Bulk Bag Filling,Doebritz,·Airtight bag sealing and closing

Doebritz Bulk Bag Filling

Highlights

• Broad range of powder specifications
• Conveying and palletising solutions to accommodate bag/crate and pallet requirements
• Modified atmosphere packing facility
• Airtight bag sealing and closing
• ” Clean floor” packing design
• Turn-key automated solutions

Applications

Bulk bag packing solutions for the dairy and ingredientsindustry. Improved bag stability during transportation,prolonged shel flife due to modifed atmosphere packing,high product quality and precise specifcation due tometering, flling and sealing solutions.

Conveying concepts

Bag on pallet

• Pallet is allowed in hygiene area.
• Conveyor is allowed in packing room.

A low cost solution for applications with low hygienic requirements to the product.

Bag on conveyor

• No pallets in hygiene area
• Conveyor is allowed in the packing room

A low cost high efficiency hygienic design for bulk bag filling. The bulk bags should preferably have a slip sheet to allow for loading on the pallet outside of the hygiene area. The conveyor transport is less sensitive to thepacking media, and allows packing of the bulk bags, crates, or cartons on the same line.

Bag on carriage

• No pallets, no conveyors in hygiene areafor washable packing rooms.

Meets the highest hygienic requirements, and allows for the bulk bagfilling and outload onto the pallet outside of the hygienic area. Suitable for washable packing rooms.

Suspended bag

• No pallets, no conveyors in hygiene area

Meets the highest hygienic requirements, and allows for the bulk bagfilling and outload onto the pallet outside of the hygienic area. Suitablefor washable packing rooms. Less sensitive to bulk bag stability issues during filling.

Doebrit offers thebulk bag filling solutionsto meet varying customerstandards for hygiene,packaging media, linethroughput, product qualityand shelf life. Doebritzhas developed specificexpertise in tacklingprobably the most criticalproblems of the bulk bagfilling: weight accuracyof the finished bag andmodified atmospherepacking (MAP).

MAP: PRE-gassing

Time saving due to gassingduring transport cycleThe vacuum powdertransport transfers theproduct by means ofa vacuum can wherethe atmospheric air isevacuated, and is replacedwith a MAP gas (nitrogenor carbon dioxide). Oncethe required concentration of the gas is reachednside the vacuum can, theproduct is discharged intothe buffer filling hopper.

MAP: POST-gassing

Lower consumption of hitroger.Post-gassing means enriching the powder with a modified atmosphere gas following the bulkbag filling. In this case,porobes, are introduced into the powder to evacuate trapped air inside the bagand then inject a MAP gas.As a rule, post-gassing consumes 4 times less of hitrogen gas compared tothe pre-gassing process.The post-gassing operations often pertormed immediately prior to plastic inner liner sealing to prevent the MAP gasescaping from the bag.

PRE-weighing

Required sufficient building height to allow for weigh hoppers.High Accuracy of filling.A load cell mounted weigh hopper (loss-in-weight or gain-in-weight) is installedprior to the filling head, and is used forpre-weighing the amount of the powderto be filled into a bulk bag. The powder is delivered to the weigh hopper via a VSD-controlled metering screw, which allowsachieving the bag target weight with ahigh precision.

POST-weighing

High filling rate,Less equipment to maintain, lower capital expenditure.Load cells are mounted on a bag carriage or under the conveyors, depending on the bag conveying concept. The bagis weighed as it is being filled. Post-weighing generally provides for a lessaccurate filling, but allows higher packingrate. Filling accuracy control is anotherapplication of post-weighing, when the post-weighing load cells are usedin conjunction with the pre-weighing equipment arrangement.

Technology highlights

Filling square bags

The Inner plastic liner issecured on the filling headprior to filling by an inflatableclamp.

Bag inflation with air ormodified atmosphere packinggas prior to filling is importantfor the bag stability duringconveying and palletising.Together with bag inflation, thefurther filling process, assistedby base vibration, providesfor a safe process and precise specification of the powderproduct.

Special design filling headswith radial distribution of thepowder allow filling the cornercompartments of the squarebags before the central volumeof the bulk bag.

The bulk bags equipped withslip sheets provide for a cost-effective solution for hygienicfilling and conveying of thebulk bags, while allow loadingthe bulk bags onto the palletsin the warehouse area.

Heat sealing

The bags with inner plastic liner can be heat-sealedstraight after filling to prevent any possible productcontamination or spillage. In cases when pre- or post-gassing is used the heat-sealing can be also preceded by supplying additional amount of the modified atmospheregas above the powder surfaceto create an additional “gasblanket” and prevent the atmospheric air from entering the bag volume.

“Clean floor” concept

A fully hygienic solution for bag transportation on a carriage eliminating conveying systemsfrom the packing room and leaving unobstructed access to the floor area for cleaning for example, between product changes.

Dual filling systems allow simulteneous filling of the twobulk bags at a time. The fillingprocess, being synchronised with the folowing operations of bags closing and conveying allow to double the packing line performance.

Automated palletising

Sophisticated control systemsare developed based onthe systemic analysis of the operational hazards, andprovide for ultimate security ofthe personnel and plant.