National Bulk Equipment, Inc. (NBE) announced a bulk bag filler material handling system that combines integrated automation and performance-proven construction to increase per-tonne process contribution and ensure reliable production operation. From one central, menu-driven HMI (human–machine interface), a single operator can facilitate system-wide functions, including: creating material recipes, metering material feed rates, dispensing pallets, customizing fill/densify cycles by material, weighing filled bulk bags to an NTEP-certified accuracy of +/-.01%, creating operator-specific equipment interaction settings, and generating system-wide control layer data reporting. The integrated automation of NBE bulk bag filling stations increases material delivery accuracy, improves labour utilization, and optimizes total line throughput.
NBE bulk bag filler systems enable packaging and processing operations to run at designed speeds of up to 20,000 pounds (9.072 metric tonnes) per-hour without concern for constant material waste, re-work, or excess labour costs. The cantilevered
lift carriage design on NBE bulk bag fillers has a 4,500-pound (2,041kg) hang weight bag capacity, well beyond that of manual or swing-style designs. Thick-wall structural tubing, heavy-gauge carbon and stainless steel, high motor HP and torque ratings on gear reducers and drives, and process-specific, UL listed PLCs and HMIs built by NBE combine to provide in-use performance advantages of shortened cycle times, sustainable and repeatable process quality, increased reliability, and reduced maintenance.
Rigorous NBE risk assessment procedures work to prevent hazards to those who operate and maintain the equipment while identifying improvements in physical ergonomics and equipment access points. NBE expertise in domestic and international regulatory matters protects personnel and product from potentially harmful contaminants. And, being certified by multiple governmental and third-party standards organizations, NBE design and manufacturing processes provide the assurance of performance-proven construction, streamlined start-up, and advanced productivity.
INNOVATION: FLOUR PRODUCERS IN EGYPT AND TANZANIA WILL FILL FLOUR INTO PP VALVE
BAGS In 2010 the German packaging machine specialist BEHN + BATES, which focuses its extensive expertise exclusively on the food and pet food industry, intensified its contacts with the African flour industry. Its efforts are already seen as being highly successful, according to managing director Ralf Ho¨velmann. On top of this, the company sold the first ROTOSEAL packers for the filling of flour into woven PP valve bags.
The optimum interaction of low-air filling, tight filling spout and efficient product de-aeration is vital for the packing of flour, as one of the basic challenges is the reduction of dust emissions during bag filling. This goal is achieved simply by using a valve bag. Due to the use of a valve, the filling opening is reduced in size. Thus, the bag only absorbs a minimum of air during the packing process. This small quantity is sucked out fast during and after filling. In addition, the filled valve bag has a very stable and compact shape. The end-user gets appealing and clean full bag pallets that can be processed comfortably.
Due to historic developments, in the past flour has always been filled into open-mouth woven PP bags. The reason is obvious: this bag type can be delivered at much more favourable prices by many bag suppliers. After filling, the bags are normally closed by a sewing machine. The end-user re-opens the seam to take the needed product out of the bags that are normally recycled afterwards or even used as building material or for the manufacture of handbags. But it may also happen that bags with impeccable first opening are re-filled by others a second or third time without any knowledge of the original producer who thus cannot even prevent this misuse. The result may be that the printed bags contain products of minor quality or completely different products that do not at all correspond to the bag imprint.
In order to avoid the possible misuse and to assure the quality of the original products the valve bag presents an excellent alternative in comparison to the open-mouth bag.
After filling, the bag valve is hermetically sealed. Opening the sealed bag valve means that the bag is destroyed and it is therefore impossible to re-use it.
In addition, hermetically tight bags are of immense importance to flour producers for reasons of quality. After all, the filled flour must not absorb humidity in order to reach an optimum suitability for storage and long storage times. At this point, the valve bag made of polypropylene becomes attractive: it is as tight as a woven PP open-mouth bag, which ensures the optimum product protection together with improved compact bag shapes. The raw material needs are low as thinnest foils are already extraordinarily tear-resistant. Under consideration of the globally requested sustainability of packages the PP valve bag does not only score with regard to material cost savings but also as to its recyclability.The PP-woven bag can be completely transformed into PP granules thus being reusable.
THE MACHINE TECHNOLOGY — SOLUTION-ORIENTED IF ADAPTED TO PRODUCT AND BAG
Based on the bag alone, the flour producer does not get the requested results. He also needs the appropriate equipment, and this can be delivered by BEHN + BATES.
The African flour producers requested hourly outputs of 1,200 up to 1,700 bags with bag weights of 25 and 50kg. Early project studies revealed that only the valve bag would come
under consideration due to its easy handling. The customers were even so enthusiastic about the new PP valve bag that they decided to produce the required bag quantities in their own bag manufacturing facility affiliated to the flour production. The existing production lines for PP woven flat bags are being extended for the manufacture of valve bags with weldable valves.
