for failure, extending the life of the wheel.

    Wheel design may seem secondary to other factors in choosing a new landfill compactor, but the number of cleats, their placement, and their geometry can influence compactor performance. Wheel design affects everything from performance to stability and compaction. A solid design that focuses on performance and longevity using top-quality materials will help you improve the return on your investment and increase the profitability of your operation.

  • Can You Really Get 30,000+ Operational Hours Out of a Scrap Logger/Baler?

    Can You Really Get 30,000+ Operational Hours Out of a Scrap Logger/Baler?

    Extending the lifespan of scrap equipment can be challenging due to its constant exposure to the elements and a variety of not-exactly-pristine materials. In addition, scrap logger/balers are capable of producing immense amounts of force, but incorrect materials or operation can be damaging to both the frame and the hydraulics, requiring expensive repairs. So, how in the world can any scrap yard expect to get 30,000+ operational hours out of their scrap logger/baler?

    In short, they shouldn’t expect this. However, after analyzing Aljon customers that HAVE achieved this and the many more surpassing industry averages, we have been able to divise a few tips that can help to maximize the lifespan of these important investments.

    The Right Machine

    No matter how well a machine is made, if it’s the wrong tool for the job, you will always cause unnecessary wear and tear. For smaller, occasional jobs, it’s sometimes possible to get away with a less durable piece of equipment or one that isn’t perfectly suited for your business. Some owners are perfectly happy to crush scrap metal with an excavator once a year and haul it off to be processed. However, this kind of use doesn’t scale well and isn’t the safest option for operators and nearby workers. “Macgyvered” solutions are not usually the most efficient routes, especially for continual use. A dedicated scrap logger/baler of the right size can handle everything from cars to rebar, day in and day out for years on end.

    Once you’ve identified the right machine for your operation, the next step is finding a great machine. Investigate long-term ownership costs like repair and maintenance, as well as the availability of manufacturer support. Some questions to ask a potential manufacturer include:

    • How long have they been in business? Are older machines still in use?
    • Do they keep replacement parts in stock and have a large onshore inventory?
    • Are they known for sturdy construction and good customer support?
    • Is there a large pool of knowledgeable mechanics who are happy to work on their machines?

    Follow. The. Manual.

    After you your new machine arrives at your scrap yard, it’s time for the most important step: reading the operations manual. This is necessary both for identifying maintenance needs and understanding how the equipment operates. The manual is the key to creating an effective maintenance schedule that will keep the machine running smoothly. It should include details about everything from how to protect seals and prevent leaks as well as how to clean high-use areas of the machine such as the pusher block and box.

    Scrap logger/balers need regular lubrication to protect moving parts. But different areas of the equipment may need different viscosities depending on how much friction they encounter. This can also change with the environment – different temperatures and humidity levels can affect how well different greases perform. It can be tempting to bypass these specifics and just use large amounts of the heaviest grease available, but over-lubrication can cause its own set of problems, including buildup and the trapping of dirt or other contaminants.

    Proper Operation

    Scrap Logger/Balers are workhorses designed to take (and give) a beating. They don’t need to be babied like an expensive sports car, but they will last longer if they are treated with respect. Use them for their intended purpose with correct materials and for reasonable lengths of time to reduce the risk of stressing the machine unnecessarily. They may not need a full detailing, wax, and polish every week, but basic cleanliness goes a long way towards preventing particulates like dust and sand from infiltrating the system or corrosives like salt damaging the frame.

    Operator Training

    It may cost a little more to hire operators who are both experienced and willing to learn, but it will help maximize the life of your machine. Scrap logger/balers that are run by workers who pay attention to operation and maintenance needs are more likely to last longer.  So, consider prioritizing the hiring and training of committed operators who will regularly check equipment, schedule maintenance, and run the machines efficiently and effectively.

    Most importantly, make sure that operations are organized to reduce the three main “overdoing” risks: overworking, overheating, or overloading the scrap logger/baler. The manual should explain what those limits are, and operators should be trained to stop when they notice any signs of getting close. Operators can also increase the longevity (and efficiency) of equipment by using optimum cycling or idling procedures, e.g. coordinating with the material handler so that cycles are only run when the box is full.

    If all of this seems a little overwhelming, it’s important to remember that you don’t have to get every detail right for your scrap logger/baler to run effectively for years. But if you want to maximize the life of your scrap equipment, every little step towards care and maintenance will help you give your machines an edge when it comes to long-term productivity. Regular maintenance and thorough employee training will help you make sure your investments pay dividends for years to come.

  • How To Reduce The Risks Of Operating A Ferrous Scrap Metal Logger Or Baler

    How To Reduce The Risks Of Operating A Ferrous Scrap Metal Logger Or Baler

    Heavy machinery – especially landfill machinery specifically designed to crush and compact like ferrous scrap metal loggers or balers – will always pose a number of safety hazards, ranging from electrical malfunctions or mishandling to common physical risks like falls, impacts, and crushing. Additionally, lesser-known risks related to ergonomics, toxic materials, and operational design can impact the long-term health and well-being of operators. Neglecting these safety issues can increase the unwanted turnover of experienced staff.

