Application
Report 24
The Problem...
15,000 Corrugated Cartons Daily
Dillard's Department Stores, a large retailer operating more than 225
stores in 21 states, needed to dispose of approximately 15,000 corrugated
cartons daily at each of their five major distribution centers. The
cartons range in size fro 12"x12"x12" to 24"x24"x36". Dillard's cost
containment objective required the removal of these thousands of cartons
with minimum manpower, and the least possible number of hauls of their
40 cu. yd. containers.
The Solution...
A Conveyor Disposal System
A conveyor disposal system specifically designed for warehouses and
distribution centers carries empty cartons to BloApCo shredders mounted
over compactors, which are located outside the distribution warehouse
freeing up valuable floor space. Dillard's large distribution centers
often have two shredders. Each shredder, operating unattended, is capable
of processing up to 60 cartons a minute...equaling 58,000 cartons in
an eight-hour shift. The shredder's unique "Pierce-and-Tear" action,
with teeth specifically designed to handle corrugated material, actually
"pulls" the cartons into the shredder without a requirement for any
type of mechanical in-feeder. It effectively tears the cartons apart,
reducing them to smaller, uniform pieces -- eliminating the possibility
of clogging the compactor inlet hopper, and permitting more densified
container loads.
Shredding before
compacting increases the amount of material that a 40 cu. yd. container
can hold from 8,000 pounds of cartons (compacted only) to 18,000 to
20,000 pounds of shredded, compacted material. They now have three containers
to be hauled where it would have been necessary to haul seven without
shredding.
In setting up their
distribution centers, Dillard's evaluated various disposal methods,
comparing no-shred compacting vs. shredding before compacting. The hard
figures on all the methods in the evaluation showed that the BloApCo
shredder/compactor system resulted in MORE DENSE loads with lowest overall
costs. It yielded the best economic return, was the least labor intensive
and the most trouble-free, high-volume production system.
Dillard's installs
shredder/compactor systems in all their major distribution centers...a
total of nine BloApCo shredders so far. The scrap handling system, operating
unattended, means to Dillard's that "It's an automatic system. The boxes
go in...get shredded... get recycled. No problem."
