How a vertical cardboard baler forms a bale

To operate a vertical cardboard baler like the TONNA E60, open the top door and load in cardboard or film. Close the door and the press will start automatically, as it does on the TONNA E80 and HSM V-Press 503 eco, 605 eco, and 610 eco. Continue loading and pressing until the machine indicates the bale is full (TONNA E60 and TONNA E80).

Tie the straps while the press plate is down. Open the doors from the side and remove the bale. The TONNA E60 produces bales measuring 70 × 50 × 70 cm and weighing up to 50 kg for cardboard or 60 kg for film.

Each time you load the chamber and close the door, the press plate compacts the new material onto the previous layer, building the bale in layers. Distribute each load evenly in the chamber. TONNA manuals warn that uneven loading can tilt or damage the press plate. On the HSM V-Press 504, 605 eco, 610 eco, and 818 plus, the HSM TCS system monitors plate tilt for this reason.

Begin each new bale with a large, flat piece of cardboard on the chamber floor. This helps catch the straps and small pieces, providing a solid base. Add material as it is generated throughout the day to avoid a buildup of loose boxes next to the baler.

Models with retaining claws, such as the HSM V-Press 605 eco, 610 eco, and TONNA20, keep the compressed material down when the press plate rises, so the next load is added on top instead of the material springing back. If you tie a bale after the plate is raised, it will expand and the straps will be loose. Stand to the side when opening the doors, as a compressed bale can push the door open as it expands.

Finish the bale the same way you started it. HSM manuals for the V-Press 503 eco, 504, and 818 plus recommend using a large piece of cardboard for both the first and last pressing. This prevents small pieces from falling off the top or bottom of the bale.

Uneven loading has a direct impact on HSM balers with TCS. On the HSM V-Press 818 plus, if the press plate comes down tilted several times, the machine stops and signals that the bale is ready. This means you must tie and remove a smaller bale than expected. On the HSM V-Press 504, a fault message appears on the display, asking for even loading.

Selecting a cardboard baler by pressing force and bale weight

Cardboard balers are classified by pressing force: compact 3–5 t (TONNA E60 3 t, HSM V-Press 503 eco 3 t, HSM V-Press 504 4 t, TONNA E80 up to 4 t, TONNA5 5 t), medium 5.7–12 t (HSM V-Press 605 eco 5.7 t, TONNA10 10 t, HSM V-Press 610 eco 12 t), and large 18.5–45 t (HSM V-Press 818 plus 18.5 t, TONNA20 20 t, TONNA25 25 t, TONNA45 45 t). Bale weights range from 30–50 kg on TONNA E60 and HSM V-Press 503 eco up to 450 kg on TONNA45.

A small cardboard baler produces lighter bales that can be moved with a trolley. An industrial cardboard baler creates bales up to 450 kg, which require a pallet truck or forklift. Heavier bales mean fewer bales for the same amount of waste.

Start by measuring your weekly waste output and the bale weight your staff can safely handle. For example, the HSM V-Press 503 eco and 504 produce bales up to 50 kg and 60 kg, which are removed with a discharge trolley. In contrast, the TONNA20, TONNA25, TONNA45, and HSM V-Press 818 plus make bales from 150–450 kg, which are handled on pallets.

A higher pressing force allows more material to fit into each bale. This reduces the number of bales you need to tie, store, and send to the recycler. It also means fewer pickups.

Compare models by their pressing force and the bale weights they produce. The HSM V-Press 605 eco, with 5.7 t of force, makes bales up to 70 kg. The HSM V-Press 610 eco, at 12 t, produces bales up to 100 kg. The HSM V-Press 818 plus, with 18.5 t, creates bales up to 200 kg. The TONNA45, at 45 t, makes bales up to 450 kg.

The TONNA45 forms bales with a base of 1200 × 800 mm, matching the size of a EUR pallet. The HSM V-Press 818 plus produces bales with a 1200 × 780 mm base. This allows the bales to be handled like any other palletized load in your warehouse.