    Fortunately, once safe working practices are established, most of them become second nature and do not add significant time or effort to normal operations. Those that do still do not require nearly as much time or effort as recovering from downtime caused by an accidental injury.

    A good operational safety plan will cover operators, bystanders, and maintenance staff as well as correct usage of the machine itself. Ideally, any plan will start with reading the equipment’s manual provided by the manufacturer and thoroughly training operators on correct operations. Operating ferrous scrap metal loggers or balers correctly not only improves safety and reduces the risk of malfunction, it can extend the longevity of equipment and increase overall efficiency. It may feel like being a stickler, but if you want to achieve optimum production levels, following manufacturer guidelines is the most important place to start.

    Operator Safety

    Keeping logger/baler operators safe is a multifaceted project that requires collaboration with operators themselves, but many principles are straightforward and easy to set up across your wider operation. Creating a culture of safety empowers your employees to notice hazards before they become accidents and solve problems independently to keep themselves and other workers from being injured. This kind of atmosphere also helps keep expensive equipment in top shape. The following steps can dramatically improve the safety of your operations:

    • Training
      Many potential problems can be prevented by sufficient training. Do your operators know which materials are prohibited from the scrap metal baler and how to identify them? Have they practiced safe loading and unloading? Do they know how to recognize toxic materials and reduce exposure? Sufficient practical training will increase their ability to spot problems and maneuver material in a safe and controlled manner.
    • Inspections
      Operators should inspect equipment at least daily in addition to regular maintenance checks by certified techs. Before turning on the logger/baler, operators should make a quick circuit of the machine looking for leaks, cracks, or other damage to fuel lines, hydraulics, and any moving parts. They should also check for lock-out tags and test that emergency stops, alarms, screens, and guards are all working as intended.
    • PPE
      Personal Protective Equipment may not be the most fashionable, but worn properly, it can save lives. At minimum, logger/baler operators should wear steel-toed boots, sturdy gloves, and safety glasses. Hearing protection, hardhats, reflective vests, and respirators may also be appropriate depending on the location and setup in a particular scrapyard.
    • Electronics
      While operators are not typically interacting with any high-voltage electronics during machine operations, it’s important to make electrical safety foundational to all operations. Liquids should be kept away from screens and panels in the cab, and the surroundings should regularly be checked for standing water and any other voltage risks. For battery-powered logger-balers, this is doubly true.
    • Ergonomics
      Ergonomic injuries may take longer to appear, but they can put an operator on the sidelines (and your scrapyard at risk for a lawsuit) just as easily as acute injuries. Comfortable cabs with seats of an appropriate size for the operator can reduce strain and the risk of repetitive stress injuries. Easy-access cabs can reduce the risk of falls, and climate control can reduce the risks of heatstroke and hypothermia.
    • Weather Exposure
      All employees, but particularly those working outdoors in inclement weather and their supervisors, should know the signs of heatstroke, heat exhaustion, and hypothermia, and be encouraged to take safety breaks in extreme weather without penalty. All employees should have access to water and first aid, as well as know who to alert if a coworker seems fatigued, intoxicated, or otherwise impaired (heat exhaustion can resemble intoxication in its early stages).

    Bystander Safety

    In some ways, operator safety is the easy part: operators are in control of their machines and are trained to know and avoid specific hazards. Bystanders (mechanics, drivers, supervisors, and even operators of other machinery) may not know what to look for or be aware that they are in danger from the logger/baler. In loud or busy environments, they may not hear warnings or even be visible to the operator. In such cases, prevention and precautions are key.

    The most important precaution is the establishment of an “Exclusion Zone” around all heavy machinery, especially ferrous scrap metal loggers or balers with cranes. Built-in material handlers usually have a range of around 25’, and pedestrian access should be fully prohibited within in a full circle of this distance around the machine.

    Ideally, a physical barrier should be raised around the exclusion zone, but some kind of visible warning or no-entry line should always be fixed around the perimeter. Good signage protects bystanders from both the crane and debris from the compactor and helps them avoid becoming trapped or stuck. A clear radius around the equipment also gives the operator a better line of sight, enabling them to hit the emergency stop immediately if the need arises. The exclusion zone should be kept as clean as possible to avoid the slippery or dusty ground, tripping hazards, or confusion about where the exclusion zone starts and ends (cleanliness often has the side benefit of improving machine performance and reducing maintenance needs).

    Maintenance Safety

    Operators are intentionally positioned a safe distance from a ferrous scrap metal logger/baler’s moving parts. During maintenance (especially the removal of jams), mechanics are often in more dangerous positions. This makes maintenance safety protocols among the most important.

    In 1989, OSHA codified the “Lock Out, Tag Out” (LOTO) safety protocol, a two-step system where mechanics to lock machines and personally control when they may be restarted (Lock Out) while also alerting others that the equipment is being serviced (Tag Out). Aljon’s logger/baler batteries feature a built-in LOTO system that locks the battery on the machine, making it impossible to start it during maintenance.

    Working with heavy equipment is inherently dangerous, and poorly-designed equipment can increase those risks. Aljon takes that responsibility seriously and includes multiple safety features on its scrap equipment, including an emergency stop button in the cab to halt operations instantly.

