Specification of Truck Mounted Rear Loading Garbage Compactor (Rearpak®) Page 1 of 7

SPECIFICATION OF TRUCK MOUNTED GARBAGE COMPACTOR 14 M3 CAPACITY

REARPAK®
GENERAL

Vehicle mounted rear loading garbage compactors shall be robust in construction and
shall be able to collect of garbage and refuse from different spots and then transport it to
dumping ground. The volume of the compactor shall be around 14 m3. The unit shall be
operated by hydraulic systems. The positive compaction against the ejector plate shall
be used to enable desired compaction to be achieved at all times for even loading.
Proper distribution of load on front & rear axles should be achieved without overloading
the axles in any circumstances. The refuse shall be pressed into the compactor by a
pressing plate & the mechanism shall enable the full body volume to be filled with
compacted refuse. The refuse shall be unloaded by an ejector plate.

The operations of this unit shall be such that one driver assisted by two helpers shall be
adequate.

COLLECTION & DISPOSAL OF GARBAGE

Collection of garbage shall be done by emptying/unloading the garbage into the hopper
of the compactor from the bins. These bins shall be emptied hydraulically by the bin lifter
or even emptied manually as the hopper is easily accessible. The compacting process
shall be carried out in stages as described below.

 The packer plate, which initially is at a closed position parallel to the floor of the
body, shall open hydraulically.

 Due to the actuation of the carrier plate hydraulic cylinders, the carrier shall come
down and the hopper shall shut by the packer plate.

 The garbage from the hopper shall be swept by the packer plate and pulled into the
container body by the reverse actuation of the carrier plate cylinder.

 The garbage shall be compacted against the ejector plate as the carrier ascends.

 The tailgate shall be unlocked from the self locking/unlocking arrangement and the
entire assembly shall be hydraulically lifted using the two cylinders.

 The compressed garbage within the container body shall be unloaded by the ejector
plate by pushing the garbage out of the body with its double acting multi stage
hydraulic cylinder.

 This system shall facilitated easy and quick unloading with assured machine stability
during discharge.

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Specification of Truck Mounted Rear Loading Garbage Compactor (Rearpak®) Page 2 of 7

The skid-mounted unit shall consist of;

a) Suitable power takes off arrangement from the truck chassis which shall be used
for driving various components of the unit.

b) Body

c) Tail gate

d) Packer plate

e) carrier plate

f) Ejector Plate

g) Bin lifter

h) Controls

i) Hydraulic system

j) High Pressure Washing System (Optional)

k) Safety Features

l) Standard Accessories

m) Painting

The above equipment shall be mounted on client supplied chassis with cabin & PTO like
TATA / ASHOK Leyland or equivalent of 16T GVW and 4200 mm wheelbase. Bidder
shall furnish full details of vehicle chassis. The Client will make direct payment to the
Chassis manufacturer/ their dealer against their Proforma Invoice to avail special Govt.
rates. The standard tools accessories and spares supplied with the chassis shall be
handed over to the client at the time of delivery of the unit.

The Bidder shall make arrangements for mounting equipment on the chassis according
to the rules laid down by the Regional transport Office, and loads recommended by the
chassis manufacturer on the front and rear axles. The Client shall make arrangements
for registration of the complete unit with the Regional Transport Office. The Government
fees required for registration & insurance of the units shall be paid by the client directly to
the concerned authorities.

REAR LOADER:-
The skid mounted rear loader unit and its hydraulically assisted packer body shall be
designed to perform the assigned work. Unit shall conform to the best practice known
to the body fabrication trade in design, quality of material and workmanship.
Assemblies, subassemblies, components and accessories shall be standard and
interchangeable. Accessories not specifically mentioned herein but necessary to
furnish complete unit ready for use shall be included.

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Specification of Truck Mounted Rear Loading Garbage Compactor (Rearpak®) Page 3 of 7

Unit shall be rear-Ioading type with loading height approx 1 meter from ground level.
The operation of compacting, ejecting the refuse shall be hydraulic system. The
system shall include the hydraulic pump driven by the chassis engine overheating,
necessary filter, adjustable relief valves, DOCV's directional control valves, restriction
valves and associated pipelines.

The hydraulic cylinders, hydraulic pump and control valves shall be of reputed make,
manufactured by the firm having vast experience in the same field.