Before making your choice, check with your recycler to find out what bale size and weight they accept. These requirements determine both the machine you need and the equipment for moving the bales. For example, if your recycler only accepts palletized bales with a minimum weight, a small baler may not be suitable.

Overview table of all cardboard balers and presses

The table below lists all cardboard balers and presses in this category, including their type, pressing force, bale weight, and power supply.

To use the table, first check the power supply available at your location: single-phase 230 V, three-phase 400 V, or no electricity for manual balers. Next, look at the bale weight you can move and that your recycler accepts. Then compare the pressing force for each model. The type column shows which machines have a discharge trolley or bale ejector, and which compact waste in the bin. If the table refers you to the product page, the information is provided there.

Cardboard compactors and bin presses: for waste in bins

The TONNA bin press 240L (up to 2 t, for 240-liter bins) and TONNA1100 (3 t, for 1100-liter containers, pressing plate 660 × 1000 mm) compact waste directly inside the bin. To operate, hold the ON button and push the lever down to press, then up to lift the plate.

A bin press is suitable when waste is already collected in bins and the goal is to reduce the number of pickups. If you have enough clean cardboard or film to make sorted bales for recycling, a vertical cardboard baler is the better choice. A cardboard shredder turns boxes into packing material instead of compacting them.

The pressing plate moves down into the bin, compressing the waste. The collection company empties the bin as usual, so there are no bales to tie, store, or hand over to a recycler. This is helpful where waste is mixed or when you want to fit more into each bin before pickup.

The TONNA bin press 240L is designed for standard 240-liter bins. The arms are adjusted to fit the bin width, and each pressing cycle takes 20 seconds.

A pressed bin weighs much more than a bin with loose waste. Always check the bin’s weight limit and confirm with the collection company that they accept pressed bins. The TONNA bin press 240L can handle cardboard, paper, plastic, film, foam, soft materials, and food waste, but not pressurized containers, cans, metal, wood, glass, or other hard materials.

The TONNA bin press 240L can reduce the volume of waste in the bin by up to 80 percent. To use, place the bin on the platform with the lid facing out, then hold the ON button and press the lever down until the plate stops. Add more waste and repeat until the bin is full.

For the TONNA1100, always lock the wheels of the 1100-liter container on the platform before pressing. If the pressing plate is down, raise it first. The manufacturer’s manual recommends keeping the plate down as long as possible between loads for better compaction. The TONNA1100 is for indoor use only, in a dry room, so plan to bring containers to it. If the TONNA bin press 240L does not start, pressing the OFF button resets it. Slow or weak pressing on either bin press may be due to low hydraulic oil, a clogged filter, or a leak. The TONNA bin press 240L must be anchored to a wall or concrete floor and leveled to prevent movement during use.

Cardboard and plastic balers: one material per bale

TONNA E60 and TONNA E80 have separate operating modes for cardboard and plastic film. HSM V-Press 504 and HSM V-Press 818 plus offer a program for each material. Each bale contains only one type of material.

The manual balers, TONNA T-Portable and HSM V-Press 60, do not use electricity. A lever compresses the material at a ratio of 5:1 or more. Each bale weighs up to 40 kg and is tied three times with twine. These bales can be further compacted in a hydraulic baler.

A cardboard and plastic baler can press both cardboard and film, but not together in the same bale. For example, after making a cardboard bale, you must empty the chamber before switching to film.

Film expands more than cardboard, so it is important to use the correct mode or program. On the TONNA E60, a cardboard bale weighs 30–50 kg, while a film bale of the same size weighs 40–60 kg. Keep stretch film and shrink film separate from cardboard at the unpacking area.

Bales from the TONNA T-Portable and HSM V-Press 60 are 800 × 600 mm and up to 800 mm high. Since they do not need a power outlet, these manual balers can be placed right where goods are unpacked.

