Saphir 450AT Fully Automatic Refurbishment
A case study showcasing and highlighting our workshop services and the refurbishment we have provided to customers. This refurbishment of a Saphir 450AT is an extreme overhaul example of the extent we can go to.
Stage 01: Arrival & Project Start
The baler when it arrived at WHS. The machine had been sat for three years outside and was in a state of disrepair.
Stage 02: Stripped & Accessed
When a machine arrives for refurbishment we did a detailed inspection. This machine was determined it needed to be stripping back to its bare shell and all aspects addressing individually.
Disassembly of all parts off the machine, many of which are rotten and rusted, in need of replacing or fabricating in-house.
A previous attempt to repair the machine in the past. This leg holds the compression section at the front of the machine and is integral to the structure of the baler.
The rigging screws were found to be missing on one side of the machine. These are used to adjust the tension in the bale.
The press plate after being removed from the machine and checked before starting the overhaul.
The twister system removed from the baler for refurbishment.
The twister cassette on the machine before removal and refurb.
The tying needle gantry needed to be overhauled. The pick-up needles have become rusted in place along all the mechanisms.
Stage 03: Jig & Straightening
The baler was no-longer straight and was an essential repair that needed to be made. The straightness of the machine stops the balers hydraulic press from pushing bales out inconsistently and eventually twisting the frame over time.
New, replacement rigging screws were replaced the missing ones.
The machine in the jig being realigned. The new supporting frame piece being sized.
The rigging screws fitted for alignment testing on the new frame arm.
The baler being measured for the alternative side of the frame to be welded in correctly.
The frame alignment being held at the correct position to even the differences in each side of the machine.
The new supporting frame welded into place and complete.
Stage 04: Shot Blast & Respray
Once the baler frame had been corrected it was shotblased back to bare metal ready to be placed in the spray booth to be resprayed.
Resprayed in gloss green paint and ready to be reassembled.
The channel baler frame. Primered and not gloss painted.
The underside of the machine gloss painted and finished.
Stage 05: Assembly
Once the baler frame had been corrected it was ready to be placed in the spray booth to be prepared and sprayed.
Parts Upgraded & Ready for Assembly
Overhauled hydraulic power pack. Ready to be re-installed onto the baler.
The top of the twister system showing ready for install onto the baler.
The twister system after being stripped, cleaned and restored, assembled and ready to be re-installed.
The press plate after it has been refurbished and ready for installation.
The old panel had been completely stripped and rewired back to OEM standard.
The twister system after being stripped, cleaned and restored, assembled and ready to be re-installed.
Needle rods have been cleaned with the removal of all the rust and reassemble.
New components including the bobbins, wire feed, rollers and covers that were missing from the machine.
New components including the bobbins, wire feed, rollers and covers that were missing from the machine.
Machine Assembly
The tying needles, now refurbished and painted back on the baler.
A close shot of the needles installed.
The twister system installed back on the baler.
The overhauled hydraulic power pack installed on the baler.
Stage 06: Installation
The baler delivered and installed at the customers warehouse.
The baler at WHS ready to be loaded and taken for delivery.
The baler after it has been delivered and installed.
The baler installed on-site with conveyor-belt feed.
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