Modern production and logistics chains increasingly depend on the efficiency of packaging and transportation of bulk materials. In response to the growing needs of the market, a fundamentally new complex for automated packaging of products in soft containers (big bags) was developed. This solution radically changes the approach to processing bulk materials, offering an unprecedented level of autonomy and productivity.
Operating principle of the automated station
The process begins with minimal operator participation, whose task is to place a roll of empty containers on the unwinding table. After this, a fully automatic loading cycle is launched, consisting of several high-precision stages.
Feeding and positioning. The empty container is transported by a system of belt conveyors to the gripping area of the robotic manipulator.
Preparation for filling. A special mechanism carefully opens the neck of the big bag and fixes it for subsequent gripping. The robotic manipulator precisely positions the container and places it on the unloading nozzle of the station, after which the locking mechanism is triggered.
Formation of the volume. Before the actual filling with material, an important stage is performed: the air injection system aligns the container, giving it the ideal shape for uniform and dense filling, which eliminates the formation of voids and guarantees the safety of the product.
Accurate weighing and filling. The valves of the loading and aspiration pipelines open. The material is fed into the container, and the built-in strain gauges continuously monitor its weight in real time. This method ensures the highest dosing accuracy.
Sealing. Upon reaching the specified weight, the product supply stops. Then the automation straightens the neck for reliable grip by the heat-sealing device, which ensures the tightness of the valve.
Marking and packaging. The sealed container is moved to the transport conveyor. A pass-through printer applies all the necessary information to it: the packaging date, the batch number and, if necessary, a barcode.
Completion of the process. At the final stage, the filled and labeled big bag is carefully placed on a pallet using a lifting mechanism or delivered to the loading platform, where it is picked up by loading equipment for further shipment.
Key advantages and flexibility of the complex
The main difference of the complex is its modularity and adaptability. The main technological equipment, including frames, conveyors, dosing and aspiration systems, is manufactured at the plant, which guarantees quality control and compatibility of all components.
Industrial robotic manipulators of any leading global brands, such as KUKA, Fanuc, ABB, Yaskawa, Kawasaki and others, can be integrated to perform container collection and handling operations. This gives the customer the freedom of choice in accordance with specific technical requirements and preferences.
The system’s performance is one of its key competitive advantages. Depending on the configuration and type of product, the complex is capable of providing stable packaging of 40 to 80 large-sized containers per hour, which sets a new industry standard for efficiency.
Conclusion: A look into the future of logistics
The implementation of such automated solutions is not just a modernization of a separate section, but a strategic step towards the creation of a «smart» production. The complex eliminates the influence of the «human factor», significantly increases the accuracy of operations, improves working conditions and reduces overall operating costs. A fully automated big bag packaging line is a ready-made solution for enterprises striving for leadership in the conditions of high competition and growing demands for the quality and speed of logistics operations.
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