What Are The Best Bagging Machines For Wood Pellets?

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Choosing A World Class Bagging Machine For Wood Pellets?

Wooden pellets are clean energy and fuel sources used in place of charcoal, oil and gas. They're popular for use on farms in everything from animal bedding to flooring. Made from the sawdust, shaving and offcuts produced during wood processing, wood pellets are dried and compacted to form a range of different size pellets that clients can easily handle and store. Many pellet producers have chosen to invest their resources in automatic packaging solutions, with their goal being to reduce production costs through automation and be more competitive in the market.

If you're manufacturing wood pellets, you'll want a packaging solution or bagging machine for wood pellets that offers fast speeds and reliable weighing accuracy. Here's how Form Fill Seal/ FFS bagging for pellets could meet your needs and why It’s worth considering palletising wood pellets that you’ve packaged and prepared for sale.

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Here are a few options for packaging your wood pellets in a range of volumes:

FFS Velocity 1500: This machine offers FFS bagging for pellets. This means it automatically uses a roll of polyethylene film to form bags up to 50kgs in capacity at speeds of up to 1500 bags an hour. Because the integrity of wood pellets relies on having a completely dry packaging environment, this machine is a popular choice. Its deaeration and an air evacuation system keep packaged wood pellets free from air or moisture for a longer shelf life.

ABS 250/600: This open-mouth bag and sack filling machine operates around the clock and offers a higher throughput of bagging at a lower cost. It takes pre-made open mouth bags, adding handles and gussets to them to create blocked bags with a weighing accuracy of +/- 0.5%. It uses a bag vibration system to ensure each bag is filled properly and also includes a deaeration device and extractor fan to ensure clean and dust-free filling.

IBC PF4 - Big Bag Filling

IBC PF4: This Big Bag filling machine can package bulk wood pellets in volumes ranging from 500kg and 1500 tons at a rate of between 30 and 60 bags an hour. It fills cleanly using a dust tight inflatable collar and internal dust extraction. The ATEX version can also prevent the risk of explosions when handling dusty products in your working environment.It fills wood pellets without mess or wastage thanks to its pressure balance control and vibration table to settle the bagged pellets

Preparing Your Wood Pellets For Packaging And Distribution

Your packaged wood pellets will need protection as they’re distributed throughout the supply chain. You’ll want a solution for palletising wood pellets that will waterproof them and keep them in place while being transported. A robot palletiser can accomplish this with the use of an automatic or semi-automatic stretch wrapper.

The right packaging solution can help you reduce your wood pellet production costs and become more competitive in the market. Webster Griffin can help you create an all-inclusive packaging solution covering your entire production cycle — including analysing your product flow, palletising your product and distributing it to the end customer. For more information, contact our team today.

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Which Bagging Machines Can Package Plastic Pellets Or Resins?

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Bagging Solutions For Plastic Pellet Manufacturers & Suppliers

Plastic pellets are a key ingredient in many plastic products millions of people use every day and demand is set to exceed $10.25 billion in just five year’s time. With product manufacturers likely to demand larger volumes, manufacturers can increase their productivity and meet orders in a timely manner through using automatic bagging machinery to package their products. Here's how a robot palletiser combined with a plastic pellet FFS bagging machine can help you meet this demand.

What Are Plastic Pellets Used To Manufacture?

Plastic pellets are made from extracted crude oils that are heated and transformed into hydrocarbons and then combined with catalysts and additives before being extruded, melted and formed into pellets. Depending in their composition they can be made from plastics like Polypropylene (PP), Low-density polyethylene (LDPE) and Polyethylene terephthalate (PET) pellets range from 2 mm to 6 mm and can take barrel, ball disc, granule and chip forms. Their uniform shape, weight and firmness at room temperature makes them free flowing. Due to these characteristics, bagging pellets can be done at high speed. Plastic pellets are easily distributed within bags which results in a good shape of bag that is ideal for palletising. When manufacturers melt the pellets, they can be reshaped and moulded into product packaging, textiles, flooring, containers, electrical fittings, soft drink bottles, shoes, gaskets and more.