    A safe working environment benefits those working in it, but it also has farther-reaching effects. Carefully planned safety strategies are more likely to be in compliance with local and national regulations. They’re also more likely to impress your insurance carrier, which could result in lower rates. Most importantly, a scrapyard known for safety will attract the best employees and make them more likely to stay with your yard for many years to come.

  • Does A Low-Maintenance Landfill Compactor Make A Difference?

    Does A Low-Maintenance Landfill Compactor Make A Difference?

    Ease of maintenance on a landfill compactor may seem like a common design concept, but at Aljon, it’s one of our top priorities. Maintenance that is easy, equates to maintenance that is most often completed properly per the manufacturer’s recommendations.  Fewer maintenance requirements and convenient access to all the maintenance points is paramount. For landfill compactors, there are three key areas to consider when determining the ease of maintenance on the machine.  

    1. Keeping the Wheels Clean

    Landfill compactor wheel have cleats that are designed to shred and break down material as the compactor navigates the working face, making the material more compactable. These cleats are a large part of the wheels design to achieve optimal compaction ratios, however they can cause problems if the wheels are not designed to reduce the risk of material build up, and wire wrap. Material can build up on the wheel, rendering them nonfunctional and sometimes require cleaning which is very time consuming. Wire wrap prevention can also be a challenge. Wire can wrap around the axle causing damage to the wheels, the wheels seals, and the axle structure. 

    Some compactors are designed with wire cutters, requiring regular maintenance and adjustments to function properly. By design, wire cutters are a wear item, leading to the need for replacement over the life of the machine, which increases cost of ownership. Aljon’s compactors are designed with self-cleaning wheels to help prevent these problems from occurring. 

    2. A Well-Designed Chassis

    Not all equipment chassis are the same. There are several different design concepts from each manufacturer of landfill compactors that impact both function and the maintainability. 

    Some manufacturers have removable belly pans underneath the machine. This enables trash, fluids, and other waste to build up inside the belly pan, which requires regular cleaning. Others have a sealed “tub” design that is fully enclosed, which can also retain fluids, requiring regular cleaning as well. The Aljon chassis solves both of these problems. The “I-Beam” type chassis doesn’t trap waste material or fluids and allows ease of maintenance without lying underneath the vehicle. 

    3. Powertrain Maintenance 

    Aljon machines are designed so that all powertrain components are accessed from the ground level, simplifying the maintenance process and reducing the time required to perform recommended maintenance intervals.  

    Performing all of the recommended maintenance on any machine will reduce downtime, cost of ownership, and keep your compactor in the trash, which equates to improved airspace, and a decrease in cost of ownership. Machines are more likely to be properly maintained when maintenance is simplified. 

  • Do You Need A Built-In Crane On Your Scrap Logger Or Baler?

    Do You Need A Built-In Crane On Your Scrap Logger Or Baler?

    Unless you have a tip pan or pre-hopper system to prep your scrap, there’s only one way to get recyclables into a baler: via crane. The question is, should you get a logger/baler with a crane built in? Or should you get a craneless model as well as a standalone crane that can be used for other tasks? This “crane or no crane” question is one you’ll face with almost every logger/baler on the market, so it’s important to evaluate which one will be the best fit for your operations.

    Benefits Of Built-In Cranes

    Often, built-in cranes will be tailored specifically to the type of logger/baler they’re attached to, such as a car logger/baler vs. one designed for other types of scrap. Their length, weight capacity, and claw grab type (such as orange peel vs. clamshell) will be optimized for loading and unloading into their machine quickly and efficiently. Because they are operated from the same cab as the logger/baler itself, they also provide superior visibility into the compression chamber. This allows operators to make better decisions about where and how to distribute material for more even compression.

    Built-in models are also typically more portable, as you only have to move one piece of equipment between locations rather than two. If your goal is to reduce double-handling of material, you can bring the logger/baler to the scrap rather than requiring a separate machine to transport it to the baler’s location. Because they are self-contained and can be operated by one person, it’s also possible to move them between yards or even to new sources of scrap without having to coordinate moving material handlers and operators as well. If your scrapyard needs a standalone workhorse for loading, baling, and logging, a built-in crane makes sense.

    Advantages Of Going Craneless

    Craneless logger/balers rely on separate material handlers, which adds an extra level of expense and organization to recycling operations. However, standalone cranes can also be much bigger with longer reach and larger grapple than built-in models. This can significantly increase productivity. Larger grapples can pick up more scrap with each pass, reducing the time it takes to fill the chamber, and their longer reach increases the potential loading radius so that loose scrap can be picked up from further away.

    High-volume operations likely already have dedicated material handlers onsite as well as trained operators to run them. In that case, it makes sense to keep using existing equipment and processes to load a logger/baler, especially because separate cranes run by skilled operators can reduce the baler’s downtime and increase the amount of scrap processed in a day. If you plan to keep the logger/baler stationary – or, at least, only in a yard that has separate material handlers available – and you want to achieve maximum production, a craneless unit is likely a better fit.

