Economic big bag unpacking with the SmashR Eco

In the process of manufacturing food syrups, the customer uses big bags of sugar and maltodextrin. During storage and transport, some of these big bags are subject to variations in temperature and humidity, causing the product to swell despite the addition of an anti-caking agent in their formulation. This compaction considerably complicates their emptying at the stations provided for this purpose.

When the blocks of hardened sugar obstruct the flow, operators must intervene directly at the big bag emptying station, often hitting the material with tools such as mallets or metal bars or even having to cut open the big bags with a box cutter or other sharp tools. These repeated actions expose workers to the risk of injury, particularly musculoskeletal disorders and accidents. Similarly, the quality of the sugar can be affected by the presence of foreign bodies or pieces of big bag fabric due to ‘unauthorised’ cutting. In addition, the use of inappropriate tools to break up agglomerates increases the risk of contamination of the product by foreign bodies, jeopardising the quality of the finished product.

Prolonged and repetitive interventions also delay the production process by lengthening emptying times, which reduces the overall throughput of the line and can lead to production stoppages.

Faced with these problems, the customer was looking for an economical solution that guaranteed 100% resumption of powder flow without manual intervention. The challenge was to eliminate risks for operators and ensure optimal product quality by eliminating any risk of contamination.

To address the problems of bulking big bags of sugar and maltodextrin, Palamatic Process proposed the integration of a SmashR Eco, a hydraulic lump breaking system specially designed for powders that tend to form lumps.

The SmashR Eco is an economical solution for automated deagglomeration that allows massaging the big bag at different heights thanks to an integrated lifting table with a stroke of 870 mm and a lifting capacity of 2 tonnes. This system offers a pressure force of up to several dozen tonnes, applied via high-powered hydraulic leaves, guaranteeing efficient re-flowing of the product without human intervention.

The device operates according to several massage cycles that can be adapted according to the degree of bulk in the big bag:

Standard mode:

activation of the hydraulic leaves on two sides, with a number of massage ‘touches’ of 3: top of the big bag / middle of the big bag and bottom of the big bag.

Intensive mode:

the operator can turn the big bag over using a forklift to treat the other sides of the big bag.

Automatic height management:

the lifting table is equipped with a laser sensor that allows the adjustment of the height and therefore the number of ‘touches’ according to the mass taken.

The design of the leaves hinged at a pivot point ensures massage of the big bag without risk of tearing the fabric. This unique concept is the key element in choosing the SmashR solution.

Our client's decision to install the SmashR Eco in its logistics area means that big bags can be processed just before they are used in the emptying stations. This upstream location in the production area ensures a smooth and continuous production flow. This system completely eliminates the need for manual intervention, thereby reducing the risk of accidents for operators and the risk of product contamination associated with the use of unsuitable tools.

The installation set up is based on the integration of the SmashR Eco, a piece of equipment designed for the crushing and deagglomeration of big bags presenting mass take-up. This solution is based on several technical elements ensuring optimal and secure operation.

1. SmashR Eco - High performance hydraulic crushing

Standard mode:

3 massage buttons and progressive pressure on the two opposite sides of the big bag.

Intensive mode:

5 or 6 massage buttons + option to turn the big bag over with a quarter turn using a forklift for complete treatment.

• High-pressure hydraulic doors: apply a force of several tens of tonnes to the big bags in order to break up the lumps of sugar or maltodextrin effectively. => guarantees extraction
• Motorised lifting table: allows the massage height to be increased and adjusted according to the size and dimensions of the big bag using a laser sensor.
• Adjustable processing modes:

2. Automated massage cycle management system

• Ergonomic control interface allowing selection of different pressure levels and cycles according to the degree of compaction of the product via the ergonomic and simplified touch screen.
• Automatic control of cycles guaranteeing homogeneity of treatment and the absence of manual intervention.

3. Advantages of the SmashR Eco Palamatic Process solution

• Increased operator safety: elimination of dangerous manual interventions (striking, shaking, handling and cutting big bags directly, using the forklift as an anvil).
• Preservation of product integrity: elimination of the risk of contamination by foreign bodies by avoiding the use of unsuitable tools or cutting big bag liners.
• Optimisation of production flow: reduction of emptying times thanks to preliminary preparation of big bags in the logistics area.
• Adaptability to different types of big bags: flexible solution with automatic adjustment of pressure and height according to the packaging.
• Quick and easy installation: plug and play equipment, easily integrated into an existing line.

In short, faced with the critical issues of safety, quality and fluidity linked to the mass intake of sugar and maltodextrin in big bags, the integration of Palamatic Process' SmashR Eco has provided a comprehensive and effective solution. This case study demonstrates how an automated and economical lump breaking solution, judiciously installed upstream of production, not only makes it possible to eliminate dangerous manual interventions and preserve the integrity of the product, but also to significantly optimise the rate and continuity of the process. The SmashR Eco is thus a major asset for making operations in the food industry more reliable, secure and profitable.