How much do bales of aluminum weigh?

The weight of a bale of aluminum depends on the size of the baler you’re using. The weight can go up to 850 lb, with the average weight for mill-size bales being around 500 pounds. Average bales measure approximately 30 x 48 x 60 inches.

Learn about aluminum bales and what affects their weight. Partner with Baling Wire Direct for US-made baling wire for recycling aluminum.

How does bale size affect weight?

The bale weight of aluminum is based on size and density. Here is a comparison of common aluminum bale categories:

Bale size	Bale dimensions (inches)	Bale weight
Small	24 x 25 x 30	60–80 lb (27–36 kg)
Medium	30 x 48 x 60	around 500 lb (226 kg)
Large	Varies	525–850 lb (238–385 kg)

About vertical aluminum balers

Vertical balers produce lighter bales for aluminum recycling operations with low- to medium-volume needs. These machines use vertical hydraulic presses to compress aluminum baling materials into bales. Their chambers and presses are smaller than in horizontal balers and produce small- to medium-sized bales.

About horizontal aluminum balers

Horizontal baler machines can handle high volumes of aluminum and generate larger bales (up to about 2,200 lb) in industrial environments. The high press force of these heavy-duty balers compacts aluminum bales, which maximizes density and reduces transportation costs.

Horizontal, automatic two-ram balers create the heaviest, densest bales. Automated baling systems apply consistent pressure (e.g., 110,000 lb press force) to produce bales with minimal air gaps.

Does all aluminum weigh the same?

Not all aluminum weighs the same, even when baled. The weight of aluminum bales depends on the types of aluminum waste, its density, and how it’s processed.

• Aluminum alloys: Aluminum comes in different alloys (e.g., 3004 for different types of cans, 6061 for automotive parts). Each alloy has a slightly different density due to added elements such as magnesium or silicon. Beverage cans and beer cans are thinner and lighter per unit, while aluminum scrap from machinery or construction is denser and heavier. This means a bale of aluminum soda cans will weigh less than a bale of the same volume filled with thick automotive aluminum, even if they’re the same size.
• Form factor: How aluminum is prepared before baling affects its weight. Bales that contain aluminum foil (thin and lightweight) will weigh less than those with aluminum blocks or heavy scrap.
• Contamination adds weight (but lowers value): If a bale includes non-aluminum materials (e.g., plastic labels, steel food cans with leftover food, or dirt), the total weight increases, but the recycled aluminum content decreases. Recycling centers often penalize contaminated bales by paying less per pound.

Most buyers (e.g., smelters) measure bales by purity and total aluminum content, not just gross weight. For instance:

• A bale of aluminum cans (clean, sorted) might weigh 800 lb and fetch a higher price per pound.
• A mixed bale with aluminum foil and contaminants might weigh 900 lb but sell for less.

What gauge baling wire is best for aluminum?

The baling wire gauge you should use for baling aluminum depends on two factors:

1. Number of wires your baler uses (typically 3 or 4).
2. Bale weight (heavier bales require stronger wire).

The combined load strength of all bale wires must exceed the aluminum bale’s weight to prevent breakage. Thinner wire is cheaper, so businesses should go with the thinnest baling wire that can safely support their bales. For example, a 1,200-lb bale made by a 3-wire baler could use an 11 gauge wire since:

3 (# of wires) x 735 (load strength of 11 gauge black annealed stem wire) = 2,205 lb

Always follow your baler manufacturer’s wire recommendations, and contact us for specific wire selection assistance.

Recommended wire gauge by bale weight:

Bale weight	3-wire baler	4-wire baler
Under 500 lb	12 gauge	13 gauge
500–1,000 lb	11 gauge	12 gauge
1,000–1,500 lb	10 gauge	11 gauge
1,500-–2,200 lb	9 gauge	10 gauge

What type of baling wire is best for baling aluminum?

The most common types of baling wire used to bale aluminum are black annealed and bright wire. If you need to store the bale for longer or in harsh conditions, opt for galvanized wire instead.

Black annealed wire

Black annealed baling wire is used for high-density aluminum bales that require flexibility, bales that are stored indoors, or bales stored for a short period. We offer black annealed wire by the box or stem. The benefits of black annealed wire for baling aluminum include:

• High tensile strength: secures dense bales of aluminum without snapping.
• Compatibility with automatic balers: feeds smoothly in high-volume machines (use box or stem black annealed wire).
• Elongation properties: stretches up to 25% to accommodate shifting materials as bales settle.
• Moderate corrosion resistance: finished in a wax coat that provides some resistance to moisture and chemical exposure.

Bright wire

We also offer bright baling wire as single loop and double loop bale ties. Here’s why you should use bright bale ties to bale aluminum:

• Economical: uncoated steel wire is the cheapest option.
• Aesthetics: some operations prefer bright baling wire for client-facing applications.
• Indoor use: sufficient for dry environments, where bales of aluminum should be kept.

Single loop bale ties can be tied to different lengths to accommodate different bale sizes. They work with horizontal and vertical manual machines that bale aluminum. Double loop bale ties are pre-cut to length. The double loop configuration accelerates the tying process.

High-tensile galvanized wire

Aluminum can expand, especially when heated or kept in warm conditions. High-tensile wire with a galvanized surface offers more load strength than regular wire and withstands extreme outward pressure from expansive materials.

We carry hi-tensile galvanized stem wire for high-throughput automatic feeding balers. Choose between a simple Class 1 or more resilient Class 3 galvanization based on the level of resistance you need.