PLANT MANAGEMENT
which results in lost revenue that can accumulate over time. Inconsistent fi ll weights only increase potential losses. “Processors don’t get paid for the extra pounds they overfi ll the bag. If they can improve the weighing accuracy, they are not giving away as much free produce,” says Mackrill. Switching to a bulk bag fi ller that off ers precise weighing accuracy can eff ectively resolve this issue. When the bagging rate exceeds 30–35 bags/hr. pre-weighing the material in a hopper above the fi ller should also be considered. “Pre-weighing the ‘shot’ of material while a bag is being densifi ed and removed from the system and the next bag is rigged, signifi cantly increases the bagging rate,” says Mackrill. He notes that some bulk bag fi ller systems such as the CTE from Spirofl ow are capable of fi lling more than 40 bags per hour if the material is pre-weighed. To further enhance the precision of weighing, it is important to consistently fi ll hoppers with equal amounts of material and align this process with the pace of bagging operations.
ACCURACY TO RECOVER LOST REVENUE Upgrading bulk bag fi lling equipment to a more eff icient system that can
compact or densify the material in each bag is another opportunity to reduce costs. One eff ective strategy for doing this is to eff iciently increase the density of the product in each bag. This can lead to an operating facility purchasing smaller bulk bags while still shipping the same quantity of product. On the other hand, for powders
with bulk density of less than 25–30 lbs./ft3, it may be possible to increase the product capacity within the existing bag size. This allows food and beverage processors to consistently approach the maximum weight restrictions permitted on truck trailers and avoid additional shipping expenses incurred when the weight falls below the limit. Mackrill notes that enhancing
material densifi cation leads to a “ripple eff ect” of savings. “You’ll weigh out every trailer and over time fewer trailers will
Fill hoppers with equal amounts of material to enhance weighing precision Accurate weighing saves production costs
be required to transport the total product weight within a specifi c timeframe. Additionally, the increased capacity of each bulk bag results in fi lling fewer bags, thereby reducing packaging costs,” explains Mackrill. Another benefi t is improved bag
stability. Some dry materials will entrap or entrain air between the particles more than others, and those that do require more vibration or densifi cation to drive out the air between the particles. When that is not the case, the bulk bags can become unstable and tip and fall during transport, handling, or storage. This can put operators at risk of injury, damage product, and increase operational costs. Food and beverage manufacturers
who acknowledge the untapped potential of optimising their bulk bag fi lling systems stand to reap considerable rewards. As the crux of eff icient packaging operations, precise and automated bulk bag fi lling solutions can help food and beverage processors increase productivity and streamline operational costs in a way that is sure to positively impact the bottom line. ●
For more information visit https://www.spirofl
ow.com/
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