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Bespoke Solutions Offering Automatic Bagging For Plastic Pellets

These plastic pellet FFS bagging options could help your business improve its productivity:


 

The Velocity 1500 is an automatic FFS packaging machine that can fill and seal bags ranging between 5kg - 50kg in size at a rate of 1500 bags hours. It reduces costs by using a single PE film roll to continuously and simultaneously form and fill bags and includes a valve that lets air to escape and prevents water and moisture from entering. Switching out reels takes seconds, reducing downtime and each bag can be labelled and barcoded for tracking and identification.

The ABS 1000 is an automatic bag and sack filling machine that weighs, fills and tightly packs pre-made open-mouth, flat or gusseted bags that are with or with handles weighing up to 50kg. Its gusseting device creates block appearance bags while another forms handles. Empty bags sit in a magazine before they're prepared for filling using a bag feeder device.

IBC PW  - Big Bag Filling

The IBC-PW is a Big Bag filling machine that fills FIBC (Flexible Intermediate Bulk Container) or bulk bags from 500kg up to 1500 ton and between 30 and 60 bags an hour depending on product density and other variables. It pre-weighs the product before filling for a filling accuracy of ±0.5% and adjusts to different bag sizes and heights. It produces tightly packed and stable bags thanks to its semi-suspension filling mechanism. It also uses an auto tare functionality to calculate each bag's net weight.

Integrating an Plastic Pellet Robot Palletiser Into Your Packaging Line

An automatic bagging line for plastic pellets won’t be complete without a robot palletiser for plastic resins and automatic or semi-automatic wrappers. Robot palletisers can quickly, accurately and safely stack and move packaged products. Programmable to be highly precise and operate faster than human operators, it can adapt to different bag sizes and weights. Following this you can stretch wrap then under tension to create compact, waterproof and stable pallets for distribution and shipping.

Webster Griffin’s Plastic Pellet Bagging, Palletising And Wrapping Solutions

To truly save time and money while increasing your productivity you should explore fully automated solutions combining product filling and bagging, palletising and wrapping in one. Webster Griffin can create a customised solution for your business. Contact them today to explore your packaging options.

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What Are The Best Bagging Machines For Packaging Animal Feed?

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Bagging Solutions For Animal Feed Manufacturers & Suppliers

Animal feed has always been in demand and with the world's current feed production estimated at over a billion tons annually, it won't be slowing anytime soon. The UN’s Food and Agriculture Organisation estimates that by 2050 meat production will grow by 70%, aquaculture by 90% and dairy by 55%.

Feed manufacturers wanting to keep up with this demand will need to scale up their production. This means considering an automatic, high speed animal feed Form Fill Seal (FFS) Bagging solution. Here’s why open mouth bagging for animal feed (amongst other filling solutions) and a robot palletiser for animal feed can accomplish this.

What Animal Feeds Can Be Processed With Bagging Machines? 

Animal feeds typically combine low protein feed and inexpensive but low nutrient roughage with cereal grains, high protein meal and palatable carbohydrates. Manufacturers process the feed into pellets,  and mash as well as crushed bran, granules and flakes to make it easier and safer to store and more economical to dispense.

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Popular FFS Bagging Options For Animal Feed

The following machines can be used to package animal feed for your business:


 

For clients who need to bag animal feed in polyethylene bags The FFS Velocity 1000 is a low cost high production system that can fill bags with dry pellets, solids and flakes weighing between 5kg - 50kg at a rate of 1000 bags an hour. It uses a flat film roll to form tube shaped bags with overlapping back seals to force air out and prevent moisture from entering. It also creates tightly packed bags thanks to its patented “semi-suspension” filling mechanism and de-earates each bag to make it light and dustproof.

The ABS 250 is a fully automatic bag and sack filling machine that can fill open mouth bags made from paper, woven polypropylene and PE bags ranging from between 5kg - 50kg at a rate of 250 bags an hour. This compact system can fill pre-made open-mouth, flat, gusseted bags with or without handles. Designed for use in harsh industrial environments, it uses vibration to settle each bag's contents. It also relies on an extractor fan and deaeration device to ensure dust free bags and a dust free operating environment. With animal feed, the usual closing system will be sewing.

