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

Client's Objectives

The client, a food and beverage manufacturer specialising in the production of carbonated cola drinks, receives sugar in palletised bags via shipping containers. The primary objective was to modernise and automate the entire de-bagging and transfer line to the dissolution area, in order to increase throughput, reduce the physical strain of manual operations, and improve food safety.

Already equipped since 2008 with a MINISLIT automatic bag splitter for opening and emptying sugar bags, the client wished to take advantage of recent technological advances, particularly in machine vision and robotics, to make their process more reliable.

Furthermore, the installation had to take into account specific geographical constraints related to an island location:

• supply logistics,
• temperature and humidity variations,
• limitation of heavy maintenance interventions.

The Proposed Solution

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

• a depalletising robot with 3D vision,
• a MINISLIT® 3000 automatic bag splitter,
• a dense phase pneumatic conveying system to buffer silos.

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

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

The sifted sugar is then automatically transferred via dense phase pneumatic conveying 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 metres. The system integrates level sensors for the 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 Composing the Installation with the Advantages of the Palamatic Process Solution

1. Sackbot® 200-M3 Depalletising Robot with 3D Vision

Palamatic Process integrates the Sackbot® 200-M3 depalletising robot with 3D vision to automate bag emptying. This solution guarantees speed, accuracy, and safety while reducing the physical strain of manual operations. Combined with the automatic bag splitter and pneumatic conveying, it offers a high-performance, hygienic, and fully robotic line.

• Automatic bag depalletising by articulated claw gripper.
• On-board 3D vision for precise bag localisation and geometry reading.
• Gripping possible on mixed or partially empty pallets.
• Speed: up to 8 to 10 bags/minute depending on the format.
• Integrated function for managing empty pallets and layer pads.
• Optimised autonomy for operation in an isolated cell.

2. MINISLIT® 3000 Automatic Bag Splitter

The MINISLIT® 3000 automatic bag splitter ensures the opening, cutting, and emptying of bags without human intervention. With a throughput of up to 15 bags/minute, it guarantees a clean process thanks to its stainless steel screening system and integrated dust extraction. Compact and secure, it easily integrates into automated lines for maximum productivity.

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

3. VFlow® Dense Phase Pneumatic Conveying

The VFlow® dense phase pneumatic conveying system is specially designed for transporting sensitive powders such as granulated sugar. It ensures 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 reverse-jet cyclofilter guarantee a reliable, hygienic, and energy-efficient process.

• Conveying technology adapted to sensitive powders (granulated sugar).
• Flow rate: 4.5 t/h for a distance of 35 m.
• Low compressed air consumption (~0.7 m³/min).
• Ø100 mm stainless steel piping.
• In-line cyclofilter with automatic cleaning.

4. Intermediate Buffer Storage Silos

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

• Capacity: 2 x 3 m³.
• High/low level sensors for automation of the filling cycle.
• Inclined bottom for gravity flow towards the dissolution line.
• Inspection hatches and manual discharge butterfly valves for cleaning.
• Hygienic design, entirely brushed stainless steel inside/outside.

5. Automation & Supervision

• HMI interface for the global control of the line.
• Programmable product recipes.
• Traceability of cycles (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 optimise the entire bag emptying process. Thanks to the integration of the Sackbot® 200-M3 robot and associated equipment, the installation guarantees reliable operation, in compliance with ATEX standards, and is designed to reduce physical strain while maximising productivity.

With a 100% automated line, ATEX compliant and 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 environments.
• Reduction of physical strain for operators by eliminating manual handling.
• Productivity gain through increased throughput and reduced downtime.
• Integrated customer feedback: natural evolution from a MINISLIT semi-automatic bag slitting line to a "full" robotic line.