Hydraulic seamless pipes, hoses, couplings should be of high quality and standard to
withstand high pressures. The pipe ends should be flared to ensure perfect seal and
prevent leakage even at high pressure.

a) PRIME MOVER:-

The unit shall be run on the power transmitted from vehicle engine through P.T.O.
(Power Take Off Unit). The P.T.O. shall be of sturdy design of reputed make and
should be able to provide sufficient power to run the system.

b) BODY

1. Body shall be fabricated from IS 2062 Steel sheets (5 mm thick floor , 3 mm side
wall and top plate) having Hexagonal shape for better aesthetic and reinforced by
front and rear stiffeners so as to withstand continuous operation at maximum
imposed loads & without harmful deformation or excessive wear.

2. The body interior shall have a smooth floor, sides and roof in order to prevent
damages. No cylinders, valves and other hydraulic components shall come in
contact with refuse into the body.

3. The body sides shall be equipped with extra heavy structural steel guide rails so
that will guide and support the ejector panel having UHMWPE / PTFE slider
blocks provided on both side of ejector.

4. To prevent the corrosion from leachete, the body floor is provided with
Stainless Steel grade 304 having Keel shape plate and ensure proper
collection of leachete in the floor sump at the front of the body.

c) TAIL GATE

1. Tailgate side shall be fabricated from high strength mild steel IS 2062 (3mm
thick).

2. Hopper floor shall be fabricated from Stainless steel Grade 304 (5mm thick).

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3. Loading height shall not be higher than the top of the chassis frame rails or 1m .

4. The tailgate shall have self locking / unlocking arrangement and raise to
permit ejection of the refuse when hydraulic valve is manually actuated.

5. Tailgate shall be provided with sturdy arrangement for raising and controlling of
descent.

6. The valve that operates the tailgate lift action shall be located at the front end of
the body (far away from the tailgate) to prevent any harm to the operator when
the refuse is being ejected from the body.

7. The valve operating the tailgate shall be of the spring centered (dead man) type
so that the operator must stand at side of tailgate (away from moving packing
blades) and physically hold the handle that activates the valve all of this for safety
purposes.

8. The hydraulic system shall include relief valves to prevent excess pressure that
may damage hoses, tubes and other hydraulic components.

9. A hydraulic fluid velocity fuse restrictor (Pilot Check valve) shall be installed at the
base of the tailgate cylinder to prevent rapid and dangerous fall of tailgate in case
of a hydraulic hose or tube rupture.

d) PACKER PLATE:

1. Packer plate shall be heavily reinforced & fabricated from high strength IS 2062
mild steel 3mm thickness.

2. Packing cycle complete shall be around 20 seconds.

3. The truck's engine shall be accelerated to sufficient speed (rpm) when the
packing plate valves are actuated to packing sequence at the rated speed and
pressures to compact the refuse.

4. Press Compaction: - Each hopper full of material shall be compressed between

the packing blade and ejector panel.

5. The heavy duty packer shall be fitted with sturdy mountings for rams.

e) CARRIER PLATE:

The carrier plate shall be fabricated from high strength mild steel sheets IS 2062
(3mm) and shall be made strong enough to withstand all the abuse imposed upon it
by the refuse.

The carrier plate shall slide on integrated side channels provided with low
friction, self lubricating UHMWPE / PTFE guides.

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f) DISCHARGE OF LOAD: (EJECTOR PLATE)

1. Discharge shall be by means of positive ejection.

2. The ejector panel shall be fabricated from high strength IS 2062 6mm thick mild
steel plate. The ejector panel should be angled and smooth to ensure clean
discharge and eliminate risk of waste adhering to the plate. The ejector plate
should be suitably reinforced.

3. The hydraulic telescopic cylinder shall extend and retract ejector over full length of
the body and shall be double acting.

4. Ejector plate shall be supported as well as glide on heavy duty UHMWPE /

PTFE self lubricating slider blocks to move smoothly along the side rails
provided within the body.

5. A large access opening at the front of the body shall be provided to attend to the
front of the ejection mechanism.

g) BIN LIFTING:

A hydraulically operated bin lifter should be provided at the rear end along with
the equipment, and should be capable of lifting the EN standard containers of
various sizes of 120, 240, 660, 1100 liters bins. Two double acting hydraulic
cylinders one on each side to be provided. Control lever for operation to be
installed at a convenient position such that the working of hydraulic cylinders can
be controlled safely. The bin arms shall have self locking arrangement to prevent
bins sliding over during unloading operation. The arms shall be locked in folded
position during vehicle movement on road.

h) CONTROLS:

1. Power take-off controls mounted in the cabin shall be conveniently located by

chassis manufacturer.