IBC MB  - Big Bag Filling

The IBC-MB is a Big Bag filling system that can fill bags weighing between 500kg and one ton at a rate of 40 to 60 bags an hour depending on product density and other variables. It can fill free flowing animal feed prills, granules, pellets, crystals and grains as well as animal feed ingredients like maize, corn seed, wheat and grains. An operator can place an empty bag onto auto releasing bag hooks for filling. The system's inflatable filling spout contains any loose dust and prevents wastage during filling with an extraction system reclaiming 99.9% of the product's escaped dust.

Integrating an Animal Feed Robot Palletiser Into Your Packaging Systems

To further protect your filled animal feed bags you can palletise and wrap them. Wrapping systems pre-stretch plastic wrap around pallets to make them secure, stable and waterproof ahead of shipping and handling. Most systems integrate hydraulic lifters and converters to make the process as hands off and safe as possible. Robot palletisers can automatically dispense wooden or plastic pallets onto a conveyor or into a palletiser using heavy duty forklift capabilities.

How Can Webster Griffin Help?

Integrating a turnkey animal feed packaging and palletising system into your current operations can be simpler than you think if you work with specialists like Webster Griffin. With decades of experience in helping businesses around the world package their animal feed, we can design a system that works for your business’ needs and adds value to your operations. For more information contact us today.

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What Is The Best Bag Packaging Machine For Pet Food?

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Choosing A World Class Bagging Machine For Pet Food?

An unexpected side effect of Covid-19 was that many people left the office to work from home full or part-time. As a result, many of them decided to get a family pet subsequently pet adoptions have surged across the globe. The pet food market has grown accordingly, and so have e-commerce sales of premium but affordably priced dry pet food. It means that pet food manufacturers will be facing increased demand and their products are travelling further than ever before. If you're one of them, we would recommend investing in a suitable pet food FFS bagging solution or a solution offering open mouth bagging for pet food — and possibly a packaging solution integrating a robot palletiser for pet food distribution. Here are your options.

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Here are a few options for packaging your pet food in a range of volumes:

The FFS Velocity is suitable for mass production runs and has a correspondingly low average production cost. It's well suited for packaging dry food pellets into bags ranging from 5kg to 50kg bags at a rate of up to 1500 bags every hour. It uses a flat film roll to continuously form tube bags for filling. An overlapping seal creates a value that allows air to escape the packaged pellets and keeps moisture out. During filling, the machine uses deaeration and air evacuation to eliminate dust. This extends your pet food's shelf life by up to 9 months.

Our Bag & Sack machines fill pre-made open-mouth, flat or gusseted bags with or without handles which are loaded into a bag feeder device from an empty bag machine. It's fully automatic and can fill bags up to 50kg in weight at speeds between 250 and 600 bags hourly. It's a good option for when you need to fill tightly packed and stable pet food cleanly. It also uses vibration to settle bags during filling. To keep the operating area clean, dust-free and free from wastage, this machine comes equipped with an extractor fan and deaeration device. Once filled, the bags can be sealed or horizontally for added security.

IBC PF4 - Big Bag Filling

Big Bag Filling Machines integrate food grade components and its support frame is easy to clean. It's suitable for filling and containing abrasive and oily pet food safely and securely. It's a suitable mass packaging option as it offers a throughput of up to 30 big bags or super sacks an hour weighing up to 1250kg. It can also consistently weigh and fill fine free-flowing pet food. It also has a bag inflation device (to fully open the bag and its liner for filling), spout (for dust-free filling), clamping ring (to create an airtight seal) and angled chute (to control product flow and ensure consistent filling).

Preparing Your Pet Food For Packaging And Distribution

You might want to integrate a fully automatic end of the line palletising solution. Robot palletisers are controllable by an intuitive HMI touch screen, they self-adjust to different pallet sizes and have a pick-up hand that can be adjusted to different sizes. They produce neat well wrapped pallets. You can also produce shrink-wrapped bundles to protect pallets and products from weather and ensure their shelf appeal. This also prepares them for transportation through national logistic networks or storage in high bay warehouses.

Webster Griffin can help you create an integrated solution that packages and prepares your products for sale - whether you're interested in open mouth bagging for pet food, pet food FFS bagging or a robot palletiser for pet food products. For more information, contact us today.

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How Webster Griffin Helped Reliance Automate Their Throughput & Increase Productivity With Big Bag Filling Lines

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Who Is Reliance & What Are They Famous For?

