A bagging line in a production plant is closely tied to the associated production and distribution processes, including the upstream and downstream logistics. This may have an impact on the availability of the entire production plant and must therefore be taken into account in evaluating and designing the line.

1. Digital Re-print - March | April 2010
Feature title: Designing bagging lines to meet requirements
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2. Bagging Feature
New palletiser from EHCOLO
- With servo control and energy recovery system
As the first and only in the world, Ehcolo is now supplying its palletisers with servo control and kinetic energy recovery system,
which collect all the motors braking energy for re-use, so we can supply the first ”green” palletiser.
Products: all bag types and sizes.
Capacity: types from 300 to 2500 bags per hour.
We are also supplying robot palletisers.
We are also supplying turn-key bagging-palletizing–wrapping lines for any products.
by Peter Naef, Grain Processing Division, Bühler, Switzerland
EHCOLO A/S, Smedevej 10, DK-6683 Fovling
Tel. 75398411 E-mail post@ehcolo.dk Website: www.ehcolo.dk
Designing bagging lines Ehcolo_AD_GFMT1002.indd 2 25/03/2010 11:47
SACK-FILLING SYSTEMS
to meet requirements DESIGN,
DEVELOPMENT
Specifying and designing bagging lines for the food processing industry PALLETISING SYSTEMS AND MANUFACTURE
CUSTOM-MADE PACKAGING SYSTEMS
A for low-fat dehydrated milk to wet sand
bagging line in a production plant In the grain-based food sector, bags are One key requirement is high operating
is closely tied to the associat- made almost exclusively of paper, woven reliability and maximum flexibility.
ed production and distribu- plastic or textiles. A large number of suit- Due to the complexity of a bagging line, in plastic or paper sacks
tion processes, including the upstream able bag and bag closure types are available, the individual components must be of high from tubular film to pre-made sacks
and downstream logistics. This may such as stitching with the optional addition quality and carefully matched in order to
have an impact on the availability of of tape-bound closures or a folding device; ensure high operating reliability and maxi-
with or without gussets
the entire production plant and must gluing; or sealing. Each method has its specific mum availability. from 1 to 50 kg
therefore be taken into account in advantages and disadvantages. Today, automatic bag attachers and bag by weight or volume
evaluating and designing the line. But whatever bag and closure type is chosen, transfer and spreading units are normally
this decision will always have an impact on the part of the standard equipment of bagging from 100 to 2500 sacks per hour
To achieve the best possible perform- entire bagging line and its design. In addition, the lines. If the proper bag materials are used, with any closure
ance, it is essential that the production bag materials used in fully automatic bagging lines an automatic bag attacher will be capable of
management and distribution department must meet higher quality requirements. processing woven plastic bags as well as the
palletised in any pattern
cooperate closely in defining the basic con- paper bags commonly applied. with water-resistant stretchhood
cept of such a line. Operating reliability A bag transfer and spreading unit trans-
The ”bag” as a container for packing and automation fers the bag from the bagging spout and
foods offers various benefits. In the design and specification of a bag- feeds it automatically to the bag closing
It allows an attractive presentation of the ging line, it is essential to satisfy the specific system. Both automatic units increase the
ARODO BVBA, Hoge Mauw 740, 2370 Arendonk Belgium
product, is a significant advertising medium plant requirements. But a number of funda- throughput capacity and reduce the man-
power requirement. Both units can be inte-
Tel. +32 14 67 23 32, Fax, +32 14 67 17 60
and reflects the quality of the product it mental requirements must always be met by
contains. bagging lines in food applications. grated either with a single-bag packer or in a www.arodo.com
184x134_UK.indd 1 9/06/09 13:04
28 | march - april 2010 Grain &feed millinG technoloGy Grain &feed millinG technoloGy march - april 2010 | 29