    Future-Proofing Your Machinery

    While these considerations can tell you which type of machine to buy now, it’s also important to evaluate how well they will fit your future operations. Some key questions to ask are:

    • Is your goal to expand mobile logging or baling so that you can bale scrap at different locations, or are you focused on increasing onsite productivity?
    • Do you need to streamline processes to reduce double-handling in your scrapyard, or are you trying to use existing machinery more effectively?
    • How many tons of material are you realistically aiming to process each day? How much can your local market support?
    • How well is your current equipment setting you up to succeed at that goal? What machines are you missing? Which ones will provide the best long-term return on your investment?

    For smaller, more mobile operations, a built-in crane will turn your logger/baler into a powerful, one-stop-shop for processing scrap. For high-volume operations that have separate cranes available, a craneless logger/baler (paired with at least one large, dedicated material handler) can speed up loading and unloading to meet high demand, whether now or in the future. Whatever you decide, all of Aljon’s logger/balers have the option to add a crane or go craneless, and it’s easy to request a quote for the 400XL logger/baler (up to 12 tons per hour) or the 580CL car logger/baler (up to 25 tons per hour). These models also have a number of other features and add-ons that improve safety and productivity while providing long-lasting, reliable construction that will improve your operations for decades to come.

  • What Are the Differences Between Electric and Diesel Powered Scrap Equipment?

    What Are the Differences Between Electric and Diesel Powered Scrap Equipment?

    Diesel engines may feel like the traditional choice while electric is the trendy new kid on the block, but both have a surprisingly long history — and an equally long list of pros and cons. They are both known for their high torque, making them extremely useful for large, power-hungry machinery like scrap equipment. Electric engines can supply full torque immediately, requiring no idling or start up time. They also have fewer moving parts, so they require less maintenance. Diesel machines, on the other hand, are more flexible in their operation. As long as a truck can reach them to keep supplying fuel, they can function anywhere.

    Diesel Advantages

    Diesel performance can vary with factors like oil age, temperature, and even the weather, but with proper care and maintenance, these engines are durable workhorses that can handle high loads and long days. Refueling only takes a few minutes, and it’s easy to move to a new location within a scrapyard or to a different yard entirely. Optimal positioning can make it easier to load and unload, saving time and effort, and streamlining landfill operations.

    It can also be easier to resell diesel equipment; high-voltage electrical power is not generally available throughout most scrapyards, so the pool of potential buyers is limited. And while diesel prices can fluctuate severely and maintenance costs are higher, diesel engines are usually significantly cheaper than electric, lowering upfront costs.

    Taking Scrap Equipment Electric

    Electric equipment — where the high-voltage infrastructure is in place to operate it — has a number of mechanical, maintenance, and usability advantages:

    1. Mechanical

    Diesel engines have to rev up to a certain number of RPMs in order to deliver maximum (or adequate) torque, and thus, power. Electric engines operate differently; as soon as they are switched on, they function at maximum power. Additionally, because maximum torque can be applied instantly, many operators feel that electric machinery gives them more precise control.

     2. Maintenance

    Combustion engines have many moving parts as well as components that need frequent replacement like oil, air, and fuel filters. Electric engines are simpler and require less frequent servicing. Additionally, environmental factors like weather, temperature, and site cleanliness can impact the longevity of diesel engines as air must pass through the engine during operation. Electric engines do not have this problem, further diminishing maintenance requirements even in less-than-optimal conditions.

    3. Usability

    Electric machinery doesn’t have to be refueled, eliminating a daily operational step as well as the need for fuel storage.

    • Starting electric scrap equipment is as easy as clicking a button, and it isn’t temperature dependent, so cold starts and stalls are a thing of the past.
    • Electric engines are much quieter than combustion ones, increasing operator comfort.
    • Finally, many are drawn to electric machinery for energy efficiency reasons or as part of Environmental, Social, and Corporate Governance (ESG) goals. As regulations become more stringent, the use of electric equipment helps “future-proof” operations. Because they don’t release pollutants during operation, electric equipment can even be used indoors (where appropriate)!

    Given these advantages, equipment powered by electricity tends to save money over the long haul. No power is wasted due to idling, maintenance costs and downtime are reduced, and the price of electricity is generally more stable than the price of diesel. Together, these factors improve long-term profitability. However, given the (often significant) upfront costs, the lack of electrical infrastructure in most yards, and the limited resale opportunities for electric, diesel remains a strong choice for many operations.

    Whatever your company’s needs, Aljon offers both diesel and electric options for many of our equipment options.  Whichever is right for your operation, you can have peace of mind knowing both are robust, reliable, and long-lasting options.

  • How Scrap Yards Can Get the Most Production Out of Their Scrap Baler

    How Scrap Yards Can Get the Most Production Out of Their Scrap Baler

    Whether they’re used to compact paper headed for recycling, ferrous material to be sold, or waste on its way to landfill storage, scrap balers are an essential part of the waste management process – and a potential choke point in the movement of materials. Optimizing the throughput of scrap balers ensures that waste flows smoothly from drop-off to transport or storage without sacrificing the structural integrity of individual bales. There are several ways to improve production rates:

    1. Ensure you have the best baler for your particular application
    2. Perform appropriate maintenance
    3. Improve operating protocols to protect hydraulics systems
    4. Choose add-ons that save time and effort

    Below we’ll discuss these more in depth.

