Bulb Eater

Bulb Eater® Machine FAQ's

Air Cycle understands that you may have questions about our lamp crushing systems. Listed below are some of the more common questions we are asked. Please click on the question, to read the answer.

What is a Bulb Eater®?
Why do people use the Bulb Eater® system?
How does the Bulb Eater® work?
How long does it take to crush the lamps?
How many crushed lamps fit in a 55-gallon drum?
How much space can I save by crushing my lamps?
What is the difference between the Model 55 VRS and the Model 55 VRS-U Bulb Eater® systems?
What does VRS stand for? VRS-U?
I've seen reference to T8, T12, and T17 lamps. What is the difference?
Is it safe?
Sure, it makes sense to crush the lamps, but what do I do with the crushed lamps?
How often do the filters need to be changed?
Where do I buy extra filters?

What is a Bulb Eater®?

A Bulb Eater® is a lamp crushing machine that processes, or crushes, spent fluorescent lamps into small fragments. The crushed glass is compacted into 55-gallon containers. The Model 55 VRS crushes over 1350 T8 4' lamps into one 55-gallon drum. The Model 55 VRS-U not only crushes straight fluorescent lamps of any length, but also u-shaped fluorescent lamps as well. This greatly improves storage of the lamps, handling, safety/liability issues, and recycling costs. The units are complete with filtration systems to help ensure both OSHA and EPA compliance, even for facilities disposing of large quantities of lamps.

Why do people use the Bulb Eater® system?

Facilities across the world use the Bulb Eater® lamp crushing systems to make their lamp disposal process more efficient. The systems will greatly reduce storage needs, minimize handling of the lamps, create a safer, cleaner work environment, and cut overall recycling costs.

How does the Bulb Eater® work?

The lamp is fed into the entry tube of the machine.
In roughly one second the lamp, whether straight or u-tube enters the machine and is crushed to pieces.
The Bulb Eater’s filtration system pulls the contaminated air out of the drum to filter out the released powder as well the mercury vapor.
The contaminated air goes through a two stage filtering process in the blue case. The first stage filter captures over 99% of the released dust particulate. The second stage HEPA filter acts as a polishing filter and captures over 99.99% of the remaining particulate.
At that point the air is clean but still contains mercury vapor.
The mercury vapor is then blown out of the blue case and through the third and final filter.
The carbon filter not only captures the mercury vapor, but also neutralizes it by converting the vapor to mercuric sulfide, which is non-hazardous.
Clean air comes out of the Bulb Eater® exhaust vent.

How long does it take to crush the lamps?

It takes roughly one second to crush a 4' fluorescent lamp and a fraction of a second longer for 8' lamps.

How many crushed lamps fit in a 55-gallon drum?

1350 Straight T8 4' Lamps / 875 Straight T12 4' Lamps / 475 Straight T12 8' Lamps / 450 U-Shape T12 Lamps

What is the difference between the Model 55 VRS and the Model 55 VRS-U Bulb Eater® systems?

The Model 55 VRS Bulb Eater® is an emissions controlled system able to crush straight fluorescent lamps of any length and diameter. The system has a removable entry tube for T12 fluorescent lamps that can be supplemented with entry tubes for T8 and T17 straight fluorescent lamps. The Model 55 VRS-U Bulb Eater® is also an emissions controlled system but is able to crush not only straight fluorescent lamps, but also u-shaped fluorescent lamps as well. The entry chute for the u-shaped fluorescent lamps can be removed and sealed while crushing straight lamps. This system also comes complete with a T12 straight fluorescent entry tube. T8 and T17 entry tubes are also available.

What does VRS stand for? VRS-U?

Vapor Removal System AND Vapor Removal System with U-Shape Capability

I've seen reference to T8, T12, and T17 lamps. What is the difference?

The diameter of a lamp is measured in eighths of an inch and expressed as a "T" number, such as T8 (equals 8/8's or one inch) and T12 (equals 12/8's or an inch and a half diameter). T17 lamps, while uncommon, are 17/8's or 2 and an eighth inches in diameter. This designation is given in lamp catalogs and sometimes printed on the lamp itself. For example, one of the most common 4' lamps is an F40T12/CW. The Bulb Eater® systems come standard with an entry tube fitted for T12 lamps. T8 and T17 entry tubes are also available.

Is it safe?

Yes. In fact, studies show that it is actually safer to package lamps by using Bulb Eater® lamp crushing systems than boxing the lamps intact. This is because the Bulb Eater® captures over 99.99% of the mercury vapor released during crushing. While there is a small amount of mercury vapor released, the overall mercury exposure is significantly less than when managing the same quantity of lamps intact and dealing with the accidental breakage of the lamps. No one intends to break the lamps while handling them, but unfortunately when handling tubes of glass up to 8' long accidental breakage is unavoidable. Based on EPA studies that show an accidental breakage rate of 3% (which based on our industry knowledge we believe to be low), our customers are considerably safer crushing their lamps with our controlled emissions systems. Due to the potential for mercury vapor exposure, our emissions-controlled lamp crushing machines have been tested for OSHA safety compliance by outside testing laboratories (test results available). These tests show that the operator experiences well under both Federal and State OSHA mercury vapor exposure levels. In fact, our most recent emission study showed non-detectable levels of mercury vapor emissions even after crushing 1500 lamps! Also, please note that the State of Illinois Environmental Protection Agency has inspected Air Cycle Corporation's facility and also the Bulb Eater® machines. In fact, the State of Illinois Environmental Protection Agency uses the Bulb Eater® to safely package their lamps prior to recycling.

Sure, it makes sense to crush the lamps, but what do I do with the crushed lamps?

Contact Air Cycle to have the drums picked up and transported to one of our contracted recycling facilities to be recycled. This is the preferred method of the Environmental Protection Agency and is the most cost efficient option. Depending on your state regulations, you may be able to exclude this waste from your hazardous waste totals. Contact Air Cycle today for a customized recycling quote!

How often do the filters need to be changed?

The filters need to be replaced on a scheduled basis. The first Stage filter bag is changed twice per drum. The second Stage filter cartridge is changed at least every 10 full drums. When changed, the filters can be placed on top of the crushed glass inside the drum (depending on applicable regulations). The filters are sent for recycling with the crushed lamps in the drum. The 3rd Stage premium-grade activated carbon filter is rated for over a million lamps. Based on these figures, most facilities will never need to change this filter. Should this activated carbon filter become saturated, the filter can be recycled.