Dust-Free, Precisely, and Safe Filling of Big-Bags at low Investment Costs

Dust-Free, Precisely, and Safe Filling of Big-Bags and Containers

The Big-Bag Filling Station LFB is used for an automatic, dust-free, precisely and safe filling of big-bags and containers in various sizes. The construction guarantees solid and stable big-bags no matter whether you want to fill plastic granules or fine powders. Due to the modular design, the filling station can be optimally configured for every task, even afterwards

The support arm with motorized, stepless height adjustment allows adaptation to different container heights. Specially developed pneumatically actuated hooks for big-bag loops ensure easy hanging and automatic hanging of the big-bag. The filling head to which the filling opening of the bundle is connected is equipped with a pneumatic seal. This ensures a largely dust-free connection.

The Big-Bag Filling Station LFB is available with a calibratable, intelligent scale and a control with standard components from Siemens.

Functional principle
In the basic variant, a pallet is placed at the seating of the filling station and is moved forward with a hand-held trolley after filling. By lowering the support arm, the big-bag can be hooked up easily to working height. The loops are hooked into sturdy stainless steel hooks and held by a fuse. In order to reach the rear hooks it is possibly to climb with one foot on the roller track. A step guarantees a safe position. The opening of the big-bag must be pulled over the filling mouth, which is coupled by a pneumatic expansion cuff and ensures a dust-free connection. To achieve this, the cuff is inflated by a pressure air system and a two-hand circuit. After the preparation of the big-bag, the filling process has to be started.

The possible bagging performance depends on the skill of the operator, the product properties, the dosing device and the feeding system. Realistic is an output of six to twelve big-bags per hour. If all labor saving options are selected a big-bag can be filled almost automatically. Manually the big-bag only has to be hooked and closed. The further sequence is automated.

Standard Version
The filling station is already semi-automatic in the standard version. The support arm is motor-driven and can lift already filled big-bags. Thus, both standing and hanging big-bags can be filled as what is required by the product.

Operation
In the simplest case, the system is operated via a few pushbuttons. It is of course possible to further automate the system in a modular way. For example, a PLC with coupling to a control system can be realized.

Control (Optional)
The control system is completely based on Siemens standard components. The verifiable weighing electronics is integrated in the S7-300. Operation is done via a color touch panel. We have also used some frequently used functions on hardware buttons to enable simple and fast operation and also to protect the touch panel.

The system can be used as a stand-alone device or optionally also control an upstream feeding system. Integration into a higher-level control system with Ethernet is no problem.

OPTIONS

Standardized and still-custom made:

OPTION: Inflation device (AV) In order to facilitate the filling of the big-bag, the bag can be inflated and shaped with an inflating device before filling. Thus, fold-free and fast filling of the big-bags is achieved.

OPTION: Inlet flap (EK) In the inlet area, the station can be equipped with an inlet flap in order to allow metered filling of the big-bags.

OPTION: Dust flap (SK) In order to prevent product trickling after decoupling the bag, the filling station can be equipped with a dust flap.

OPTION: Roller conveyor, single (RE) or complete (RS) In order to fully exploit the potential of the system, the use of one or more electrically driven roller conveyors is recommended. The installed roller conveyor can be folded up for cleaning purposes. For transporting the filled big-bags, the filling station can be equipped with further accumulation roller conveyors. With these the operator can close the big-bag while the next big-bag is being filled. In addition, the station can be equipped with a feed roller conveyor on which pallets and big-bags can be prepared so that they are directly available to the operator after the actual filling process.

OPTION: Vibrating table (RT) With the vibrating table, the product can be compressed in the big-bag by gentle shaking. The bulk cone is leveled and the fluidization is reduced. The vibrating process can be triggered by one or several percentage values from the setpoint weight or manually by pushing the button.

OPTION: Wheighing not ready to calibrated (VN); ready to calibrated (VE); calibrated (VG) With a weighing device an accurate filling of big-bags is possible. The resolution of the scale depends on the requirements of the calibration regulations. The weighing unit can be supplied as not ready for calibration,ready for calibration or fully calibrated.

OPTION: PLC control with free (SP) or Ethernet (SE) interface The sequence and weighing control is based on Siemens S7-300 series components. In the simplest version, only the coarse and fine commands of the scale are given as isolated output. All operating data can be reported to a control system via an Ethernet interface. Operation is done via a color touchpanel. The most important data are stored in a recipe management for the different container sizes and products. The filling process is operated by robust illuminated pushbuttons. The control is the standard scope of delivery, the type of coupling is selectable.

OPTION: Label printer (DE) With a receipt printer, batches and weight data can be printed directly and could be attached to the big-bag. This is absolutely necessary e.g. in case of a non-automatic weighing.

