Low Budget Baler and High Friction Ejecting

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SUMMARY

The discussion centers on creating a low-budget baler for hops, with a budget of $1,500 compared to typical balers costing $15,000. The challenge lies in ejecting the compressed bales, which tend to stick due to friction when attempting to push them sideways out of the chamber. A proposed solution involves compressing the bales more than necessary to facilitate sideways ejection while maintaining pressure on the top and bottom. Suggestions include using a tapered mold or eliminating the baler in favor of a vacuum bagger, potentially in a high-pressure environment to reduce friction.

PREREQUISITES
  • Understanding of mechanical compression principles
  • Familiarity with baling technology and its applications
  • Knowledge of friction and material properties
  • Experience with vacuum sealing techniques
NEXT STEPS
  • Research tapered mold designs for improved bale ejection
  • Explore vacuum bagging techniques for compressing hops
  • Investigate high-pressure environments for material compression
  • Examine existing robotic balers and their mechanisms to reduce friction
USEFUL FOR

Engineers, agricultural equipment designers, and anyone involved in the processing and packaging of hops or similar materials will benefit from this discussion.

ThePhysicIan
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As part of an engineering project I'm in, we've been asked to bale hops on a very low budget (close to 1500 dollars, instead of 15000 like most balers out there).
These things take a good amount of force to compact but don't stick together well, so we've figured out easily how to compress some hops into a cube, but getting it out of the chamber has proved...problematic. the bale will stay together well on all sides except the two (top and bottom) in the direction of compression, if that makes sense.
Our thought then was to compress this bale a bit more than necessary so that when we've withdrawn the ram, there will be time enough to shove the bale sideways (orthogonal to compression direction) out of the chamber and into an area that will keep some pressure on the top and bottom of the bale, where it can be bagged and vacuum sealed, as hops should be.
This was a great idea until we realized that in compressing these things, they produce a good amount of force on the walls, and that means friction if we're pushing it sideways.
What I'm hoping for here is maybe someone's seen something like this before in a different application. Most balers out there will push bales out in the same direction they were compressed, which would be easier but not an option for us, because of hops' strange characteristics.
thanks for any help!
Ian
 
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How about a tapered "mold".

Or eliminate the baler entirely and just use the vacuum bagger to compress it. If that's not powerful enough, do it in a high pressure environment.
 
Here is a video of a robotic sawdust baler. The balers are able to process wood shavings, sawdust, chopped hay or straw, hemp wood, glass fibre, glass wool or other similar products



https://www.youtube.com/watch?v=Kg1L2yodX9c

Notice the rollers that the bale is pushed into. Less friction.
 
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