Taking into account the requisite high hourly outputs, BEHN + BATES offered the rotating ROTOSEAL system equipped with three to ten filling spouts depending on the output. In comparison to conventional inline packing plants, the filling spouts are mounted on a rotating machine frame. Therefore less space is required to reach higher packing outputs with more filling spouts. In comparison only: the output of a conventional inline or open-mouth bag filling installation in the same place would be half as high.
The two customers ordered different machine versions: the ROTOSEAL system delivered to Tanzania will be equipped for manual operation i. e. the operating personnel manually places the empty bag onto the filling spout while the further filling and closing process is carried out automatically. The filled and closed bags are discharged on a conveyor belt and transported to the loading or storage area. The Egyptian flour mill decided in favour of the fully automatic variant with RADIMAT bag applicator for the fully automatic application of the valve bags onto the filling spouts. It is specifically equipped for the combination with rotating high-output filling plants.
As both mills only fill wheat flour BEHN + BATES will implement the impeller filling system that is especially suitable for the filling of hermetically tight and difficult-to-deaerate bags due to the special impeller geometry and the low air consumption during the filling process. A special inflatable sleeve ensures that the bags are filled in an absolutely clean way. It completely seals the bag valve during the filling process thus preventing the product from dropping out of the filling opening. The contamination of the filling area caused by product dusts is minimized. This also leads to a reduction of health hazards the operating personnel are normally exposed to during the filling process because of product dust.
Due to the cleanliness — not only required by the end-users for the comfortable full bag processing — ambitious customers demand the dust-tight closure of the filled valve bags that is also integral part of the BEHN + BATES ROTOSEAL system: the bag is closed directly after filling by the closing unit arranged above the filling spout. The valve is sealed hermetically tight with the help of ultrasound energy. Even the smallest product particles cannot drop out of the bag valve. Thus, one of the customers’ most essential requests is fulfilled: the packing environment is clean and free from dust. Plant components as conveyor belts and palletizers are not contaminated by product deposits. Wear and tear as well as costly and time-intensive maintenance works are reduced to a minimum. At the same time high packing outputs as well as closing rates of more than 99% are reached.
THE CONCLUSIONThe product packaging is an essential part of the value-added chain in the food and thus also in the flour industry. The new packaging concept presented by BEHN + BATES is aiming at the use of valve bags as replacement for the famous open-mouth bags, keeping the proven PP cloth as bag material. It results in new prospects: the original products are better protected, as the re-use of the bag is almost impossible. The box type valve bags have an optimum shape thus being easy to palletize and reaching a good advertising impact. High bagging outputs are attained with just one filling machine operated manually or automatically. If customers decide in favour of an expandable ROTOSEAL packer, additional filling spouts can be retrofitted for higher tonnages that might be required in future. At the same time, the cost savings might be considerable, as the upstream and downstream components, such as the product and the bag feed or the full bag discharge line, do not need any alteration.
Only a packaging material that has been carefully chosen on behalf of the user’s needs and the marketing targets — combined
with the adequate filling technology — can achieve the desired results in today’s ever-more-competitive environment.
In order to meet all the modern market requirements that accompany high machine outputs. BEHN + BATES presented the ROTOSEAL system, succeeding in convincing the first flour producers in emerging African countries of its technology. The company accepts that its ambitious marketing targets can only be reached by a new packaging solution as well as by a proven, solid and modern filling technology — a technology that, of course, has its price but at the same time offers the requested reliable product processing to the customers.
Mondi provides sustainable bag solutions for future generations
Awareness of environmental issues is constantly increasing and waste management directives are becoming more and more restrictive throughout the world. Waste prevention, re-usage, recycling and composting are the key words for sustainable packaging in the future.
To support the challenging sustainability agenda of customers across all industries, Mondi Industrial Bags developed its Green Range® of industrial bags optimized to save natural resources, reduce waste and provide a measurably reduced environmental footprint. The solutions cover various environmental opportunities such as resource economies with one-ply bags, intelligent waste management with biodegradable bags and PEFCTM/FSC® certified bags for responsible sourcing.
SAVING RESOURCES WITH ONE-PLY BAGS
ONE, Mondi’s one-ply bag solution, significantly saves resources and waste by reducing packaging weight and olume compared with two-ply 70gsm bags for 25kg and 35kg. With ONE and ONEPlus, customers benefit from up to 20% lower grammage, less waste and tangible cost savings e.g. in transport and efficient filling. ONE is especially suited for high- speed filling and is made of 110gsm high- performance paper. The excellent porosity of the paper ensures quick de-aeration of the bag while the outstanding strength and stiffness of the paper guarantee a smooth application on the filling spout and high handling resistance of the filled bag. ONEPlus, the one-ply solution featuring a film for enhanced moisture protection is available with a classic PE film or a biodegradable film.