OPTION: Displacement measuring system (WS) In conjunction with the PLC control system the displacement measuring system enables the automatic start-up of taught-in positions of the motorized height adjustment. The sequences can thus be further automated and accelerated since the operator is not bound during the travel time.

OPTION: Dosing device (DO) A precise dosing device is necessary for self-operating and calibrated filling. This can be a screw or a suitable sluice. The dosing can be performed via an analog value from the weighing controller.

OPTION: Central aspiration connection (ZA) The filling can be equipped with connection to a central aspiration in order to suck up the displaced, dusty air.

OPTION: Special versions (SX) The standard version is suitable for big-bags of 1000-2000 mm height with 150 – 250 mm loop length and a filling mouth of 300-500 mm diameter. If desired, the height can be varied within certain limits. Customized changes by arrangement.

Dust-Free, Precisely, and Safe Filling of Big-Bags and Containers

The Big-Bag Filling Station LFP is used for an automatic, dust-free, precisely and safe filling of big-bags and containers in various sizes. The construction guarantees solid and stable big-bags no matter whether you want to fill plastic granules or fine powders. Due to the modular design, the filling station can be optimally configured for every task, even afterwards

The support arm with motorized, stepless height adjustment allows adaptation to different container heights. Specially developed pneumatically actuated hooks for big-bag loops ensure easy hanging and automatic hanging of the big-bag. The filling head to which the filling opening of the bundle is connected is equipped with a pneumatic seal. This ensures a largely dust-free connection.

The Big-Bag Filling Station LFB is available with a calibratable, intelligent scale and a control with standard components from Siemens.

Functional principle: In the basic variant, a pallet is placed at the seating of the filling station and is moved forward with a hand-held trolley after filling. By lowering the support arm, the big-bag can be hooked up easily to working height. The loops are hooked into sturdy stainless steel hooks and held by a fuse. In order to reach the rear hooks it is possibly to climb with one foot on the roller track. A step guarantees a safe position. The opening of the big-bag must be pulled over the filling mouth, which is coupled by a pneumatic expansion cuff and ensures a dust-free connection. To achieve this, the cuff is inflated by a pressure air system and a two-hand circuit. After the preparation of the big-bag, the filling process has to be started.

The possible bagging performance depends on the skill of the operator, the product properties, the dosing device and the feeding system. Realistic is an output of six to twelve big-bags per hour. If all labor saving options are selected a big-bag can be filled almost automatically. Manually the big-bag only has to be hooked and closed. The further sequence is automated.

Standard Version: The filling station is already semi-automatic in the standard version. The support arm is motor-driven and can lift already filled big-bags. Thus, both standing and hanging big-bags can be filled as what is required by the product.

The position of the support arm can optionally be scanned. Thus, it is possible to start certain positions automatically. This means that the desired height for the inflation or filling must be learned only once.

The support arm is sealed with stable stainless steel visions. The lifting mechanism as well as the electrical control systems and other components of the filling station are integrated in the interior of the housing and can be reached at any time through four large maintenance doors. If the filling station is equipped with options, these are also invisibly integrated so that the station has a well-designed appearance and minimal welts and dirt spots.

Control: The control system is completely based on Siemens standard components. The verifiable weighing electronics is integrated in the S7-300. Operation is done via a color touch panel. We have also used some frequently used functions on hardware buttons to enable simple and fast operation and also to protect the touch panel.

Control concepts: The system can be used as a stand-alone device or optionally also control an upstream feeding system. Integration into a higher-level control system with Ethernet is no problem.

OPTIONS

Standardized and still-custom made:

OPTION: Inflation device (AV) In order to facilitate the filling of the big-bag, the bag can be inflated and shaped with an inflating device before filling. Thus, fold-free and fast filling of the big-bags is achieved.

OPTION: Inlet flap (EK) In the inlet area, the station can be equipped with an inlet flap in order to allow metered filling of the big-bags.

OPTION: Dust flap (SK) In order to prevent product trickling after decoupling the bag, the filling station can be equipped with a dust flap.

OPTION: Roller conveyor, single (RE) or complete (RS) In order to fully exploit the potential of the system, the use of one or more electrically driven roller conveyors is recommended. The installed roller conveyor can be folded up for cleaning purposes. For transporting the filled big-bags, the filling station can be equipped with further accumulation roller conveyors. With these the operator can close the big-bag while the next big-bag is being filled. In addition, the station can be equipped with a feed roller conveyor on which pallets and big-bags can be prepared so that they are directly available to the operator after the actual filling process.

