Big Bag and Octabin filling stations for the food industry

An integrator customer specializing in the food industry requested ISERCO to provide a solution for filling coffee powder in big bags and octabins.

This client, with whom ISERCO has a prolonged relationship, provided comprehensive information concerning the prerequisites that should be satisfied in the design and production of the equipment.

Several details were given.

Firstly, the big bag and octabin filling stations will be installed indoors, in a protected area. This is an ATEX 21 zone. All parts of the equipment must be grounded.

The coffee powder filling line is required to fill four octabins and two big bags per hour. The tolerated dosing accuracy for the big bags is ±3 kg.

The food industry requires strict standards for materials and parts that come in contact with food.

The requirements mainly pertain to welds. The supplier is obligated to follow the industry’s best practices, as described in the EHEDG reference document, for the food industry. To meet the requirements, welds must be continuous, uniform, and smooth, with no rough surfaces. These welds should eliminate any areas that could retain powder and make cleaning easier by providing a joint with mechanical strength that aligns with the design. Finally, the welds must be free of crevices, pits, or any other defects that could lead to product residues or microorganisms’ buildup.

In addition, any internal components in contact with the product must be made of 304L stainless steel, with a Ra finish of less than 0.8 and treated with the SUBLIMOTION-process® surface treatment.

Finally, the client provided a list of preferred suppliers for specific components, such as the pneumatic section, pressure sensors, and butterfly valve.

Food safety certificates have been provided for components in contact with product in accordance with CE 1935/2004.

These are constructed using 304L stainless steel, which is a high-quality and durable material.

They feature a filling head with an inflatable seal, a system that seals by pinching the big bag. When inflated, the seal perfectly fits around the big bag spout. This filling head also has 2 half-valve clasps.

This assembly offers numerous benefits as it ensures complete containment and doesn’t require any maintenance. The inflation and deflation process is carried out pneumatically. The system comprises a double layer with a suction nozzle and a nozzle for shaping the Big Bag. Both nozzles are equipped with a butterfly valve to optimize the filling and air (fines) extraction phases.

 

They are also equipped with a venturi pre-shaping ventilator the big bag. This prevents creases in the big bag canvas and ensures correct filling.

The switch from suction to inflation is made by butterfly valves controlled via a control panel.

 

A mobile table equipped with a pneumatic cylinder allows the Big Bag to be extended during the filling phase. This avoids any risk of jamming due to the angle of repose.

At the start of the cycle, the table is in the upper position. As the machine fills, it lowers to allow the big bag to rest on the pallet. This adjustment is made automatically by a decompression valve.

With the help of the mobile table, the operator can easily position of the Big Bag, ensuring that it is ergonomically positioned for safe and efficient operation.

Finally, the mobile table can be used to fill different sizes of Big Bag.

 

These stations are equipped with an automatic unhooking system using cylinders. When the big bag is full, it is automatically unhooked.

 

A stainless steel vibrating table deaerates and compacts the product, ensuring that the Big Bags are filled to optimum capacity.

 

Both structures are equipped with a pneumatic network situated behind the stations. The cabling has been installed by ISERCO, and both stations are pre-wired. When the filling stations are installed on-site, the customer only needs to make the connection.

A stainless steel pneumatic box is included.

 

Finally, these big bag filling stations are equipped with a weighing indicator and load cells. All controlled by a PLC. This allows the product to be dosed by weight via a butterfly valve.

 

All stainless steel surfaces are treated with SUBLIMOTION-process®, a surface treatment carried out by MP2S, ISERCO’s sister company. This is a mineral, natural and antimicrobial process. It makes stainless steel easy to clean and increases its resistance to corrosion.

 

Finally, the equipment was inspected at ISERCO’s premises before the filling stations were shipped. The aim was to check that all the equipment was complete and met the customer’s requirements.

Following this inspection, the equipment is validated by the customer and shipped after any outstanding issues have been resolved.