On the HSM V-Press 504 and 818 plus, the film program has two options. The press ram can return to the top after each stroke, or it can stay down on the pressed film, which is useful for materials that expand. In the second setting, the ram is raised before the next load. Both models let you tie off a bale before the display shows it is finished, for example if you need to switch materials during a shift.

For the TONNA E60 and TONNA E80, the manufacturer’s manual recommends leaving the platen down between loads as long as possible for better compaction. The HSM manuals for the V-Press 503 eco, 504, and 818 plus allow only empty cardboard, dry paper without solvents, and single-layer film. Materials that expand a lot, like bubble wrap or foam, should only be loaded after consulting HSM. On the HSM V-Press 60, press the foot brakes, load a large piece of film first, spread the material evenly, and pre-compress by hand. The lever is operated with both hands: release the safety lever with your left hand and pull the handle down gradually. Keep the press closed. The HSM V-Press 60 is suitable for plastic film, corrugated cardboard, and heavy paper sacks, but not for household waste, newspapers, cans, or bottles.

Power supply and bale removal for cardboard balers

Models that run on single-phase 230 V (220–240 V) include TONNA E60, TONNA E80, HSM V-Press 503 eco, HSM V-Press 504, TONNA5, TONNA10, TONNA20, TONNA25, TONNA bin press 240L, and TONNA1100. HSM V-Press 605 eco, 610 eco, and 818 plus require three-phase 400 V, while the TONNA45 uses three-phase 380–400 V.

Bale removal methods: HSM V-Press 503 eco and 504 use a discharge trolley. HSM V-Press 605 eco and 610 eco have a mechanical bale ejector that tips the bale onto a pallet or pallet truck. TONNA20, TONNA25, and TONNA45 feature an automatic bale ejector.

Before installation, make sure the correct power outlet is available where the machine will be placed.

The TONNA manuals state that the baler must be plugged directly into a wall socket, not an extension cord. Using an extension cord can increase current and trip the breaker, stopping the machine. If there is no three-phase outlet where a 400 V machine will be used, a qualified electrician must install one before collection. This is important in production areas with only single-phase power, as it may affect which model you can use.

Always keep the area in front of the doors clear when removing a bale, and make sure no one is standing where the bale will come out.

When preparing for installation, provide your electrician with the current draw for each machine. The single-phase TONNA20 uses 16 A and has a 2.2 kW motor. The TONNA E80 draws 11 A, and its technical sheet recommends a C16 breaker. For three-phase machines, check the direction of rotation at startup. The TONNA45 manual specifies the motor should turn clockwise; if not, the phase sequence must be switched. The HSM V-Press 818 plus will display a phase fault until an electrician corrects the wiring.

On the TONNA25 and TONNA45, the platen ejects the bale. After tying, push the bale tilting lever on the pressure plate forward into the channels at the back, then press the two-hand button together with the up button to raise the platen and tilt the bale out. Pull the lever back afterward. For the HSM V-Press 503 eco or 504, open both the loading and bale doors past 90 degrees before removing the bale so it can exit freely onto the discharge trolley. On the HSM V-Press 818 plus, only tighten the hand wheel on the door lightly, as the manual notes that overtightening makes the door difficult to open after pressing.

Tying bales with a cardboard baler

The HSM V-Press 503 eco and 504 tie each bale twice with polyester tape and come with 2 rolls of tape. The HSM V-Press 605 eco ties three times, with 3 rolls included. The HSM V-Press 610 eco also ties three times, and the HSM V-Press 818 plus ties four times. Manual balers use twine, tying each bale three times.

The textile strap in this category is 16 mm wide, 340 m per roll, 4 rolls per package, and is tied by hand with a knot. No tools are required.

The TONNA T-Portable and HSM V-Press 60 use twine, tied three times crosswise for each bale. A roll of textile strap has an outer diameter of 180 mm.

Before ordering strap, check your baler’s product page for the correct type and width. Keep extra strap near the baler so a full bale is never left untied in the chamber.