Reliance is an Indian conglomerate with a presence in the petroleum refining industry. They operate the world’s largest petroleum refinery, converting crude oil into fuel and petrochemicals.

They convert these petrochemicals into polymers with different melt flows that are converted into Linear Low-density Polyethylene (LLDPE) and Low Density Polyethylene (LDPE) resins.

These resins are used to make film and packaging products as well as in rotational moulding and injection-moulded and extrusion coating and moulding applications.

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What Solution Did Reliance Require At Their Jamnagar Petroleum Refinery?

Reliance approached Webster Griffin for help packing their LDPE and LLDPE resin pellets into Big Bags. Their desired throughput was 45 bags an hour, with each bag weighing up to 1100 kgs. Due to the business’s output, they needed three packing lines integrated into one system.

It needed to be ATEX compliant in line with EU safety directives and able to integrate into the refinery’s control systems. It also had to connect to different product feed points and connect at height to several product distribution silos — without any product cross contamination taking place. The entire system also had to be automated with minimal labour involved.

For quality control purposes, Reliance put in place a rigorous quality assurance system during the machine’s installation. This would involve two third party consultants monitoring the process.

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What Solution Did Webster Griffin Suggest & Install?

Webster Griffin customised several IBC-PF4 Big Bag Filling machines to suit Reliance’s requirements. Two storey self-supporting platforms offered access to the system’s dosing valves and feed system and a rail connected it to the silos.

The system allowed the operator to access the buffer hoppers and dosing valves to control the flow of product from the silos. Extraction units prevented dust circulating during filling. Two weighing platforms ensured accurate bag weighing, with a second weighing platform used to fill any underweight bags. A vibrating table would then compact the product in each bag.

The system logged and transmitted all data, presenting bag and weight data to the client for analysis and identification. The system featured a platform, allowing operators to apply bag labels and tie the bags. It also gave them access to an online ticket printing system to apply any tickets. Finally, the system had inline metal detection fitted to the system feeds, again ensuring the resin pellets are safe,  uncontaminated and ready for distribution.

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Did The Installation Deliver Any Tangible Benefits For Reliance?

After installing the system and training operators at the refinery to operate it, Reliance was able to achieve their desired throughput and throughput speed. Improved weighing accuracy helped prevent product wastage, also preventing accidental underfilling which could displease customers.

As requested the system was highly automated and requiring only the presence of two machine operators and a forklift operator. It was also able to operate 24 hours a day for added productivity.

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Factors To Consider When Calculating Your Robot Palletiser’s ROI?

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Picture This Scenario...

Imagine if you could hire a skilled labourer for only 50p an hour, who’d be able to work 24/7 without taking a break or needing assistance. If this sounds appealing to you, you should consider investing in a robot palletiser.

When investing in a robot palletiser, its cost on paper isn’t the only important figure you’ll deal with. It's also important that it will give you a positive Return On Investment (ROI). This should be calculated at a period of two years or longer to determine if it will offer the long term benefits needed to help your business survive in the present and grow in the future. Here’s what costs and benefits you’ll need to consider.

Consider How Many Shifts The Palletiser Will Operate Daily?

Most palletisers can operate 24 hours a day, seven days a week —  though their speed might change depending on the output of the bagging machines and conveyors that are feeding it.

You’ll need to account for any planned downtime needed or days it might not operate at all (like major public holidays). Your palletiser supplier can tell you what kind of planned downtime you can expect during operation.

 

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Consider Your current Labour Costs & Benefits

Labour costs will include what you pay the workers on your packaging line over a certain period. You’ll also need to account for hidden costs and benefits like insurance, worker’s compensation, paid time off and time lost to routine breaks. You’ll need to compare this to your new setup. How many employees will need to operate or supervise the palletiser and how many hours of training will they need? Remember that you'll benefit by making your workplace safer, reducing or eliminating workplace injuries.

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Consider The Palletiser’s Maintenance & Parts Replacement Costs 

Maintenance and replacement costs grow in volume and frequency as the robot palletiser ages. In its first few years of operation it will only need minor maintenance. As time goes by you'll need to replace worn parts.

You can expect to pay for preventative maintenance to keep its battery functional and parts lubricated. In a decade’s time you’ll need to pay at least half of what it initially cost to refurbish it for further operation.