    Use the Right Tool For the Job

    Compacting and baling materials allows them to be safely transported or stored more efficiently. Many balers are multi-purpose and can be used for anything from ferrous metals to loose scrap. Other applications, such as liquid extraction, require specialized balers that resist corrosion and collect waste. Regardless of the type of baler you need, ease of operation and baler structural design can significantly impact the productivity of operations:

    1. Ease Of Operation and Maintenance

    Operator comfort and ease-of-use can make a major difference in production rates. Cabs with good visibility and onboard computers can provide operators with additional tools and information to increase productivity. Many models also allow for simultaneous crane operation (for moving and stacking) during automated compaction and baling cycles. Easily accessible components for quicker maintenance help minimize downtime and reduce costs.

    2. Solid Baler Design

    Design choices like bale chamber accessibility, vertical vs. horizontal compaction, and single- or double-ram action influence how quickly loading and unloading can take place and what automation features (automatic tying, conveyor systems, etc.) are available. Choosing options that integrate easily into existing operations can streamline workflows and speed production.

    Make Maintenance Routine

    Most heavy equipment, including scrap balers, require regular greasing, cleaning, and component replacement. While programs exist to maximize the efficiency of maintenance systems and processes (e.g. “Total Productive Maintenance,” typically used in manufacturing), regular informal checks can achieve the same goals. Daily “eyeball maintenance” routines can catch potential problems early, minimizing the downtime of crucial equipment. Employees and operators can be your greatest asset in this process: they are the most likely to notice small changes in timing, sound, or performance. Training and empowering employees to report potential malfunctions can pay huge dividends and identify problems before they require expensive repairs.

    In addition to these informal checks, regular service is crucial to identifying (and preventing) problems below the surface. Scheduling cleanings, replacements, and thorough checkups according to your machine’s service guide will keep your baler running smoothly and extend its lifespan. For example, a regular greasing schedule (generally every 8 hours) can prevent over- or under-lubrication, both of which can damage expensive components. Too much (or the wrong kind of) friction — or overflow grease on parts that should stay clean — can grind operations to a halt and require extensive cleaning or repairs down the road.

    It can be tempting to skip recommended maintenance when times get busy, but scheduled downtime is always less disruptive (and less expensive) than emergency shutdowns and repairs.

    Follow Proper Hydraulic Protocols

    Hydraulic systems are extremely powerful, but they can also be a weak point for productivity. Fluid can congeal and damage the pump if it’s too cold at the start of production, but operators may skip this step in an attempt to get to work more quickly. Warming up hydraulic fluid slowly at system start (as well as carefully warming diesel engines) is crucial to protecting the system’s function and lifespan.

    In cold climates, add-ons like hydraulic tank heaters can speed up this process, allowing operators to start logging and baling much more quickly without damaging the hydraulics. Tank heaters can also keep the system from freezing during use. Hydraulic fluid doesn’t completely freeze until temperatures are well below zero, but the viscosity starts increasing much sooner, potentially gumming up the works if the heat from the engine and pump aren’t enough to counteract the weather. Proactive steps like adding a heater (many of which only require a standard outlet) can be a sound investment in locations that frequently experience freezing temperatures.

    Install Add-Ons & Automation

    Once the fundamentals are in place and your balers are set up for long-term success, it’s time to consider one final productivity boost: automation. Some types of balers have options for add-ons that will automatically tie bales after compaction or even allow for remote control. Maintenance tasks can also be automated using auto lube or hydraulic heaters as described above. Standardizing processes with such add-ons increase productivity by improving consistency and freeing up operators for other tasks.

    Since scrap balers play such a pivotal role in the waste management process, tweaking a few small processes to optimize their production can improve the productivity of your entire operation. By selecting the appropriate baler, minimizing downtime through proper maintenance, caring for hydraulics systems, and automating processes where possible, you can ensure you’re getting every scrap of productivity out of your baler.

  • Why is a Hydrostatic Drive Powertrain the Superior Drive System for a Landfill Compactor?

    Why is a Hydrostatic Drive Powertrain the Superior Drive System for a Landfill Compactor?

    Waste management is an industry that demands speed, efficiency and sound investment for companies to remain sound and competitive. As such, the efficiency of your equipment can make all the difference. When it comes to landfill compactors, choosing the right drive system is crucial for optimal performance and productivity.

    This article will delve into the reasons why a hydrostatic drive powertrain is Aljon’s preferred choice for your landfill compactor versus the conventional powershift transmission (mechanical drive).

    Powershift Transmission

    Powershift transmission drive train designs are a conventional, mechanical drive option for landfill compactors that consist of many more major components such as the transmission, torque converter, and differentials. With such a complex system, it often puts the machine at a higher risk of expensive component failures, which also require a much longer repair process. Additionally, the mechanical drive powertrain reduces gradability needed when compacting on steep grades, and increases the maintenance requirements as there are more components in need of routine maintenance. 

