There is not one system that fits all for a transfer station application. Every site is different and requires individual attention to determine the best solution. Machines that are
purpose built for this waste are a must for lower long-term owning and operating costs.
By Clay Layne
Just like its name implies, a landfill transfer station is a place where waste is transferred. To break it down further, this type of transfer station is a processing site—sometimes a building, but often simply a site where waste is delivered. At the station, municipal waste will be sorted or baled so that it can be sent to a new place for disposal (such as by incineration) or recycling. Sometimes, however, this waste is simply taken to a landfill.
Regardless, landfill transfer stations are a critical part of the modern waste removal process. Nobody knows your transfer station better than you. However, there is always something to learn—what to do and what not to do—from other operations.
Before selecting the equipment that will be used for efficient operation to meet production goals, a solid safety culture needs to be part of the overall operation. A safety plan is just as important as an efficient production plan.
Safety First—All Day, Every Day
Cramped buildings. Poor lighting. Slick floors. Lots of vehicle and foot traffic. Transfer stations are filled with safety risks, and that is why working safely must be the top priority all shift long. Wearing proper personal protective equipment (PPE) is essential, but commitment to safety cannot stop there.
To sustain a culture of safety excellence, implement a program that measures and manages the right activities, recognizes workers for what they do right, involves and engages all levels of the organization, and includes visible commitment from top leadership.
Considerations Before the Equipment
There are many factors to consider before selecting proper equipment. Every transfer station is different and has different goals and needs. Total cost of ownership is one key factor to consider. The purchase price of one piece of equipment may be more than a different machine that will still accomplish production goals. However, the ease of operation, operator comfort, technology, and safety will translate into greater productivity and profitability on the tipping floor.
Also, serviceability and maintenance play a big part of being productive and profitable on the tipping floor. Having service points that can be reached from ground level decreases daily and weekly machine checks and increases safety. Ground level service points and fluid checks are vital in the waste industry.
When factoring the amount of debris and slippery substances on a machine that could cause the operator to get injured while doing the daily walkaround inspection, it is important to minimize the amount of climbing on a piece of waste equipment. Easy service and protected components are not the only ways of avoiding downtime. Features that increase safety reduce the risk of the worst kind of downtime.
Other factors to consider when looking at the proper equipment include:
- How much inbound material is handled per hour/day/week
- How much outbound material is handled per hour/day/week
- The types of material—MSW, green waste, C&D—and percent of time it is being handled
- The types of work cycles—unloading, stockpiling, sorting/separating, loading and floor cleaning—the machine will perform and percent of time on those cycles
- The type of loadout for the outbound material—same level, half separation or full separation
- Peak times and the tonnage received during those peak times
- Work tool change requirements
- Will the floor be cleared of materials at end of the day
- Building restrictions—height, pillars, etc.
- The underfoot conditions—sloped, level, slick, dry, etc.
- Growth projections over the next five years
- Knowing this information is going to start the process of determining which piece of equipment is best for your operation.
Loading, Unloading and Stockpiling Equipment
There are several different kinds of equipment used in a landfill transfer station, and each type serves a different purpose. Some equipment is for sorting, some is for compacting, and other equipment is for transporting. The three main tasks at the transfer station are unloading, stockpiling, and loading. The following recommendations focus on these main tasks.
The two most common machines that can handle these tasks are the wheel loader and material handler. Wheel loaders have different types of buckets that it can be equipped with, and material handlers use different style grapples. Both are good options for the transfer station, but there are many variables to account for when determining which is best for your specific operation.
Wheel Loaders
Wheel loaders are designed for stockpiling and loading. They are a great solution for a transfer station. However, there are many things to consider before deciding on a wheel loader and the right size.
Size and Height
Transfer station size is a big factor with any machine selection. Ceiling height and tramming distance need to be considered. Wheel loaders are designed to handle a load and carry it if the tramming distance is long.
Bucket pin height is another thing that should be considered. As the tires start to wear down, this will change the bucket pin height. The height can be lowered by seven inches as the tires wear.
Buckets
There are three main types of wheel loader buckets to consider based on the operation. Once again, it is about meeting goals for that machine:
1. Load and carry buckets are very versatile. They allow for a high capacity of waste, typically a 1.5 bucket fill factor. This style allows operators to stockpile, move waste across the floor in an efficient manner, and load out trucks.
2. Dozing style buckets do exactly what the name implies. It is meant to push or doze waste across the tipping floor.
3. Tamp and clamp buckets allow the operator to load the truck and tamp. They also allow for picking and sorting due to the hydraulic rack on top of the bucket.
Tire Wear
Aside from personnel and fuel, tires are where most transfer stations spend the most money. Replacing a set can cost up to $40,000, and too much tire spin results in more frequent replacement, increasing operating costs.
Traction Control
To reduce tire spin and extend tire life, look for machines with traction control (manual or computer-aided) or computer-aided rim-pull control. These systems help operators to reduce tire spin and maintain traction.
Train the operator to not add more power once tires start to spin, as this creates more spin. Instead, teach them to back off power to gain traction. Additionally, keep floors dry and clean to reduce tire spin. Some operators use a mattress or green waste to “sweep” the floor, while others make “cleaning runs” with their buckets every third or fourth push.
Finally, choosing a wheel loader with a good payload system will also be beneficial to your site.
Material Handlers
Material handlers can stockpile and load out the trucks. A material handler with a rising cab allows the operator to see down into the truck while loading. Loading with a material handler allows waste to be layered in the truck. Each layer can be tamped to allow for maximum use of the truck bed. There is also less of a chance for damage to the truck trailer due to the operator being able to see into the trailer and have more control when loading.
A material handler that is purpose built for the transfer station also increases uptime. The reversing fan will cut down on machine overheating, and a machine equipped with technology can allow operators to set up an E-fence and eliminate the opportunity to swing into a wall or pillar—a great safety feature. Just like the wheel loader, a good payload system on a material handler will greatly improve onsite efficiency.
Material handlers can be equipped with 360-degree-rotation waste grapples to allow for greater material controllability, loading and tamping. The controllability allows for quick and efficient picking and sorting as well.
Determine the Best Solution
There is not one system that fits all for the transfer station application. Every site is different and requires individual attention to determine the best solution. The waste industry is a harsh environment, and machines that are purpose built for this waste are a must for lower long-term owning and operating costs. It also helps to increase the uptime on equipment. | WA
Clay Layne is the Sales Support Consultant in Waste Applications at Caterpillar Inc. Clay covers landfills, transfer stations and MRFs. He started working for Caterpillar in 2008 as an operator at the Peoria Proving Grounds, working with engineers on the Research and Development of Caterpillar Machinery. In 2011, Clay moved to the Edwards Demonstration and Learning Center. It was here that Clay started working in the Waste Industry, conducting onsite operator training for Caterpillar customers all over the world. Clay can be reached at (309) 675-8486 or e-mail [email protected].