For the HSM V-Press 503 eco, each tape is pulled about 400 mm over the bale door and cut. The end is removed from the fixing hook and tied securely to the tape at the top of the bale. After removing the bale, return the tape ends to the fixing hooks for the next use. For the HSM V-Press 60, cut each of the three twine cords to 3 m and thread them before loading. Once the bale is pressed, pull the upper ends tight and tie them.

On the TONNA E60 and TONNA E80, insert the straps before filling the chamber. With the platen at the top and the machine unplugged, run the straps through the chamber guides and back through the door holes, secure with a loop, and tighten with the hook. When the bale is ready, pass the straps over the top with the hook, cut to length, and pull them out through the holes on top of the lower door. For the TONNA25 and TONNA45, thread the strap through the slots at the bottom and rear of the chamber before loading. When the bale is large enough, the tying compression button presses it and stops the platen in the tying position, then tie the lower and upper ends of each strap together. On the HSM V-Press 504, pull the tape through the press ram channels with the tape insertion needle and cut the loop. Do not swap the two cut ends, or the bale cannot be tied.

When a baler is cost-effective and choosing the right size

A cardboard baler is cost-effective when loose boxes quickly fill bins or take up too much floor space. If your weekly waste fills several bins or containers, a baler reduces the number of pickups needed. For waste that goes into bins, the TONNA bin press 240L or TONNA1100 compacts it inside the bin. For clean cardboard and film, a vertical baler creates bales for recycling.

Choose a baler based on your busiest week. Select a baler that can handle your peak volume, not just the average. The chamber size determines the bale’s base, and the pressing force affects how much material fits inside.

To determine when a baler pays off, track your weekly waste by material type: cardboard, film, and paper. Note whether this waste is placed in bins or accumulates as loose boxes on the floor.

Calculate your current waste handling costs. Include the number of bin pickups per month, the floor space used by loose boxes, and the time employees spend flattening and moving cardboard. Baling reduces both collection costs and the space needed for waste.

Clean, sorted bales have value for recyclers. Depending on the current market price for cardboard or film, recyclers may pick up bales at no charge or may even pay for them.

Your busiest week is often right after large deliveries or during peak production periods.

Hourly output is rarely the limiting factor for a vertical baler. For example, the TONNA20 is rated for 6 to 8 bales per hour, the HSM V-Press 610 eco for 3 to 6, and even the manual HSM V-Press 60 for about 3 bales per hour. In daily use, the speed depends on how quickly staff can load material by hand, not on the rated output. Manufacturers recommend models for different volumes: the HSM V-Press 503 eco is for low volumes, the 504 is HSM’s entry-level model, and the TONNA20 is a mid-range baler that’s easy to load with large boxes.

Measure your waste by both weight and volume. Weigh a full bin or roll cage of loose cardboard and note its volume. HSM requests these numbers before recommending a press: the amount of material per year, month, or hour, and its loose weight per cubic meter. Bale weight can vary. The HSM manual explains this depends on the type, moisture, and condition of the material, as well as bale height, so your bales may be lighter than the table values. The HSM V-Press 504 and 818 plus displays count bales separately for cardboard and film, along with working hours, helping you plan pickups and track output.

Space, ceiling height, and access route

Cardboard balers require a solid, level floor that can support the machine, bales, and a pallet truck. Leave enough space in front for loading, for the doors to swing open, and for removing bales. The ceiling must be higher than the machine. For example, the HSM V-Press 503 eco and 504 need at least 2000 mm. The TONNA20 has a lower transport height for easier handling.

Check the access route: doors and hallways must accommodate the machine’s size. Placing the machine indoors or under cover extends its lifespan. Electrical connections must be made by a qualified electrician.

Measure the ceiling height where the machine will be placed, and check for beams, pipes, or sprinklers that could reduce usable height. The HSM V-Press 818 plus is 2370 mm tall, and the TONNA20 is 2600 mm.

The HSM V-Press 504 requires 1825 mm of depth, including the door swing. In a packing area, ensure there is enough space for a pallet truck or trolley to move bales away from the machine.

