BRAMIDAN

"Just a bit wider and slightly taller…"

This is how a development project began at Bramidan, a experienced manufacturer of waste balers based in Bramming, Denmark. The goal was to upgrade two existing products by increasing their size and strength—a relatively straightforward task, or so it seemed. However, the project quickly revealed substantial challenges.

Bramidan's well-known waste compactor, recognizable by its distinctive yellow color, is synonymous with quality and durability. To meet the demands of the American market, the largest compactor needed to be expanded by approximately 40% in both length and width, nearly doubling its footprint. Despite this, the machine still had to use the same hydraulic components as the existing models. The result? The same high compression in a larger and stronger format.

EXTERNAL EXPERTISE FROM KIRKHOLM

Bramidan decided to involve Kirkholm Mechanical Engineering in the process, as they recognized the need for specialized expertise in structural analysis and engineering calculations. The aim was to accelerate the development without compromising product quality. Instead of relying on time-consuming fatigue tests, advanced Finite Element Analysis (FEA) was utilized during the design phase - a method that significantly reduced the development time.

Bramidan decided to involve Kirkholm Machine Engineers in the process, as they recognized the need for specialized expertise in structural analysis and engineering calculations.

An initial meeting was held to ensure the alignment of the project’s goals and requirements, covering aspects such as NDAs, hardware, and software requirements, deadlines, communication, and milestones. The outcome of t he meeting was a comprehensive project documentation process that outlined the framework for further progress.

NEW DIMENSIONS REQUIRED A NEW DESIGN

Ejnar C. Christensen, Head of Development at Bramidan, explains why this project couldn’t simply follow an established approach:

“We couldn’t just modify an existing product; we had to design from scratch. The larger dimensions meant developing a completely new machine structure, even though we retained the same hydraulic components.”

The increased dimensions also called for enhanced strength and durability. Development involved rigorous structural analysis and testing to confirm that the new specifications could handle the required loads. Design changes, such as replacing square tubes with bent profiles, led to both material savings and increased flexibility.

ACCELERATED TIME TO MARKET

Finite Element Analysis was conducted alongside the design phase to optimize time-to-market. This approach allowed the team to quickly identify solutions that met strength requirements, rather than following the traditional, slower method of completing the design first and then conducting calculations. Robert Eriksen from Kirkholm elaborates:

"Although it might sound straightforward to double the press area, it involves significant technical challenges. The deflection of a beam structure increases proportionally to the cube of its length, so when the width was increased by 40%, deflection nearly tripled. Ensuring adequate stiffness in the press plate and chamber was one of our greatest challenges.”

This challenge was addressed through a combination of calculation and testing, ultimately yielding a machine with improved strength and durability.

SHOWCASED AT WASTE EXPO FAIR IN LAS VEGAS

Thanks to close collaboration and continuous optimization, the new waste compactor was ready for its debut at the Waste Expo Fair in Las Vegas, as scheduled. Ejnar C. Christensen explains:

"We could have developed the machine in-house, but that would have required more time-consuming testing. Kirkholm provided the necessary expertise and manpower, enabling us to progress rapidly. Their structural analysis expertise helped us avoid unnecessary testing, saving significant time."

The products have since been launched and are already in use with customers, and Bramidan looks forward to expanding the product line. As for future collaborations, Ejnar notes:

"I think Kirkholm would be an ideal partner if we decide to develop a larger model in the future."

You can read more about Bramidan’s vertical baler, the B50 XL, here.

Want to know more about Kirkholm and how we can help with product design, structural calculations, analysis and project management? Then don't hesitate to contact us: