Context

A customer who produces building materials wanted to replace his filling station. ISERCO was commissioned to manufacture the new installation.

The existing equipment did not allow for the optimal filling of the big bags. The customer had identified a problem with weighing accuracy and product densification in the big bags.

Installation requirements

The machine is in a closed and heated area with the ambient conditions of a foundry.

The equipment supplied by ISERCO must be able to operate continuously in 3 shifts, 8 hours a day, 5 days a week.

Noise pollution is one of the customer’s concerns. Therefore, the new installation must emit a noise level of less than 80 dB in no-load operation.

The existing installation

The existing filling station on site requires several operator manipulations to ensure that the big bag is filled correctly. The big bag filling system was not densified and had a poor weighing chain.

In addition, the product was contaminated by the presence of steel particles in the big bag.

For a 700 kg load of product to fill the Big Bag correctly, the operator must:

  • Forming the bottom of the big bag when it is positioned.
  • Tap the sides of the Big Bag during filling to compact the product and reduce the arching” effect.
  • At the end of the filling process, it is possible that the weight is incorrect. As a result, the operator must remove the big bag to re-weigh it and then remove the excess product to reach 700 kg (0/+2 kg).

The existing filling station (therefore) gave an approximate weighing and required the operator to perform numerous manual operations. This installation was no longer providing customer satisfaction. ISERCO provided a solution to this problem.

 

The proposed solution

The aim of ISERCO’s proposal was to supply a station independent of the existing equipment and to weigh the entire station and the big bag in order to obtain accurate dosing.

The objective is also to optimize the filling of the big bag.

The equipment installed at the new filling station includes :

  • A steel frame.
  • Round forks.
  • A fixed table.
  • A filling head with an inflatable seal.
  • A densification table.
  • A magnetic trap above the filling head removes any steel particles that may be generated during the product manufacturing process.

The following elements can be used to solve the problem of optimizing filling (big bag positioning, slopes formation…) and weighing:

  • A fixed table with multiple height adjustments to ensure the Big Bag remains stable.
  • A densification table with 2 vibrating motors to ensure better product compaction and avoid slopes. It also ensures that the product is deaerated and compacted by vibration, guaranteeing optimum filling of the big bag. When filling is complete, the operator simply removes the Big Bag from the pallet using a forklift truck. In this customer installation, the vibration motors are mounted under the table. The table can be easily removed using the nuts on the underside to gain access to the load cells.
  • A weighing system with a junction box and weighing indicator. The whole station is supported by 4 load cells. The indicator is connected to a control panel.

Finally, to save space in terms of height, this filling station is placed in a pit. This protects the load cells and vibrating motors from shocks (from pallet trucks, trolleys, etc.).

Commissioning and operator training were carried out by ISERCO.

The customer feedback

6 months after commissioning, the customer carried out an evaluation of the overall service provided by ISERCO. With a quality score of 100, the customer felt that the study was adapted to its environment and that the equipment was of good quality.

Deadlines were met and commissioning went smoothly.

The total score of the evaluation is 91/100. ISERCO has received positive feedback after 6 months of use. The equipment meets the customer’s expectations.

The customer was very satisfied with the way ISERCO handled the case.

Bulk information

  • Industry: producer of building materials.
  • Product: crushed fibers.
  • Conditioning: rectangular big bag with 4 lifting points and an inner bag.
  • Big Bag dimensions: 860x860x1250.
  • Big Bag filling spout: Diameter 300 mm and height 400 mm.
  • Useful load (Big Bag): 1000kg
  • Materials used: Steel frame / 304L stainless steel process section.