Level the machine so it remains stable during operation.

The TONNA20 is 1955 mm high for transport, which is lower than its working height. Measure all doors, corridors, and elevators along the route. Check if the truck can reach a loading ramp or needs a tail lift, and whether a forklift is available on site. The TONNA E60 is designed for a closed, dry room. If used outdoors, a waterproof plug and socket are required. Good lighting and ventilation are also necessary.

A baler should only be moved when the platen is lowered and the doors are closed and locked, otherwise it could tip over. The TONNA25 and TONNA45 have slots in their base for the forks of a forklift or a pallet truck. The TONNA5 and TONNA10 manuals recommend placing the machine in a corner, with both the side and back against the walls. If this is not possible, add a protective barrier at the back and sides to keep the baler out of forklift traffic lanes.

Before starting a TONNA5 or TONNA10 for the first time, replace the transport oil plug with the supplied breather cap. Running the machine without the breather cap will cause damage, according to the manual. The HSM V-Press 503 eco and 504 should only be operated outdoors under supervision and never exposed directly to rain. Maintenance intervals are shorter when used outdoors, and in freezing temperatures, use hydraulic oil suitable for cold weather. The HSM V-Press 610 eco requires 2 to 3 m² of floor space, so it can be placed where the waste is generated. The HSM site checklist also asks whether the installation site is above a basement, as this affects floor load.

Safe operation of a cardboard baler

Only trained personnel are allowed to operate a cardboard baler. The TONNA manuals specify a 1 m safety zone around the machine and the finished bale. Do not load glass, aerosol cans, metal, wood, solid objects, cardboard cores, or complete bales of newspapers or cardboard. The press only operates with the door closed.

Stand to the side when opening the doors, as a compressed bale will expand. Never lift bales by hand—use a trolley, pallet truck, or electric pallet stacker. Always wear safety shoes, safety glasses, and gloves. Walk around the machine each day before use and unplug it before performing any maintenance. Do not use the machine if there are damaged cables, hoses, or an oil leak until it has been repaired.

Only trained individuals who have read the manual should work at the baler, and only one operator should be at the machine at any time. All others must stay outside the 1 m safety zone during operation and bale removal. This helps prevent injuries from moving parts or from a bale expanding when released.

The TONNA manuals exclude the materials listed above because they can cause injury and damage the machine.

The HSM V-Press 503 eco and 610 eco have a safety switch that stops the press if the door is opened. Hearing protection is recommended.

Before each start, check that no people, children, or animals are inside the chamber or bin. Both the TONNA and bin press manuals require this check to prevent accidents. No one under 16 is allowed to operate the TONNA E60, TONNA E80, TONNA1100, HSM V-Press 60, 503 eco, 504, or 818 plus, according to their manuals. At the start of each shift, check the safety devices as required by the HSM manuals. On the HSM V-Press 504, the press will not start if the loading or bale door is open, and the locking lever must snap into place when the loading door is closed.

Lock the baler doors when the machine is not in use. At the end of the day, turn off the main switch, secure it, and unplug the machine. The HSM V-Press 504 and 818 plus allow the main switch to be locked in the off position with a padlock. Open and close doors slowly to avoid injury. Only lift manageable loads when loading, and remove loose clothing and jewelry before working at the baler. An oil leak is also a fire hazard, as noted in the TONNA E60 and TONNA E80 manuals.

What affects the price when you buy cardboard baler equipment

The price of a cardboard baler depends on pressing force, bale size, type of bale ejector, and whether it has programs for cardboard and film. Installation may require a three-phase outlet and arrangements for collection. Operating costs include strap and maintenance. Each product card displays the price. A cardboard box baler with higher pressing force and an automatic ejector will be more expensive.

Installation costs may include adding a three-phase outlet for a 400 V machine, and larger balers may require a forklift or a truck with a tail lift for collection.

