Mobile solution instead of extra production line – new customers included
Filling small containers the flexible way
Previously, the operator only used big bag filling stations at the end of its manufacturing process to weigh and fill plastic granules. Requests for smaller product quantities could not be handled, or only with increased time and effort, as filling then had to be done by hand.
A small container filling line for packaging materials with a filling volume of 20 liters is to provide a remedy in the future. The challenge was that the customer could not consider converting existing filling lines because demand for the smaller quantities was not high enough.
Instead, the operator wanted to retain the capacity of its existing big bag stations and only convert to small container filling on a case-by-case basis. It was particularly important to keep the time required for converting the line to small containers as short as possible so as to be able to respond quickly to customer requests. In addition, the handling of the small container filling itself was to be as uncomplicated as possible and easy to perform for the respective operators.
With this in mind, Engelsmann’s designers developed a mobile filling station whose dimensions are perfectly adapted to the existing big bag stations. If required, it can be easily inserted into a station by forklift and docked.
Very quickly from A to B
The mobile filling station is robustly built. A solid base frame made of stainless steel supports the actual filling unit, consisting of a platform scale with filling stand and filling head to which the empty containers are connected. Thanks to the integrated forklift pick-up, the station can be transported quickly from A to B and is not tied to a fixed installation site.
Converted in no time
If a changeover is to be made to small container filling, the first step is to remove the existing big bag filling head and loading gear before simply draining the base frame of the small container filling system on the U scale of the big bag station. Unlike big bag filling, in the filling variant for small containers the product is first passed over a screening machine before being filled.
Mobile filling station from Engelsmann: The product flows via a collecting container and the filling head into the small container connected to it. A control sieve is also integrated. To change over to this small container filling, the rack is simply moved into one of the existing big bag filling stations.
Integration of a sieve stage
The plastic granules are separated from oversize and fine particles before filling.
This task is now performed by a round screening machine with two screen inserts, which was installed on the base frame and acts as a control screen.
If separation of fines is not necessary, the operator can replace the second screen feeder with a blind plate. Then only two fractions will be screened: the good grain and the coarse fractions.
To prevent the mesh from becoming clogged with cuttings during screening, the round screen is additionally equipped with an ultrasonic cleaning system. This type of screen cleaning agitates the screen mesh at a high frequency so that the stuck grain is loosened.
After screening, the granules separated from coarse and fine particles flow via the good grain outlet through a BFM sleeve into the product collecting hopper below. A level indicator continuously measures the filling level to prevent overfilling of the hopper or dry running.
Finally, the granules flow through another BFM sleeve from the collection container through the filling head into the small container connected to it. Both the filling head and the product collection container are connected to the on-site aspiration system to ensure a particularly low-dust material feed.
Product collection tank: with smooth surfaces, sensor technology for fill levels, BFM fittings and control system
With the valve open, the product enters the filling head with bag buckle and aspiration spout
To fill the container, the operator simply has to enter the desired fill quantity into the height-adjustable control panel. The filling process continues until the scale gives a signal that the target weight has been reached. A pneumatic butterfly valve located underneath the collection container then closes automatically, stopping the filling process. The operator can now open the bag buckle of the filling head and remove the filled container.
All parts in contact with the product are made of stainless steel (1.4571 or 1.4404) and are ground and e-polished with a roughness depth of 0.6 µm. All other parts are made of V2A.
Thanks to the high level of automation, the operator achieves a throughput rate of up to 1,000 kg/h, a volume that could never be achieved with manual filling.
Uncomplicated dosing and filling for small product quantities
By simply connecting the small container filling system to the big bag stations, the plant operator can now respond to customer requests on a case-by-case basis and adapt his production at short notice without requiring additional floor space in the filling area. The system can then be switched back to regular operation in just a few simple steps.
Orders for small product quantities can now be handled easily and at short notice – without the need for new or conversion work on existing filling solutions.
Filling product samples is more economical, so they are now being used more frequently as a sales tool, e.g. to attract new customers.
Thanks to the design as a mobile filling station, existing big bag stations can be used for additional purposes without any conversion measures on site and on the process.
The setup of the additional small container filling can be implemented without significant downtimes.
Thanks to the simple connection of small container filling to the big bag stations, the operator can now respond to customer requests on a case-by-case basis and adapt his production at short notice. Afterwards, regular operation can be resumed without any complications.
By the way:
We can also handle large volumes, complex filling processes and containment
Our product range also includes filling systems for large quantities such as big bags. In addition to our standard big bag filling stations, which are predestined for use in processes with a particular focus on cost-effectiveness, we also offer big bag stations in hygienic design, containment systems or completely individually planned plants and filling systems for big bags, drums & Co.