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.