OPTION: Vibrating table (RT) With the vibrating table, the product can be compressed in the big-bag by gentle shaking. The bulk cone is leveled and the fluidization is reduced. The vibrating process can be triggered by one or several percentage values from the setpoint weight or manually by pushing the button.

OPTION: Wheighing not ready to calibrated (VN); ready to calibrated (VE); calibrated (VG) With a weighing device an accurate filling of big-bags is possible. The resolution of the scale depends on the requirements of the calibration regulations. The weighing unit can be supplied as not ready for calibration,ready for calibration or fully calibrated.

OPTION: PLC control with free (SP) or Ethernet (SE) interface The sequence and weighing control is based on Siemens S7-300 series components. In the simplest version, only the coarse and fine commands of the scale are given as isolated output. All operating data can be reported to a control system via an Ethernet interface. Operation is done via a color touchpanel. The most important data are stored in a recipe management for the different container sizes and products. The filling process is operated by robust illuminated pushbuttons. The control is the standard scope of delivery, the type of coupling is selectable.

OPTION: Label printer (DE) With a receipt printer, batches and weight data can be printed directly and could be attached to the big-bag. This is absolutely necessary e.g. in case of a non-automatic weighing.

OPTION: Displacement measuring system (WS) In conjunction with the PLC control system the displacement measuring system enables the automatic start-up of taught-in positions of the motorized height adjustment. The sequences can thus be further automated and accelerated since the operator is not bound during the travel time.

OPTION: Dosing device (DO) A precise dosing device is necessary for self-operating and calibrated filling. This can be a screw or a suitable sluice. The dosing can be performed via an analog value from the weighing controller.

OPTION: Central aspiration connection (ZA) The filling can be equipped with connection to a central aspiration in order to suck up the displaced, dusty air.

OPTION: Special versions (SX) The standard version is suitable for big-bags of 1000-2000 mm height with 150 – 250 mm loop length and a filling mouth of 300-500 mm diameter. If desired, the height can be varied within certain limits. Customized changes by arrangement.

Filling Big-Bags in the hygienic zone and unload and place them on a pallet in one single workflow

More and more, our customers are asking for the requirement to fill big-bags in a special hygiene area (so-called white zone) and unload them for further transport on pallets lower specified hygiene area (so-called black zone).

In the past, various installations have been implemented, in which an additional transport system and a building-proof lock have been installed. However, all known systems have a number of system-immortal defects.

The individual components of these solutions come from different suppliers, in some cases constructional measures are necessary or extensive interface problem occur. A more or less “unhygienic” transport trolley, which is constantly oscillating between the various hygienic areas or transport rails or tapes are mostly difficult to clean.

From this initial situation, the idea came to integrate the steps of filling, slipping and settling in a compact device so that a complete functional unit was created, which could be easily integrated into the production process. The founded solution was so interesting that it was immediately applied for a patent.

WHITE ZONE

The filling unit is installed in the hygienic lining between the black and white zones. In the white zone the operator hangs in a big-bag that has to be filled and starts the filling process.

As in the case of the existing filling systems, this also runs as far as possible in a highly controlled and automated way. Hanged filling is preferred, but a compaction unit can also be installed if the product requires it. As soon as the filling has reached the specified weight value, the operator can decouple and close the big-bag.

The ejection is now started. The doors open crosswise and the two trawls are swung into the sluice by 90 °. The gates are closed and the two others are opened. The trays can now be pivoted by a further 90 °. The operator in the white area can now equip the second support arm with an empty big-bag.

BLACK ZONE

The big-bag, which has just been filled, is now fully automatically transported to the black side. Depending on the requirements, a lifting table now takes the big-bag onto a pallet or either on a roller conveyor for automatic removal – or the pallet can be picked up by a truck for transport to the warehouse.

The integrated weighing from the support arm monitors the settling process. The hooks are opened only when no load is measured.

Due to the design with two trays with bag suspensions the filling capacity can be increased. A simple design is also sufficient for smaller performances.

The big-bag filling system is suitable for all free-flowing bulk solids to be filled under special hygienic conditions (e.g. Milk and whey powder, flour, food premixes)

OPTIONS

Standardized and still-custom made:

OPTION: Inflation device (AV) In order to facilitate the filling of the big-bag, the bag can be inflated and shaped with an inflating device before filling. Thus, fold-free and fast filling of the big-bags is achieved.

OPTION: Inlet flap (EK) In the inlet area, the station can be equipped with an inlet flap in order to allow metered filling of the big-bags.

OPTION: Dust flap (SK) In order to prevent product rickling after decoupling the bag, the filling station can be equipped with a dust flap.

