A Guide to Marathon Balers and Recycling Equipment
High Efficiency Solutions Built for Real Recycling Operations
In most recycling operations, performance is rarely determined by a single machine.
Efficiency depends on how material moves from where it is generated, to where it is consolidated, to how it is compacted, stored, and shipped. When any part of that process breaks down, the effects are immediate and significant. Material piles up, employees are pulled off productive tasks, hauling becomes inefficient, and what should be a routine day turns into a stressful problem-solving nightmare.
Marathon Equipment designs balers and recycling systems specifically for this reality, with the mission of improving the lives of the customers we’ve served for over 50 years. Their recycling lineup includes heavy-duty vertical balers, horizontal manual-tie balers, auto-tie balers, two-ram balers, conveyor systems, cart dumpers, and fully engineered material recovery facility systems (MRFs). Each Marathon product is engineered by experienced teams who understand the operational demands of manufacturers, warehouses, retailers, grocery chains, municipal recycling centers, and MRFs.
What sets Marathon Equipment apart is not just the breadth of equipment, but the brilliance of the engineering behind it. Every baler and recycling equipment system is designed for high duty cycles, long service life, reliable performance, and real-world serviceability. The result is equipment that solves problems quietly in the background and provides long-lasting peace of mind.
The most effective way to explore Marathon’s recycling equipment is to look at how each solution supports specific operational needs.
High volume cardboard recycling in retail and supermarket environments
Supermarkets, big box retailers, and high traffic commercial locations generate a steady stream of cardboard throughout the day. Space is limited, back of store areas must remain clean and safe, and recycling cannot interfere with customer facing operations.
Heavy duty vertical balers are often the most practical and widely adopted solution in these environments, and they are the cornerstone of Marathon’s recycling lineup.
Marathon heavy duty vertical balers are engineered to handle the continuous flow of Old Corrugated Containers (OCC), shrink wrap, and light packaging materials that are common in retail settings. Their vertical configuration allows them to fit into tight spaces while still producing dense, uniform bales that are easy to store and transport. For facilities processing large volumes of cardboard daily, this combination of compact footprint and effective bale density is critical to operational success.
Unlike light duty balers intended for occasional use, Marathon vertical balers are built for frequent cycling. Reinforced frames, powerful hydraulic systems, and simple, durable controls allow these machines to perform reliably across 24/7 shifts. This durability minimizes downtime and reduces service interruptions during peak business hours.
Ease of use is critical in retail environments where many employees may interact with the baler. Marathon vertical balers are designed with clear loading openings, straightforward controls, and consistent bale formation. This improves safety, reduces handling time, and keeps recycling integrated into daily operations rather than becoming a bottleneck.
For grocery chains and retailers operating multiple locations, standardizing on Marathon HD vertical balers also simplifies training, service, and parts support while producing consistent bale sizes that meet recycler requirements and maximize commodity revenue.
Click here to learn more about Heavy-Duty Vertical Balers
Creating consistent bale output without constant supervision
Facilities processing steady volumes of cardboard, paper, plastics, or mixed recyclables often need high throughput without increasing labor. In these environments, automated tying and reliable cycling are critical.
Marathon auto-tie horizontal balers are designed for continuous operation with minimal manual operator action. The TIEger series auto-tie horizontal baler focuses on tying reliability and repeatability, two factors that often decide whether a baler reliably supports production or demands constant attention.
Automated tying systems, controlled bale tensioning, and repeatable wire placement help produce uniform bales that stack, ship, and sell efficiently. This consistency improves transportation efficiency and supports more predictable commodity recovery.
Auto-tie balers are well-suited for large distribution centers, manufacturing plants, and high-volume recycling operations where material flow is steady and labor availability may fluctuate. In these settings, automation becomes less about convenience and more about operational stability.
Click here to learn more about Auto-Tie Horizontal Balers
Balancing productivity and simplicity with manual tie horizontal balers
Not every operation requires full automation, but every operation requires reliability.
Manual-tie horizontal balers are a highly effective solution for facilities with predictable material streams and regular staffing. Marathon’s Gemini and Stealth manual tie balers are designed to deliver dependable performance with fewer mechanical complexities, making them easier to operate, maintain, and reliably support long service lives.
These balers are commonly used in manufacturing facilities, warehouses and distribution centers, and smaller recycling operations processing OCC, paper, plastics, or aluminum cans. Flexible hopper configurations and feed options allow the equipment to be matched to site-specific workflows rather than forcing operators to adapt their processes to the equipment.
For operations that demand extra durability, straightforward operation, and strong bale quality without the added complexity of automation, manual tie horizontal balers remain a highly effective choice.
Click here to learn more about Manual-Tie Horizontal Balers
Achieving higher density and control for demanding recycling streams
Some recycling streams require more force and more control to produce stable, market-ready bales.
Two-ram balers are designed for these demanding applications. Marathon’s Galaxy two-ram balers provide independent control over compression and bale formation, allowing operators to achieve higher-density bales across a wide range of materials. This design is especially valuable when incoming material varies from day to day.
Two-ram balers are commonly used in municipal recycling centers, MRFs, and industrial recycling operations where bale quality, density, and consistency directly affect transportation costs and efficiency of future processing.
For operations that need two-ram performance but have lower throughput requirements or space limitations, Marathon’s Apollo two-ram baler offers a more compact solution while maintaining the core advantages of two-ram baler technology.
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Supporting baler performance with efficient material handling
Even the best baler cannot perform effectively if material flow is inconsistent or can’t feed the volume that powerful Marathon Equipment balers are capable of processing.