3. Bagging
Feature Feature Feature Feature
This is done fully automatically and with- In addition, the
out manual intervention. manpower costs of
Moreover, these systems allow fast error a block storage sys-
diagnostics of the entire bagging line, which tem are very high,
slashes line downtimes and makes it easier since several forklift
to familiarise new employees with bagging drivers are needed
operations. simultaneously.
The drawbacks
Balanced warehouse logistics of rack stor-
The performance and cost-effectiveness age systems are
of a bagging line also depends on the similar to those
warehousing system applied, which must be of block stor-
matched to the specific needs. age installations,
More and more, the method of direct though they do
loadout straight from the bagging line is being allow FIFO oper-
abandoned. ation to some
On the one hand, this is due to the high extent. They also
bagging capacity required. On the other permit order-picking thanks to the access access to each individual item must be
hand, the direct linking of bagging and loa- they allow to individual items in combina- possible at any time.
dout and the increasing number of loadout tion with flow-rack or high-bay storage
variants with the related downtimes make systems. Over 100 years of experience
this former approach uneconomical. For many packing installations, a flow- Bühler AG is a global technology group
An analysis of the plant-specific require- rack store will be found to be an adequate and a system partner for the supply of plant,
Parameters Profitability ments is a prerequisite for selecting the solution. equipment, and process know-how to the
The main company-specific parameters The profitability of a bagging line depends adequate warehousing concept, which must Flow-rack storage systems offer the food processing industries. Buhler has been
determining the selection of a bagging line are: essentially on the following factors: In the food sector, hygiene-related legal also take account of the plant’s uptime and following advantages: FIFO is possible; the supplying complete food processing plants
requirements are becoming increasingly therefore its profitability. space utilisation rate is high; the capac- for over 100 years and bagging lines in all
• Output per week (exclusive of • Investment matched to the
products shipped in bulk, Big actual requirements. stringent. A number of warehouse variants are pos- ity and uptime are high; the manpower capacity ranges for more than 40 years,
Bags, and small packages). They must be satisfied by applying the sible, which all have their specific advantages requirement is low; the capital cost is especially for meeting the stringent standards
• Employment of operating
proper system design and preventing prod- and disadvantages. relatively low, with an excellent price-to- of the food processing industry.
• Number of products and their personnel carefully planned.
respective quantities, plus uct contamination. In this area, a substrac- Today, very many plants apply the block performance ratio; and supply readiness
• Level of automation matched
precise product specifications tive bagging scale with direct bag filling will storage method due to its low capital cost. is optimal. Fully automated high-bay ware-
to specific needs. More InforMatIon:
including bulk densities. significantly reduce the risk of contamination But it also has drawbacks: The first-in- houses are the Rolls Royces in the field of
• Highly accurate bag weights. Buhler Switzerland
• Actual working hours compared to conventional batch bagging first-out (FIFO) approach is not possible; a warehousing.
• Low energy consumption. scales. Another advantage of substractive large surface area is needed, with poor space But despite their outstanding advan- Uzwil
per shift and day.
• Low cost of expendable materials. weighing is that every actual filling weight is utilisation; automatic inventory control is not tages, they are too expensive and com- Switzerland
• Number of workdays per week. Tel: +41 71 9551111
• High uptime and flexibility. registered and corrections can be made as possible; the storage and retrieval capacity is plex for many plants. A high-bay storage Fax: +41 71 9556611
• Number of bag weight and
• Short times for product and bag required even with fast bagging cycles. low; and the number of possible variants or system is especially suitable if a very large Email: milling@buhlergroup.com
product changes per shift.
weight changes, or none at all. items is low. number of items must be stored and if
• Shares of the different bag
weights of the entire product • Best possible design of the Bag compacting &
volume to be packed. entire logistics chain from bag centralised control
warehouse to loadout point. New, mechanical compacting systems
• Minimum storage time in
• Minimised maintenance allow more efficient reduction of the volume
storage and bagging bins (for
and servicing. of bagged product and give bags a more
“deaerating” or reducing the
volume before packing). stable form.
At the same time, this reduces the han-
dling volume.
As in other areas, automation and cen-
bagging carrousel equipped with three, four age systems and of bagging bins and their tralised control are becoming increasingly
or six spouts. dischargers. important for minimising the manpower Terminology / A-Z listing / Products & Services
The feed and weighing system selected requirement of bagging lines. A state-of-
International Organisations / Country data sheets
Accuracy and hygiene must be matched to the product in question. the-art control system will enable an entire
Modern bagging lines are characterised Despite optimal electronic weight monitor- bagging line including the automatic palletiser Equipment guides, including Hammermills, Extruder
by their very high bagging weight accuracy ing and automatic weight correction, it is to be controlled and monitored from a single & Expander, Pellet Press & Storage.
and their top hygienic standard. To achieve of advantage to install a check scale with an touch-screen terminal.
accurate and consistent bagging weights, a automatic scrap bag ejector between the Such control systems are capable, say, of
product feed system operating at a constant bagging line and the palletiser or loadout selecting a different bag weight together with PRE-ORDER YOUR 2010/11 EDITION TODAY
capacity is needed in addition to specialist point to ensure complete monitoring of the the appropriate bag sise or of changing the
know-how in the design of product stor- packed bags. bag layer pattern created by a palletiser.
30 | march - april 2010 Grain &feed millinG technoloGy Grain &feed millinG technoloGy march - april 2010 | 31

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In this issue:
• Designing bagging
• Roller Mill lines to meet
• Contact the GFMT Team
Grinders
requirements
Advantages, limitations
- Specifying and
and how roller mill
designing bagging lines
grinders are changing
for the food processing
for the better
industry
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