Hygienic automated bagging line with CIP for dehydrated yeast (powder and flakes)

Client objectives

As part of its industrial optimization strategy, a Canadian manufacturer of dehydrated yeast in both powder and flake forms aimed to drastically reduce the cleaning time for its bagging line. Previously, two operators were required to fully dismantle the line for thorough cleaning every weekend. This task demanded 4 hours of labour on Fridays and led to 2.5 days of downtime, resulting in significant production losses.

The product is particularly sensitive to moisture and bacterial growth, which required the bagging station to meet hygiene standards equivalent to those in the pharmaceutical sector. Packaging had to occur immediately after drying, with no intermediate storage stage. Preventing any product retention was therefore essential.

Key technical requirements

 

• Automated multi-format packaging (10, 15, and 25 kg): The line needed to offer production flexibility with fast changeovers between bag sizes, without complex manual adjustments or mechanical disassembly, ensuring high efficiency.

• Bag-in-box configuration: To reduce contamination risk, protect the bag from mechanical damage, and optimize transport and storage, the system needed to include automated cartoning. This secondary packaging format also offers a more hygienic and ergonomic final product, ready for industrial use.

• Preservation of flake texture: Given the fragile nature of the product, the packaging line needed to avoid compaction and heat generation. The filling process required gentle, controlled handling with no free fall, to maintain the physical integrity of the flakes and achieve optimal density within the bags.

• Complete Clean-in-Place (CIP) system: To ensure optimal hygiene, the line had to include a fully automated washing circuit with pre-rinse, alkaline and acid washing, and hot filtered air drying. The goal was to restart production within four hours with no residual moisture or cross-contamination.

• High level of containment: To prevent powder dispersion, ensure operator safety, and maintain hygienic standards, the equipment required containment features at every process step (sealing sleeves, enclosed filling zones, source dust extraction), enabling compliance with health and safety regulations.

• Centralized control and integrated traceability: The full line had to be automated and managed via an ergonomic operator interface capable of controlling product recipes, monitoring CIP cycles, logging production data, issuing maintenance alerts, and adjusting quality parameters.

Proposed solution by Palamatic Process

To meet this Canadian yeast manufacturer’s specifications, Palamatic Process engineered and installed a fully hygienic automated bagging line, directly connected to the drying system outlet. This configuration allowed immediate packaging with no buffer storage, preserving the yeast’s physical characteristics, especially the low hygroscopicity of flakes.

The solution is built around a bottom-up automatic bagging station designed specifically for delicate powders and fragile products. The bottom-up filling system matches the rising product level inside the bag, avoiding free fall, which could damage the flake structure or create dust. The station is equipped with a deaeration and progressive compaction system to ensure uniform filling, excellent bag shape, and optimized packaging volume.

The bagger handles three different bag sizes (10, 15, and 25 kg), with easy format switching that requires no mechanical disassembly. A vertical conveyor was added to meet the bag-in-box requirement. This module automatically adjusts its height based on the current configuration, ensuring controlled bag placement into the carton, free from drop or strain on the packaging, while maintaining full lot traceability.

The line is designed for stringent hygienic environments. About 15 CIP nozzles are installed on all critical zones, enabling complete automatic cleaning of the station. These nozzles are connected to a drying unit using a closed loop with built-in filtration. This system allows production to restart just four hours after the cleaning cycle, eliminating residual moisture, a key factor in preventing bacterial growth.

Control is handled through a user-friendly HMI, offering visual access to CIP cycles, product and bag recipes, production logs, and quality control protocols aligned with the client’s standards.

Palamatic Process equipment and key benefits

Bottom-up progressive filling system

This technology enables precise, clean packaging with zero product degradation. Bags are filled from the bottom upward, matching the product level to eliminate free fall. This greatly reduces dust generation and preserves the granularity of fragile materials.

Filling speed automatically adjusts based on the bag format (10, 15, or 25 kg), ensuring optimal throughput. The process delivers ±20 g dosing accuracy for consistent quality and reduced product loss.

Deaeration and compaction system

The bagging station features two micro-perforated lances inserted directly into the product mass. These are connected to a high-performance vacuum generator, which removes trapped air during filling.

This ensures a uniform product density without altering physical properties or granule size, especially important for fragile flakes. The process also enhances stability during transport by preventing air pockets and bag deformation.

Elevating conveyor for bag-in-box cartoning

This integrated conveyor plays a vital role in the secondary packaging process, supporting a smooth and hygienic transition from filling to cartoning, while adapting to various bag sizes.

• Auto-adjustable drop height: The motorized conveyor adapts its vertical height in real time to the bag size (10, 15, or 25 kg) and the carton dimensions. This automatic control ensures optimal ergonomics and seamless compatibility with on-site packaging formats.
• Controlled placement without drop or deformation: Filled bags are gently guided into the box using a vertical funnel system, avoiding any free fall. This keeps the bag’s shape intact, avoids sagging or damage, and guarantees a uniform, hygienic layout inside the box. Carton detection is automated to prevent any cycle errors.
• Dual configuration mode: Operates either as a bag-in-box or as a direct bagging system depending on production needs.

Clean-in-Place (CIP) unit

The line includes a fully automated CIP system equipped with fixed spray nozzles at critical process zones. The complete cycle consists of pre-rinse, alkaline wash, acid rinse, and hot air drying with filtration down to 0.01 µm. Thanks to a blower delivering 50 °C air, the line can be restarted just four hours after cleaning, completely free of residual moisture.

High-precision vertical screw dosing system

The vertical dosing screw with integrated agitator allows for precise, steady product feeding, suitable for both powdered yeast and yeast flakes. The design limits compaction issues and ensures smooth product flow, even with slight residual moisture.

The entire screw mechanism is fully removable, allowing for easy visual inspection, maintenance, and cleaning, without affecting production throughput.

Inline detection, quality control and automation

The line incorporates several quality control systems to ensure every process step meets standards. Included are:

• A high-sensitivity metal detector,
• A dynamic checkweigher for continuous weight control,
• An industrial labeller for batch identification,
• An automated reject conveyor for non-compliant bags.

These features ensure full traceability, food safety, and accurate quality management during every production cycle.

Complete integration

The system is managed via a PLC with an OPC/UA interface, allowing seamless integration with plant-wide SCADA and monitoring systems aligned with Industry 4.0 principles.

The entire line features IP69K protection in areas subject to high-pressure washdowns, ensuring long-lasting durability and maximum hygiene under demanding Canadian manufacturing conditions.