    The Hydrostatic Drive Powertrain

    The hydrostatic drive powertrain design provides fluid power to drive all four planetaries at each wheel, resulting in full-time 4-wheel drive capability. Each wheel is driven by an individual pump and motor, providing fluid power individually to each wheel. This design offers several distinct advantages for landfill compactors.

    Fluid Power to Each Wheel = Full-Time 4-Wheel Drive

    With a hydrostatic drive, you benefit from continuous power to all four wheels, ensuring optimal traction and gradeability in the challenging terrain of landfill sites. This enables the compactor to navigate slopes with minimal wheel slippage, keeping each wheel in full contact with the material, which helps produce optimal compaction ratios, regardless of which area of the working face the machine is compacting. 

    Each Wheel is Powered by a Single Pump and Motor

    The simplicity of the hydrostatic drive design is a key factor in its performance. Each wheel is powered by an individual pump and motor, minimizing the number of moving parts. This streamlined approach not only enhances reliability and gradability, but also facilitates easier maintenance and repair, reducing downtime and associated costs.

    Easy to Maintain and Repair

    Landfill compactors equipped with a hydrostatic drive are renowned for their ease of maintenance because they were designed with simplicity and durability in mind. With fewer components and a straightforward design, routine maintenance tasks become more accessible. This not only translates to cost savings but also ensures that your compactor spends more time on the landfill, contributing to increased operational efficiency.

    Optimal Gradability

    One of the critical performance metrics for landfill compactors is gradability – the ability to navigate and operate on slopes. Hydrostatic drives excel in this regard, providing optimal gradability. The continuous and independent power distribution to each wheel enhances stability and control, allowing you to tackle steeper inclines with confidence.

    Beyond the advantages listed above, the innovative, yet simple, design of the hydrostatic powertrain offers practical performance benefits. Here are 6 additional characteristics of this system which attribute to it being a superior choice for landfill compactors.

    1. Unmatched Precision and Control

    The hydrostatic drive powertrain allows you to vary the speed smoothly and seamlessly, ensuring that you can adapt to the changing conditions of the landfill terrain.  

    2. Enhanced Productivity through Variable Speeds

    The hydrostatic drive powertrain offers variable speeds, allowing you to tailor the compactor’s pace to the specific requirements of each task.  

    3. Seamless Reversing Capability

    Maneuvering in reverse can be tricky, especially in the confined spaces of a landfill. The hydrostatic drive’s seamless reversing capability eliminates the unpredictable transitions often associated with other drive systems.

    4. Operator Comfort and Reduced Fatigue

    The hydrostatic drive powertrain enhances the operator’s experience by offering a smoother and more comfortable ride. The absence of abrupt gear shifts and the ability to control speed with precision contribute to reduced operator fatigue.  

    The Drive System That Puts You in Control

    In the fast-paced and competitive environment of landfill operations, every advantage counts. At Aljon, we believe the hydrostatic drive powertrain system offers unmatched precision, control, and efficiency. From variable speeds to reduced maintenance requirements, this innovative technology puts you in control of your compaction process, ensuring optimal performance and productivity. 

    The hydrostatic drive has been Aljon’s preferred powertrain for over 60 years, which is why our ADV 500, ADV 525, and ADV 600 landfill compactor models come equipped with this system. To learn more about this or any of our product lines at Aljon, please contact us today.

  • Four Key Design Specifications To Consider When Purchasing a New Scrap Baler

    Four Key Design Specifications To Consider When Purchasing a New Scrap Baler

    Scrap metal recyclables can be converted to manageable bales that can be held for better markets or increased room in the yard. These bales will then be transported by shipping container, rail car, or trailer. The denser and more consistent these bales, the more efficient (and less expensive) later processes will be. Scrap balers are key to this process; without their ability to compact and package scrap metal, it would be impossible to transport them to new facilities safely or store them to wait for more favorable market conditions. Not all scrap balers are suitable for every job, and even small design differences can have a massive impact on operations. Four key considerations to evaluate before you buy include mechanical design, cab configuration, height and footprint, and access to parts and services down the line.

    1. Mechanical Design

    If a crane is going to be used to load or unload the chamber, the chamber design can have a significant impact on productivity. Some designs compress the bale to inconvenient positions like the back wall of the baler, requiring a skilled crane operator to remove.

    For example, the Aljon 580CL car logger/baler has a 10’ opening width, while most competitors use an 8’6” opening. The 580CL is also designed so that the finished bale sits in the middle of the chamber rather than against the side, making it easier to grab the bale/log.

    2. Cab Configuration

    This can be an afterthought in many products, as the hydraulics and mechanical components are the parts most obviously tied to production capacity. However, user-friendly control spaces speed up access and startup times. Most machines have ladder access only, but some machines, like the Aljon 580CL, have stairs and an observation platform that make it easy to get into the cab. The extra room even provides space for a trainer or supervisor to observe and guide new operators safely while the baler is in use.

    The interior layout of the cab can also improve productivity. Touchscreen displays can provide options to change the bale count and density (this is especially important when switching from logging to baling), run diagnostics, adjust climate control, and start or stop the engine from one central location. Comfortable, ergonomic seating, as well as armrest and joystick controls, make the cab less fatiguing for the user, as can larger cabs which allow people with different body types to work safely for many hours at a time.

