Automation of bag emptying for the preparation of powder premixes in the manufacture of technical oils and greases

As part of the modernisation of its production lines at its site specialising in synthetic chemistry, the client, a manufacturer of industrial lubricants, wished to automate and improve the reliability of the operations involving the emptying of sebacic acid bags, followed by the filling of stainless steel IBC containers, with a view to ensuring a controlled feed into the production reactors.

The main objective was to eliminate repetitive operator interventions, guarantee product integrity, control dust emissions and ensure full traceability of packaged batches. The automation sought also aimed to increase production rates whilst maintaining a high level of safety and cleanliness, which are essential for the handling of chemical powders used in complex industrial formulations.

The study therefore focused exclusively on the container packaging area, upstream of the pneumatic transfer systems to the reactors.

To meet the identified requirements, Palamatic Process has designed a complete, automated system, centred around a system for unpacking and packaging into stainless steel IBC containers.

The line is fed by a motorised inclined conveyor which ensures a steady supply of sebacic acid bags to the Minislit 3000 automatic bag-opening machine. This model is designed to handle different types of bags without any prior adjustment, at a rate of up to 5 bags per minute. The bags are opened by a band saw which cuts them along three sides, whilst a patented flipping system ensures they are completely emptied. The empty bags are then automatically compacted to minimise waste volume.

The emptied product is directed into a hopper fitted with an integrated dust extraction system, ensuring clean, emission-free operation in the workshop.

The containers are filled via a sealed connection head of the IBCfill® 2 type, fitted with a telescopic tube featuring anti-static metal spirals. This system channels the product whilst ensuring an airtight connection between the hopper and the container, thereby preventing any loss of material. The filling cycle is fully automated, with pneumatic cylinders controlled by sensors, level monitoring via sensors and the option to integrate a weighing system to ensure load compliance.

The containers used, with a capacity of 1,800 litres and made from 304 stainless steel, are designed with 60° slopes and rounded corners, facilitating complete emptying and minimising the risk of product retention. Handling is made easier thanks to a reinforced base compatible with forklift trucks and pallet trucks.

The entire installation is secured by a mesh enclosure fitted with sensor-operated doors, interlocked with the emergency stop circuit. The automation system is based on a control cabinet incorporating a Schneider Electric PLC, ensuring the coordinated control of the conveyors, the Minislit, the filling head and the safety devices.

This design not only eliminates the need for repetitive operator intervention, but also increases the packaging rate, whilst ensuring consistent traceability and quality of the prepared batches.

• Fully automated bag removal and container filling.
• Increased throughput: up to 5 bags per minute.
• Enhanced safety thanks to dust containment and the mesh enclosure
• Reliability and robustness: equipment designed for intensive and long-term use.
• Improved ergonomics: elimination of repetitive tasks and heavy lifting.
• Quality control: batch traceability, controlled filling and a clean working environment.

This design not only eliminates the need for repetitive operator intervention, but also increases the packaging rate, whilst ensuring consistent traceability and quality of the batches prepared.