OPTION: Roller conveyor, single (RE) or complete (RS) In order to fully exploit the potential of the system, the use of one or more electrically driven roller conveyors is recommended. The installed roller conveyor can be folded up for cleaning purposes. For transporting the filled big-bags, the filling station can be equipped with further accumulation roller conveyors. With these the operator can close the big-bag while the next big-bag is being filled. In addition, the station can be equipped with a feed roller conveyor on which pallets and big-bags can be prepared so that they are directly available to the operator after the actual filling process.

OPTION: Vibrating table (RT) With the vibrating table, the product can be compressed in the big-bag by gentle shaking. The bulk cone is leveled and the fluidization is reduced. The vibrating process can be triggered by one or several percentage values from the setpoint weight or manually by pushing the button.

OPTION: Wheighing not ready to calibrated (VN); ready to calibrated (VE); calibrated (VG) With a weighing device an accurate filling of big-bags is possible. The resolution of the scale depends on the requirements of the calibration regulations. The weighing unit can be supplied as not ready for calibration,ready for calibration or fully calibrated.

OPTION: PLC control with free (SP) or Ethernet (SE) interface The sequence and weighing control is based on Siemens S7-300 series components. In the simplest version, only the coarse and fine commands of the scale are given as isolated output. All operating data can be reported to a control system via an Ethernet interface. Operation is done via a color touchpanel. The most important data are stored in a recipe management for the different container sizes and products. The filling process is operated by robust illuminated pushbuttons. The control is the standard scope of delivery, the type of coupling is selectable.

OPTION: Label printer (DE) With a receipt printer, batches and weight data can be printed directly and could be attached to the big-bag. This is absolutely necessary e.g. in case of a non-automatic weighing.

OPTION: Displacement measuring system (WS) In conjunction with the PLC control system the displacement measuring system enables the automatic start-up of taught-in positions of the motorized height adjustment. The sequences can thus be further automated and accelerated since the operator is not bound during the travel time.

OPTION: Dosing device (DO) A precise dosing device is necessary for self-operating and calibrated filling. This can be a screw or a suitable sluice. The dosing can be performed via an analog value from the weighing controller.

OPTION: Central aspiration connection (ZA) The filling can be equipped with connection to a central aspiration in order to suck up the displaced, dusty air.

OPTION: Special versions (SX) The standard version is suitable for big-bags of 1000-2000 mm height with 150 – 250 mm loop length and a filling mouth of 300-500 mm diameter. If desired, the height can be varied within certain limits. Customized changes by arrangement.

Dust-Free and Safe Filling of Big-Bags and Containers

The Big-Bag filling station LFB is a simple and cost-effective system for the dust-free filling of big-bags. Big-bags with or without inliners can be used. However, since the station has to be mounted on the ceiling, it can only be used if the existing ceiling can accommodate the load of the big-bag. The adaptation of the station to differently high big-bags is considerably simplified by the use of differently long adapters for the filling tube. The adjustment to different loops is made by height-adjustable load hooks. For the connection of the big-bag to the filling station, the filling tube is additionally equipped with a manual buckle

For dust-free filling of big-bags the station must be connected to an aspiration filter with a fan whereby the integrated, pneumatically actuated aspiration flap allows a connection of the aspiration.

In order to guarantee straight and stable big-bags after filling, the big-bag is inflated and shaped by the integrated fan before the filling process.

Hygienic and Dust-Free Emptying of Big-Bags with or without Inliner

The Big-Bag emptying station LEB is used to empty big-bags with a pre-filled outlet. The design, which is optimized according to hygienic aspects, makes the emptying station particularly suitable for use in food and pharmaceutical plants.

The design is modular. Different elements and alternatives can be combined to an optimal solution. The base is variable in height and can be supplied as a single unit or as a series unit. It can be supplemented by a variety of accessories, such as:

• Vibrating table with unbalance motor as discharge aid
• Walk floor as discharge aid
• Pneumatically or manually operated clamping device for the big-bag outlet
• Automatic tensioning device for the spout
• Pneumatic or PLC control
• Port construction with electric chain hoists and running kits of different manufacturers and heights (also in EX version)

The big-bag to be emptied is placed on the vibrating table by an electric chain hoist and lifting bar. This electric chain hoist is either mounted with a crane rail to a load-bearing ceiling or to an optional port construction.

Normally the outlet of the big-bag is connected to the emptying station by a pneumatically operated clamping device. After loosening the outlet cords with which the big-bag is closed, the emptying process can start. The tightening device is now activated. During the emptying process, the outlet is automatically tightened so that the maximum discharge cross-section is available.

Since the outlet of the inliner or big-bag is clamped around the connecting pipe of the emptying station, no impurities, which are located on the outside of the big-bag and possibly between the big-bag and the inliner, can get into the product stream.