Marathon conveyor systems are engineered specifically for recycling and waste applications, moving material efficiently from sorting areas, dock doors, or collection points directly into balers. Properly designed conveyors reduce manual handling, improve safety, and ensure balers operate at their intended capacity.
From lighter duty conveyors to heavy duty steel belt designs, Marathon conveyors are integrated into recycling operations of all sizes. Because Marathon’s experienced engineering teams work directly with recycling facilities every day, conveyor layouts are developed with a clear understanding of material type, volume, loading points, and downstream equipment. When conveyors are designed as part of the overall system rather than added later, material flows more consistently, balers operate closer to their capacity, and bottlenecks that can drain efficient productivity are reduced or avoided all together.
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Designing complete recycling and MRF systems
For facilities planning new recycling operations or major upgrades, Marathon also designs complete MRF material recovery facility systems.
These systems integrate conveyors, sorting platforms, balers, and storage areas into highly efficient layouts that maximize throughput while minimizing labor requirements. By viewing the facility as an entire system rather than a collection of machines, Marathon helps operations achieve the very best performance under real world conditions.
This approach is especially valuable for municipal recycling centers and commercial MRFs where space, staffing, and material variability must all be balanced very carefully in order to achieve maximum efficiency and profitability.
Click here to learn more about MRF and Transfer Station systems
Consolidating material efficiently across large sites
Large properties and multi-building facilities often rely on carts and containers to collect recyclables from multiple locations. Without efficient consolidation, labor costs rise and handling time increases.
Marathon cart dumpers streamline this process by safely and efficiently emptying carts into centralized baling or compaction systems. By reducing manual lifting and dumping, cart dumpers improve safety, speed up collection routes, and help smaller teams manage larger volumes of material.
When paired with centralized balers, cart dumpers help keep recycling operations clean, efficient, and predictable.
Click here to learn more about Marathon Cart Dumpers
Turning balers into managed assets instead of reactive equipment
Unexpected downtime is one of the most disruptive forces that a recycling operation can face. When baler status, production levels, and service needs are only discovered after a problem occurs, operations are forced to become reactive by necessity. Maintenance gets rushed, baling and hauling schedules become out of sync, and what should be predictable production turns into uncertainty and stressful chaos.
Connected Baler technology, developed through a collaboration between Marathon and 3rd Eye, both Environmental Solutions’ sister companies, fundamentally changes how balers are managed. By combining onboard sensors, weight capture, and cloud-based monitoring software, Marathon Connected Baler brings real visibility to stationary recycling equipment and turns balers into fully-managed assets rather than equipment that only gets attention when something goes wrong.
At the core of Connected Baler smart technology is precise, fully automated bale data. Instead of estimating output or relying on manual logs, facilities can see the actual weight of every bale produced, tied to material type and production history. This level of accuracy allows operators to understand true productivity, align hauling schedules with real output, and reduce unnecessary pickups or overflow situations.
Beyond production data, Connected Baler provides insight into utilization and equipment behavior. Operators and back-room managers can see how often balers are cycling, how usage patterns change over time, and when equipment begins to operate outside normal parameters. Alerts and customizable, easy-to-read dashboards help identify developing issues early, allowing maintenance to be scheduled proactively rather than in response to an unexpected failure.
This complete shift in baler management can have a HUGE impact on uptime. By addressing small issues before they become big problems, facilities reduce emergency service calls, avoid unexpected shutdowns, and keep recycling operations running efficiently and on schedule. Over time, this proactive approach can extend equipment life and lowers total cost of ownership.
Connected Baler also supports more informed operational planning. Historical data and customizable reports make it easier to identify peak production periods, balance staffing levels, and evaluate how changes in material streams affect bale output. For companies or municipalities managing multiple facilities, the ability to view performance across all sites creates consistency and helps standardize best practices.
From a sustainability perspective, accurate bale weight and material tracking provides a clear, defensible record of recycling activity. Facilities can confidently document diversion volumes, support their sustainability goals, and respond to reporting requirements without relying on estimates or incomplete data. This transparency strengthens recycling programs and reinforces their value across the organization.
By integrating 3rd Eye’s real time visibility with Marathon’s proven baler platforms, Connected Baler transforms stationary recycling equipment into a source of insight and control. It replaces guesswork with data, reactive maintenance with planning, and uncertainty with confidence, delivering a more stable, efficient, and resilient recycling operation.
Click here to learn more about smart Connected Baler technology
Click here to learn more about Connected Collections
Choosing the right Marathon recycling solution
Selecting the right baler or recycling system starts with understanding four key factors.
Material type and variability influence whether a vertical baler, horizontal baler, or two ram system is the best fit. Throughput needs and labor availability determine the value of automation. Space constraints and material flow make the use of conveyors, cart dumpers, and maximized layout design, invaluable to maximized efficiency and productivity regardless of operation size or layout.
Marathon’s strength lies in its ability to address all of these considerations within a single, integrated product lineup, with friendly, experienced teams here to guide you every step of the way.
The baler bottom line
Marathon balers and recycling equipment are built to solve real problems in real facilities. They are engineered for high efficiency, long service life, and dependable performance across retail, industrial, municipal, and commercial recycling operations.
From heavy-duty vertical balers in supermarkets to high-capacity auto-tie and two-ram balers in MRFs, supported by conveyors, cart dumpers, and complete system design, Marathon provides the tools needed to build recycling operations that are stable, scalable, and engineered to provide years of reliable, stress-free operation.
For organizations that value dependability, worry-free operation, and long-term return on investment, Marathon delivers equipment designed by people who understand what it takes to keep recycling operations running day after day, without surprises.