    3. Baler Height, Footprint, And Size

    A logger/baler’s efficiency depends significantly on its surroundings. Some balers are designed to have a smaller footprint, which can make it easier to maneuver around them for loading and unloading in confined spaces. Aljon scrap loggers/balers are purpose-built to make loading and unloading more efficient. Considering ahead of time what kind of baler footprint, height, and size will match your space and workflow best will save you time and money in the future.

    4. Access To Parts & Service

    Even a few days of downtime come at a high cost, particularly for large or high-throughput operations. Having to rely on secondhand parts or wait months for service can grind operations to a halt. It’s important to investigate whether parts are readily available and whether the manufacturer has a good reputation for service. Aljon’s long history of exceptional customer service begins with an in-house service department that employs expert technicians and keeps parts in stock to support customers in need of service.

    Finding the right machinery for your operation takes time. Every site is different, from size and throughput to the types that pass through the yard. When you invest in a new scrap baler, it’s important to consider the following questions:

    • Does the bale chamber design make it easy to maneuver bales in and out, or does it require a highly-trained operator?
    • Is the cab well-designed for long periods of operation, or will it cause operator fatigue, potentially increasing operator error (or employee turnover)?
    • Does the baler meet height and footprint requirements of your operation?
    • Finally, will you be able to rest assured that spare parts and experienced technicians will be available to keep your investment running for decades down the line?
  • Aljon Landfill Compactors – Strong Aftersales Support Solutions

    Aljon Landfill Compactors – Strong Aftersales Support Solutions

    Aljon has spent decades earning a reputation as one of the industry’s leading suppliers for landfill compactors. We earned our reputation by not only manufacturing the industry’s heaviest, most powerful compactors by class, but also by providing distinctive customer service.

    To help our customers maximize uptime, we are highly focused on aftersales support with strong parts availability and machine service options. Whenever you need help with repairs, or scheduled maintenance, our experts are here for you.

    Parts

    We are dedicated to our customers’ uptime by maintaining a strong inventory of spare parts, and parts support experts always ready to assist you with parts needed for a repair, or filter kits to plan your scheduled preventative maintenance service and more. Our supply chain team has managed to create a strong inventory of spare parts to minimize your down time. We have service dealers throughout North America who stock parts locally, and a full inventory in our factory in Iowa.

    Service

    Aljon has technical experts who work in the field to keep your machine operating at peak performance, as well as a network of service dealers whose technicians have been trained and certified by our factory experts to quickly diagnose any performance issues and return your machine to operation as quickly as possible. Our technicians have decades of experience and are dedicated to your uptime.

    It’s no secret that preventative maintenance is the key to uptime. At Aljon, we offer a number of programs to assist you with manufacturer recommended service intervals, oil sample analysis and more. Often times, our customers prefer Aljon, and our service dealers take care of all the maintenance, so we offer service agreements for our customers to provide peace of mind that your machine is getting the maintenance recommended for best performance and uptime.

    Our Compactors

    We offer three different models of compactors to specifically meet the needs of your landfill operation, based on the type of material you are processing, and your daily tonnage.

    • ADV 500 Compactors: The right choice for a landfill needing to process up to 950 tons per day. This model doesn’t compromise on power and efficiency. The ADV500 is powered by a 503 HP Volvo Penta engine, with multiple blade and wheel configurations, and 8 inch MacPactor Diamond or M-Trax cleats.
    • ADV 525 Compactors: The right choice for a landfill needing to process up to 1200 tons per day. The ADV525 is powered by a 543 HP Volvo Penta engine, with multiple blade and wheel configurations, and 8 inch MacPactor Diamond or M-Trax cleats.
    • ADV 600 Compactors: The right choice for a landfill needing to process up to 1200 tons per day. The ADV600 is powered by a 603 HP Volvo Penta engine, with multiple blade and wheel configurations, and Aljon’s exclusive 10 inch MacPactor Diamond cleats.

    Our Volvo Penta Engines are the perfect choice for the landfill application, requiring no DPF or regen.

    Let Us Help!

    Contact us to discuss your compactor needs, to determine the right Aljon for your Landfill, and how we can provide you with unparalleled customer service and support.

  • 9 Reasons to Choose Aljon’s Powerful Landfill Compactors

    9 Reasons to Choose Aljon’s Powerful Landfill Compactors

    Over the years, Aljon has developed into one of the world’s top manufacturers of landfill compactors and scrap equipment. If you’re in need of solutions for your landfill that meet your unique requirements, Aljon is here for you.

    Here are the many benefits of utilizing powerful landfill compactors from Aljon.

    1. Reliable Designs and Construction

    One of the main advantages of using Aljon landfill compactors is our combination of reliable, powerful designs and construction. Every piece of equipment we provide is built for peak performance, with the ability to process 950 – 1,300 tons per day, depending on the model.

    The dependable construction of each machine will help reduce the need for excessive repairs, which will subsequently increase your return on investment with each purchase.

