Replacement of a bagging line in the dairy industry

Customer objectives

The customer's project involved replacing an outdated bagging line that no longer met modern productivity standards, particularly regarding hygiene and dosing accuracy as required in the dairy industry. The previous installation could not maintain the desired production rate or ensure effective dust containment during packaging.

The primary goal was to implement a new automated bagging line capable of processing up to 300 bags per hour, while ensuring:

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

• A clean, controlled processing environment with Clean-in-Place (CIP) systems and effective dust containment.

• Adaptability to existing plant constraints, including room dimensions and product inlets.

• Secure open-mouth bagging with airtight sealing that meets food safety regulations.

The customer also required the integration of in-line quality control tools such as checkweighers and magnetic detectors to ensure product compliance and automatic rejection of defective bags.

The proposed solution

Palamatic Process engineered a high-speed automated bagging line based around the HBM 1040 system, which integrates all packaging and quality control modules. This solution delivers a nominal throughput of 300 to 400 bags/hour, with dosing accuracy of ±10 grams on 25 kg (55 lb) bags.

The system is fully designed for food-grade applications, maintaining a high level of cleanliness:

• Product-contact parts in 316L stainless steel, external structures in 304L stainless.

• All assemblies are removable for manual or automated CIP cleaning.

• The equipment complies with EHEDG guidelines and ATEX (explosive dust zone) standards. For U.S. installations, NEC Class/Division compliance or UL-listed alternatives would apply.

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.

The bags follow this operational sequence:

1. Automated pickup from a 120-bag magazine.

2. Suction-based opening and Bottom-Up filling: the bag moves vertically during filling, ensuring even distribution and minimizing airborne dust.

3. Degassing through porous lances, ensuring compact, controlled filling of light powders like skim milk or whey.

4. Airtight closure using the FTS (Fold, Tape, Seal) system, suitable for kraft paper bags with PE liners.

5. Dynamic weighing with automatic rejection for out-of-spec bags (tolerance ±40 g ≈ ±0.088 lbs).

6. Central dust extraction system rated at 650 m³/h (≈383 CFM) at 20 m/s (≈4,000 ft/min), piped via Ø100 mm (≈4 inch) ducting at the line head, ensuring a clean zone around the bagging unit.

The system also includes magnetic detection and an integrated sampler to guarantee product integrity. Bag dimensions (length: 31.5–39.4 in, width: 19.7–23.6 in) are handled automatically by a centralised HMI interface.

Main equipment and features

HBM 1040 automatic bagging station:

• Up to 400 bags/hour
• Bag materials: paper, PE, or PP (lined/unlined)
• Dimensions: 19.7–39.4 in long, 15.7–23.6 in wide, up to 10 in thick
• Bottom-up filling, degassing
• Fast disassembly, easy wash-down
• EHEDG & ATEX certified (UL/NEC equivalents in North America)

Vertical screw feeder with 400 L (≈106 gal) hopper:

• Variable-speed drive, agitator, ATEX vent
• Sanitary BFM® fittings
• ±10 g dosing precision

Degassing station:

• Porous lances, vacuum extraction
• Optimized compaction for bulk densities between 25–48 lb/ft³

Bag sealing station (FTS - MEYPACK):

• Thermal and adhesive sealing
• Optional liner blow-cleaning
• Hygienic seal, quick format change

Dynamic checkweigher with auto-reject:

• ±40 g tolerance
• Ensures legal-for-trade compliance

Centralized dust extraction system:

• 650 m³/h (≈383 CFM) at 20 m/s (≈4,000 ft/min)
• Ø100 mm (≈4") piping
• Dust-free workspace

Additional equipment:

• Removable 316L screw feeder with custom mount
• In-line sampler, robotic sack handling
• Height-adjustable conveyors

Conclusion

This complete line offers a reliable, automated bagging solution tailored for the U.S. dairy processing industry, delivering high-speed, precise dosing, full compliance with food safety and dust control standards, and smart integration of quality assurance.