2. The position of Ejector and tailgate controls by two-spool directional control valve
shall be outside the body on the left side at the front part of the body.

3. The position of carrier plate, packer plate and bin lifter controls by three spools.
Directional control valve shall be outside the body on the left side near the rear
part of the body.

4. A Pneumatic acceleration device to raise engine speed to required R.P.M.

during packing cycle shall be provided.

i) HYDRAULIC SYSTEM:

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1. A heavy duty, single speed power take-off shall be provided by chassis

manufacturer and shall be compatible with that of chassis transmission.

2. The power take-off must run quietly. Gearing shall be selected for minimum engine
R.P.M. compatible with recommended R.P.M. for correct operating pressure and
flow per minute.

3. The hydraulic pump shall be designed to operate continuously with peak loading at
frequent and short interval. The pump displacement at 1500 rpm should be 75
L/min. It shall be drived by the PTO via propeller shaft.

4. All hydraulic hoses shall be as per relevant standards for designed pressure.
Hoses shall have adequate safety factor over maximum relief valve pressure
setting. The hoses shall be rigidly mounted on the body, wherever possible.

5. The hydraulic system shall incorporate relief valves to protect all components from
excessive pressure and overloads.

6. A replaceable, 10 micron filter should be provided in return line of hydraulic

system.

7. All hydraulic components should be easily accessible for inspection.

HYDRAULIC VALVES:

All the valves provided shall be of reputed make and of international standard. The
valves shall be rated 140 kg/cm2 pressure.

HYDRAULIC CYLINDERS:

1. All cylinders must be tested at 1.5 time the rated working pressures.

2. There must be a minimum of 9 cylinders as follows :

a) 1 No.: Heavy duty Multi stage telescopic, double acting hydraulic cylinder for
Ejection plate.

b) 2 Nos.: Heavy duty double acting Hydraulic cylinder with spherical bearings at
one end, for tailgate.

c) 2 Nos.: Heavy duty double acting hydraulic cylinder with spherical bearings at
one end, for carrier plate.

d) 2 Nos.: Heavy duty double acting hydraulic cylinder with spherical bearings at
one end, for packer plate.

e) 2 Nos.: Heavy duty double acting hydraulic cylinder with spherical bearings at
one end, for Bin lifter.

3. Cylinder rods of all cylinders shall be constructed of high strength, hardened steel
rods, centreless ground to an RMS smoothness rating of 8 and shall be hard chrome
plate to a minimum thickness of 0.13 mm.

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4. Pin mounting connections of packer and compaction cylinders shall incorporate

hardened spherical bushings on hardened pins where necessary.

5. The cylinders should be of reputed make.

HYDRAULIC RESERVOIR TANK AND FILTERS:

The reservoir tank shall be minimum 200 liters capacity and includes a sight fluid level
indicator, spin on return filter of 10 micron rating, suction line shut-off cock, and filter
cap with chain to prevent loss.

j) HIGH PRESSURE WASHING SYSTEM: (OPTIONAL)

Stainless steel water storage tank of 750 Ltrs. and hydraulic motor driven Jetting Pump
is provided for washing the internal walls of Compactor after dumping the garbage at
garbage station. The pump operated by hydraulic direction control valve.

k) SAFETY FEATURES:

1. Hose burst valve shall be fitted to the system to prevent the tailgate descending in the
event of the hydraulic failure. Emergency stop switch shall be provided to stop all the
operations instantaneously in case of emergency. The switch shall be provided on
either side of the vehicle.

2. There shall be a 'body prop' provided on the tailgate to hold the tailgate in the open
position for safety of workshop personnel when entering the body for maintenance or
repair.

l) STANDARD ACCESSORIES

Following accessories as a part of the machine shall be provided alongwith each model
to enhance the performance and safety features of the machines.

(i) Mud flaps - 2 nos.

(ii) Mud guard – 2 Nos.
(iii) Aluminium chequered plate lockable tool box – 1 No.

m) PAINTING

The entire unit shall be painted with two coats of superior quality anti-corrosive primer
with two coats of approved quality paint. The bidder shall get the paints and shades
approved from the client.

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