Operating costs include strap or tape for each bale, electricity, and the annual service with an oil change recommended in the TONNA manuals. Each product card has a Get offer button for a quote, for example, for a baler with strap, and an Add to inquiry button to group several products in one request.

Electricity is a minor part of the operating costs: the TONNA E60 and TONNA E80 use 0.008 kWh per pressing cycle. For the annual oil change, the TONNA bin press 240L uses 14 liters of hydraulic oil, the TONNA1100 uses 8 liters, and the TONNA E80 also uses 8 liters.

Plan for the installation of the HSM V-Press 818 plus as well. It is supplied with its hydraulic cylinders retracted for transport, and trained personnel must move them into operating position and secure them before making the first bale.

Checklist before you order a cardboard baler

Check your recycler’s requirements for materials, bale size, and bale weight. Measure your weekly waste and compare your largest boxes to the baler’s loading opening. The floor must be level and strong enough for the machine and a pallet truck. The ceiling must be higher than the machine.

Check the power supply at the installation site. Decide who will load the machine and where bales will be stored before collection. The table above lists the specifications for each model, including pressing force, bale weight, and power supply.

Start by asking your recycler which materials are accepted, the required bale size and weight, whether bales need to be loose or on pallets, and the minimum quantity per collection.

The HSM V-Press 504 has a loading opening of 700 × 470 mm, the 605 eco and 610 eco have 800 × 495 mm, and the 818 plus is 1195 mm wide. If a box does not fit, it must be folded before loading. Make sure a suitable outlet—single-phase 230 V or three-phase 400 V—is within reach.

Decide where to store the strap. In some cases, one baler may not handle all materials, so a bin press for mixed waste and a baler for cardboard may be the best solution.

When requesting a quote, describe the material: whether it is dry or wet, loose, stacked, already pressed or shredded, and the size of the smallest and largest pieces. HSM asks these questions before recommending a press. Anything other than cardboard, paper, or film is confirmed with the manufacturer first. HSM may request a compression test.

Check the loading height against the people who will be loading the machine. The HSM V-Press 610 eco has a loading height of 655 mm, and the HSM V-Press 818 plus has a filling height of 958 mm with a door that folds down. Note the working hours and site conditions: days and shifts per week, whether the area is protected from the weather, and the temperature range.

Questions about cardboard balers

How heavy are the bales from each cardboard baler?

TONNA E60 bales weigh 30–50 kg with cardboard and 40–60 kg with film. HSM V-Press 503 eco bales weigh 30–50 kg, and TONNA E80 cardboard bales weigh 40–60 kg. TONNA5 bales weigh 40 kg, and TONNA10 bales weigh 80 kg. HSM V-Press 504 makes bales up to 60 kg, HSM V-Press 605 eco up to 70 kg, HSM V-Press 610 eco up to 100 kg, TONNA20 up to 150 kg, HSM V-Press 818 plus up to 200 kg, TONNA25 up to 250 kg. TONNA45 bales weigh up to 450 kg, and both the TONNA T-Portable and HSM V-Press 60 make bales up to 40 kg.

Which cardboard balers operate on a standard 230 V supply?

TONNA E60, TONNA E80, HSM V-Press 503 eco, HSM V-Press 504, TONNA5, TONNA10, TONNA20, TONNA25, TONNA bin press 240L, and TONNA1100 all run on single-phase 230 V (220–240 V).

How long does one pressing cycle take on a cardboard baler?

Cycle times are 20 seconds for the TONNA bin press 240L, 27 seconds for the TONNA E60 and TONNA E80, 21 seconds for the HSM V-Press 605 eco, 22 seconds for the 610 eco, 27 seconds for the 504 and 818 plus (HSM idle cycle, without material), and 40 seconds for the TONNA20.

What ceiling height is required for a cardboard baler?

The HSM V-Press 503 eco and 504 require a minimum ceiling height of 2,000 mm. The ceiling must be higher than the machine itself: the HSM V-Press 818 plus stands at 2,370 mm, while the TONNA20 is 2,600 mm tall. The TONNA20 is lower during transport.