    2. Versatility of Applications

    We offer multiple landfill compactor options to meet our customers’ unique application requirements. Depending on the volume of your landfill and your budget, you can find the right solution in our product line.

    For example, if you’re operating with a smaller budget but need the power of a larger compactor, you might opt for our ADV 525 compactor. Meanwhile, landfills requiring the compaction of large volumes of materials may benefit from our ADV 600, which is capable of processing as many as 1,300 tons of material per day.

    3. Years of Experience

    Another aspect that sets Aljon apart is our long history in the industry. Since 1963, we have grown into the world’s leading manufacturer of compactors, scrap equipment, and snow removal equipment. As a result of this experience, we’ve also grown a loyal following among our customers who consistently turn to us.

    4. American-Made Products

    When you buy an Aljon landfill compactor, you get a product that’s made in our facilities right here in the USA. Because of this, you get the benefits of American-made products, which include readily available parts and reliable service and support. More on both of those points below.

    5. Access to All Required Spare Parts

    We have a strong inventory of parts readily available for all our customers’ equipment. Our priority is to keep your equipment up and running, which is why we have a wide range of parts such as:

    • Pump drive boxes
    • Final drives
    • Pumps and wheel motors
    • Steering cylinders
    • Control valves
    • Electrical parts

    6. Top-Tier Customer Support and Service

    If you have any questions or concerns, or if you require service for your equipment, Aljon is ready to help. You can easily get in touch with us whenever you need assistance with selecting equipment, learning more about each solution, or requesting customer service for your compactor.

    We always aim to keep our customers satisfied and give them the help they need as soon as possible.

    7. Pre-Owned Equipment Options

    Are you interested in budget-friendly options? You’re in luck, because not only do we manufacture new equipment, but we also offer pre-owned options.

    We have an entire dedicated division that’s responsible for restoring previously owned machinery before reselling it. This division ensures that all equipment is completely restored to be in optimal condition before selling it.

    8. Industry Innovation

    To consistently provide our customers with some of the most reliable solutions available for any application, we work to innovate through our equipment designs.

    We work under the philosophy of “Keeping It Simple, Building It Strong” by using highly efficient designs that culminate in powerful compactors. In turn, you can meet all of your compacting needs with equipment built to do the job right.

    9. Access to All Necessary Product Resources

    If you want to learn everything there is to know about our products, you have access to plenty of documentation. Learn about the different features that come with each compactor, along with detailed specifications to help you make the right selection.

    These benefits make entrusting Aljon worth it if you’re in the market for reliable, powerful landfill compactors. With the help of Aljon’s solutions, you’ll fully equip your landfill to handle compacting operations of any volume.

  • What Should I Consider When Looking for a Quality Landfill Compactor?

    What Should I Consider When Looking for a Quality Landfill Compactor?

    Landfill compactors are the most important piece of equipment in landfills. The right compactor with the correct configuration will be able to easily and efficiently compact waste materials and maximize your air space, but not every compactor comes with the same features or level of performance and compatibility.

    As you search for the ideal landfill compactor for your application, it’s important to know what factors to consider as you do your research. The following are some of the specific elements to look for in a landfill compactor today.

    Dependable Designs

    The overall design of the landfill compactor must be reliable to provide you with the right solution. Different elements will combine to create the best compactor design, but each model has some differences to consider.

    Here are some of the individual design components to consider as you assess each compactor in your search:

    • Drive Systems: Different types of landfill compactors come with varying drive system designs that greatly impact their performance, such as hydrostatic and power shift transmission systems. The main difference between these two is that hydrostatic systems provide fluid power to each planetary resulting in all-time four-wheel drive, providing higher gradability, and maintainability when compared to power shift transmissions.
    • The Cab: The operator cab should also be comfortable and include all necessary features for ease of operation and visibility. Everything from machine controls to ergonomic seating and safety features should factor into the compactor selection.
    • Compaction Volume: You should also consider the size of the compactor needed based on the daily volume of waste that needs to be processed. The weight and horsepower of the compactor are significant factors to consider, but even more importantly, the configuration and geometry of the wheel, the cleat design, cleat quantity, all of which contribute to optimum compaction ratios. 
    • Wheel Cleanability: A compactor must be designed with a system to ensure the wheels remain free of waste material. If the wheels get clogged with material, this will reduce the wheels’ efficiency, reducing the overall compactibility of the machine. 

    Overall Ease of Maintenance

    Ease of maintenance is important to ensure landfill personnel are able to keep the machine in safe and operating condition. Consider a compactor designed with access points to all service areas and compartments, which can greatly simplify routine maintenance, repairs, and parts replacement. Options such as auto lube systems, fire suppression, and quick drain features for ease and rapid maintenance are also beneficial to keeping your compactor well-maintained and in good operating condition. 

    Determine What Kind Of Compactor You Need For Your Operations

    Based on the nature of your application, you must take the time to find the best landfill compactors for your specific application. Like any other big investment, you must take care when choosing a compactor for your landfill, as this could help determine the cost-effectiveness and sustainability of your operations. Choosing the right compactor with the right design and wheel configuration will go a long way in helping you achieve optimal compaction ratios and maximum uptime levels.