Replacement of a bagging line in the dairy industry

Client objectives

The client aimed to replace an ageing bagging line that no longer met productivity standards, particularly in terms of hygiene and precision, as required by the dairy sector. The existing system was unable to meet production rate targets or provide adequate containment of the dust released during packaging.

The main objective was to install a new automated bagging line, capable of filling up to 300 bags per hour, while ensuring:

• High-accuracy dosing for sensitive products such as lactose, milk powder, and whey powder.

• Full hygienic control of the production environment, with Clean-in-Place (CIP) and efficient dust containment.

• Adaptability to the factory’s physical constraints (room dimensions and product entry points).

• Secure open-mouth bagging with hermetic sealing, meeting food industry standards.

The client also required in-line quality control systems, including dynamic weighing (checkweighers) and magnetic detection, to ensure maximum product compliance and automatic rejection of non-compliant bags.

Proposed solution

To meet these requirements, Palamatic Process designed a high-throughput automated bagging line centred around the HBM 1040 system, integrating all packaging and quality control modules. The line achieves a nominal rate of 300 to 400 bags/hour, with dosing accuracy of ±10 g for 25 kg bags.

The installation is fully tailored for use in the food industry, ensuring a high level of sterility:

• Product-contact components in 316L stainless steel, outer structures in 304L stainless steel.

• All subassemblies are removable for manual or automatic cleaning (CIP included).

• Equipment complies with EHEDG standards and ATEX regulations (dust zones).

The dosing station uses a vertical screw with a buffer hopper, equipped with an agitator and a level probe. As an option, a second "fine-dosing" screw is available for precision adjustment, to add the last few grams of missing product and thus increase the production capacity of the bagging line.

Each bag follows the steps below:

1. Automated bag pick-up from a magazine holding up to 120 units.

2. Suction-based bag opening, followed by Bottom-Up filling: the bag is vertically moved during filling to ensure uniform product distribution and reduce dust (for hygiene and product loss).

3. Degassing using porous lances, enabling controlled densification (e.g. for skimmed milk powder or whey).

4. Hermetic sealing via an FTS (Fold, Tape, Seal) system, compatible with kraft bags with PE liners.

5. Dynamic checkweighing at end of line with automatic rejection of out-of-tolerance bags (±40 g).

6. Centralised dust extraction with flow rate of 650 m³/h at 20 m/s, connected via Ø100 mm ducting at the bagging station, ensuring a clean atmosphere around the machines.

The line also features magnetic detection and an integrated sampler to ensure product conformity. All bag formats (length: 800–1000 mm, width: 500–600 mm) are automatically handled via a centralised HMI interface.

Installed equipment and key benefits

HBM 1040 automatic bagging station

• Throughput: up to 400 bags/hour

• Compatible materials: paper, PE, or PP bags (with or without liners)

• Bag sizes: length 500-1000 mm, width 400-600 mm, thickness up to 250 mm

• Bottom-up filling, integrated degassing

• Quick dismantling of conveyors and filling nozzles

• EHEDG & ATEX-compliant

Vertical screw doser and 400L buffer hopper

• Variable-speed screw for precision dosing

• Hopper with agitator and ATEX vent

• Hygienic BFM® connection

• ±10 g dosing accuracy, easy cleaning and disassembly

Degassing station

• Porous lances inserted into the product

• Vacuum-based extraction

• Optimised densification for light powders (400–770 kg/m³)

• Reduced residual air in bags

Bag mouth preparation and sealing station (FTS - MEYPACK)

• Thermal sealing with adhesive tape

• Optional liner cleaning/blowing

• Hygienic sealing, preserving product quality

• Fast format changeover and easy opening without contamination

Dynamic checkweigher with auto rejection

• ±40 g tolerance

• Ensures weight compliance

• Quality assurance at delivery

Centralised dust extraction system

• 650 m³/h at 20 m/s

• Ø100 mm ducting

• Maintains a clean work area

• Reduces airborne dust

Additional equipment

• Removable 316L feed screw with custom support

• In-line 316L sampler

• Robotic arms for bag handling

• Adjustable-height conveyor systems

Conclusion

This fully integrated bagging line is designed to meet the strict hygiene and safety standards of the food industry. With precise dosing, high-speed operation, and smart quality control integration, the client now benefits from safe, efficient, and compliant powder packaging.