INTELLIGENT WASTE MANAGEMENT WITH BIODEGRADABLE BAGS
Terra Bag is the first biodegradable valve bag with certified compostability. The compostable paper bag features an optional biodegradable film for humidity protection. Through the different types of Terra Bags (one or two plies, with or without film), fillers
can now select the bag solution best suitable for their filling equipment and logistics — and at the same time underline their commitment for sustainable development. With either composition the entire bag is biodegradable and optimized for industrial composting — turning waste into valuable humus. Life-cycle analyses of bioplastics show that CO2 emissions can be up to 20% lower than those for commodity polymers1, when properly disposed of in industrial composting facilities. The
‘OK Compost’ logo can be applied to the customers’ bags thus clearly showing their green commitment and making the compostable bags easily identifiable for further waste treatment. 1 Source: European Bioplastics
RESPONSIBLY SOURCED FSC® AND PEFCTM-CERTIFIED BAGS
Mondi’s FSC® and PEFCTM certified bags present clear, informative labelling, and have already built a loyal customer base since their launch in 2008. Both, the FSC® (Forest Stewardship Council) and the PEFCTM (Programme for the Endorsement of Forest Certification) promote sustainably managed forests through independent third party certification. This offers customers and consumers the option to choose products from environmentally and socially responsible and economically viable forestry. Both schemes are internationally recognized.
ABOUT MONDI INDUSTRIAL BAGSMondi Industrial Bags, a Business Unit of the Europe & International Division, is a leading international producer of industrial paper bags, selling around four billion bags per year.
Thanks to its broad range of bag specifications, Mondi Industrial Bags serves major industries including cement and building materials, chemicals, food, feed and seed. The Business Unit operates a dense sales and service network as well as its Bag Application Centre, where researchers develop and test innovative packaging solutions.
ABOUT MONDIMondi is an international paper and packaging group, with production operations across 31 countries and revenues of €6.2 billion in 2010.The Group’s key operations are located in Central Europe, Russia and South Africa and as at the end of 2010, Mondi employed 29,000 people.
Mondi is fully integrated across the paper and packaging process, from the growing of wood and the manufacture of pulp and paper (including recycled paper), to the conversion of packaging papers into corrugated packaging, industrial bags and coatings.The Group is principally involved in the manufacture of packaging paper, converted packaging products and uncoated fine paper (UFP).
Mondi has a dual listed company structure, with a primary listing on the JSE Limited for Mondi Limited under the ticker code MND and a premium listing on the London Stock Exchange for Mondi plc, under the ticker code MNDI.The Group has been recognized for its sustainability through its inclusion in the FTSE4Good UK, Europe and Global indices in 2008, 2009 and 2010 and the JSE’s Socially Responsible Investment (SRI) Index in 2007, 2008, 2009 and 2010.
New ‘Rise and Fall’ bulk bag filler from Spiroflow
A Middle East-based supplier of a mixed fruit and nut product required a means of loading 300kg batches into bulk bags with no damage. Its product contains whole walnuts that are particularly fragile. Spiroflow has a long history of developing its ranges of bulk bag fillers and dischargers to meet the needs of individual customers. As marketing manager, Keith Simpson, confirms, “This challenge was an excellent opportunity for us to apply our ingenuity and vast bulk materials handling experience. The result is a new ‘Rise and Fall’ model for our Bulk Bag Filler range”.
To avoid fruit and nuts having to fall the full height of an empty Bulk Bag, the bottom of the empty bag is raised up to just below the outlet of the filling tube. The gap, between the end of the tube and the bottom of the bag, is just enough to allow the nuts to gently flow into the bag without damage. The bag is then lowered slowly to allow filling to continue. As anyone involved with dry particulate materials will readily appreciate, the lowering of the bag controls the flow of the fruit and nuts down the filling tube due to the ‘self-choking’ action caused by the natural ‘angle of repose’ of the product as it exits the tube and spreads out. Accordingly, the bottom of the bag is incrementally lowered until it is filled to the desired weight. Following gentle vibration, the bag is ready to be removed on a pallet by a forklift truck.
For this application, a total of six ‘Rise and Fall’ Fillers were supplied. Four with load-cell weighing, to OIML standards, and gentle vibration to consolidate the bag contents. Two were supplied just with vibration but
no weighing. Vibration not only makes the bags aesthetically pleasing but, more importantly, safe to handle, transport and store. The four fillers with the weighing capability were supplied with printers which generate labels indicating weight, date, time and batch number.
Of course the new ‘Rise and Fall’ model can incorporate all of the standard ‘Spiroflow’ bulk bag filler options such as pallet dispensers, pallet delivery conveyors, bag inflation, weighing, displaced air filtration, vibration and automatic removal of filled bags.