Automated emptying of sugar bags – Extension of a robotic line for feeding a bag emptying machine

Customer objectives

The client, a food manufacturer specializing in the production of cola-based soft drinks, receives sugar in palletized bags in shipping containers. The main objective was to modernize and automate the entire line for unpacking and transferring sugar to the dissolution area in order to increase throughput, reduce the drudgery of manual operations, and improve food safety.

Already equipped since 2008 with a MINISLIT automatic bag emptier for opening and emptying sugar bags, the customer wanted to take advantage of recent technological advances, particularly in industrial vision and robotics, to make its process more reliable.

The installation also had to take into account the specific geographical constraints associated with an island location:

• supply logistics,
• temperature and humidity variations,
• limitations on heavy maintenance work.
   

The proposed solution

To meet the objective of fully automating the sugar bag emptying line, Palamatic Process proposed an integrated solution based on three main pieces of equipment:

• ​​​​a depalletizing robot with 3D vision,
• a MINISLIT® 3000 automatic bag emptying system,
• a dense phase pneumatic transfer system to buffer silos.
   

The heart of the installation is the Sackbot® 200-M3 robotic depalletizing system, equipped with a 3D vision module. This robot is capable of identifying the position of the bags, regardless of their orientation or the configuration of the pallet. It also allows them to be gripped with a clamp specially adapted to the weight and texture of the sugar bag. This robotic equipment manages the automatic removal of empty pallets and cardboard spacers, optimizing the system's autonomy.

The bags are then continuously transferred to the MINISLIT® 3000 automatic bag emptier, designed for a rate of 6 bags/minute. This model guarantees the clean opening and emptying of bags without human intervention, while limiting dust emissions. It is equipped with an integrated dust removal system and a stainless steel safety screen to remove any foreign bodies before transfer.

The sifted sugar is then automatically transferred by dense-phase pneumatic transport to the intermediate silos. This technology, chosen for its low air consumption and its ability to preserve particle integrity, ensures an average flow rate of 4.5 t/h over a distance of approximately 35 meters. The system incorporates level sensors for automatic control of silo loading.

The entire line operates in a closed cycle, controlled by an industrial PLC and a local HMI interface with remote supervision. The design complies with ATEX Zone 22 standards (excluding the robot), given the potentially explosive nature of sugar dust.

 

Industrial equipment comprising the installation with the advantages of the Palamatic Process solution

1. Sackbot® 200-M3 depalletizing robot with 3D vision
Palamatic Process integrates the Sackbot® 200-M3 depalletizing robot with 3D vision to automate bag emptying. This solution guarantees speed, precision, and safety while reducing the drudgery of manual operations. Combined with the automatic bag emptying and pneumatic transfer systems, it offers a high-performance, hygienic, and fully robotized line.

• Automatic depalletizing of bags using articulated claw grippers.
• Onboard 3D vision for precise bag location and geometry reading.
• Gripping possible on mixed or partially empty pallets.
• Speed: up to 8 to 10 bags/minute depending on format.
• Integrated empty pallet and spacer management function.
• Optimized autonomy for stand-alone operation.
   

2. MINISLIT® 3000 automatic bag emptying machine
The MINISLIT® 3000 automatic bag emptier opens, cuts, and empties bags without human intervention. With a rate of up to 15 bags/minute, it guarantees a clean process thanks to its stainless steel screening and integrated dust removal system. Compact and secure, it easily integrates into automated lines for maximum productivity.

• Opening, cutting, and emptying of bags without human intervention.
• Nominal speed: up to 15 bags/minute.
• Integrated screening system: 2 mm stainless steel mesh for removal of foreign bodies.
• Integrated dust removal: centralized filtration for a clean atmosphere.
• Sealed enclosure with secure access for maintenance.
• Siemens S7 PLC + touchscreen HMI.
   

3. VFlow® dense phase pneumatic conveying
VFlow® dense phase pneumatic conveying is specially designed for transporting sensitive powders such as crystallized sugar. It delivers a flow rate of 4.5 t/h over a distance of 35 m with low compressed air consumption. Its stainless steel piping and automatic self-cleaning cyclofilter guarantee a reliable, hygienic, and energy-efficient process.

• Conveyor technology suitable for sensitive powders (crystallized sugar).
• Flow rate: 4.5 t/h over a distance of 35 m.
• Low compressed air consumption (~0.7 m³/min).
• Stainless steel piping Ø100 mm.
• In-line cyclone filter with automatic cleaning.
   

4. Intermediate buffer storage silos
The intermediate buffer storage silos (2 x 3 m³) ensure continuous, automated feeding of the dissolution line thanks to their level sensors. Their sloped bottom promotes gravity flow, while the inspection hatches and butterfly valves facilitate cleaning. Made of hygienic brushed stainless steel, they guarantee the safety, reliability, and cleanliness of the process.

• Capacity: 2 x 3 m³.
• High/low level sensors for automation of the filling cycle.
• Sloped bottom for gravity flow to the dissolution line.
• Inspection hatches and manual drain butterfly valves for cleaning.
• Hygienic design with brushed stainless steel interior/exterior.

5. Automation & supervision

• HMI interface for overall line control.
• Programmable product recipes.
• Cycle traceability (time, batch, number of bags).
• Remote maintenance diagnostics

Advantages of the Palamatic Process solution

The solution developed by Palamatic Process offers much more than simple automation: it combines performance, safety, and hygiene to optimize the entire bag emptying process. Thanks to the integration of the Sackbot® 200-M3 robot and associated equipment, the installation guarantees reliable operation, complies with ATEX standards, and is designed to reduce drudgery while maximizing productivity.

With a 100% automated line that complies with ATEX and is designed to guarantee hygiene, safety, and performance, Palamatic Process transforms the constraints of bag emptying into a real lever for productivity and competitiveness:

• Complete automation of the emptying line, from unloading to process feeding
• Guaranteed hygiene: all contact points are designed to limit cross-contamination and loading errors
• ATEX compliance for safe operation in dusty areas
• Reduced operator strain thanks to the elimination of manual handling 
• Increased productivity through higher throughput and fewer stoppages
• Integrated customer feedback: natural evolution from a MINISLIT semi-automatic bag emptying line to a fully robotized line