Consider Any Hidden System Costs 

Not all the benefits of switching over to a robot palletiser will be obvious. Your planning and scheduling can become more efficient due to automation and more flexible if the palletiser is programmable. You can also look forward to reduced product and packaging waste and consistently high quality outputs. You might find that in the future your palletiser can perform added functions.

The Bottom Line

Consider The Palletiser’s Installation & Operation Costs

To get your robot palletiser up and running you might need to dispose of your previous machine and prepare the site. Once the replacement is commissioned and installed you'll need to integrate and program it.

You'll also need to add custom fixtures, safety guards or extra tools and conveyors. You'll enjoy saving floor space, which might allow you to downgrade to a more affordable workspace. Palletising systems often merge many packaging areas and functions into one cell. This could save you time if it performs several tasks at once in the cell.

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Multiple formulas exist to help you calculate the exact ROI your machine will offer you in financial figures. This will depend on many factors, such as how much work it will be performing and if you have any throughput goals. However to begin with you need to work out the amount of shifts per day, week and year the palletiser will perform. If you're still unsure what you need to consider or what a robot palletiser can offer you, Webster Griffin can help you. Contact us today to get paired with a system that will give you the ROI you require.

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Robot Palletisers

Why You Need To Automate Your Fish Feed Packaging system

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Fish Feed Industry Overview

The fish feed industry is an essential part of humanity's food supply chain and has been for centuries. Without it, we wouldn’t be able to produce the volumes of salmon, tilapia, shrimp and shellfish required to meet the planet’s demands. The global aquafeed market supports economies around the globe by helping them produce export grade fish. As wild marine fishing resources become more finite and controlled fish farming becomes more common, demand for fish feed will increase.

In 2020, the global aquafeed market exceeded USD 50 billion, and it's projected to reach over USD 71 billion by 2025. Consumer demand will drive increased seafood consumption as protein rich diets become more popular and the overall fish feed market will grow on average by CAGR 5% per year.

The increasing viability of commercial fish farming, lower costs and ease of access to aquaculture feed is will also increasing the demand for fish feed. If you are a high volume manufacturer of salmon food and prawn feed the technology is now available to help you to cut labour costs, speed up production, improve traceability, and benefit from robust packaging that’s suitable for distribution to remote coastal fish farms.

Here’s how automating your fish feed bagging systems can help you meet these challenges head on.

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Today’s Fish Feed Market In Statistics

Manufactured fish feed is the fourth largest animal feed group in terms of global annual production and is projected to have the highest future growth. Most fish feed comes in dry extruded  pellets or granular form, with wet feed remaining popular in some markets.

This feed can be floating, which means that it will sit on the water’s surface until eaten to prevent product wastage. Both feeds are made from fishmeal and oil or plant meal and oil , but can include fish processing waste, seaweed, soybean, barley, rice and other grains. It may also contain additives such as vitamins, anti-parasitics and preservatives.

While manufacturing processes differ from business to business, most manufacturers use extrusion to form high quality pellets of various sizes for different ages, breeds and sizes of fish. The chosen ingredients are crushed using a feed hammer mill. A grain power mixer combines the materials with grains and additives in certain proportions to form a mash. The mash is then passed through an extruder which ‘injects’ the mash through a dye with a certain diameter to form pellets. The pellets are then dried or baked  before being packaged.

Herbivorous fish consume more plant proteins while carnivorous fish consume more animal proteins. Most fishmeal and oils come from small open ocean fish and scraps that come after processing fish for human consumption. These types of fish rapidly reproduce to replace their stock levels, making them a renewable resource. However, their prices are expected to fluctuate as fish oil demand for human consumption increases and crop prices change due to seasonal output and availability.

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Why Is The Cost Of Fish Feed Increasing?

Demand for fish feed is increasing and experts say it's unlikely to drop to Pre-2000 levels anytime soon — even though it makes up over 70% of a fish farmer’s production cost. Fish food prices are expected to increase from between a few hundred dollars to over 1000 USD a tonne as ingredients, global commodities (including rice, wheat and fish oil) and energy prices continue to rise in a climate with supply chain issues due to Covid-19. Hence, the pressure is on fish feed and mael producers to become more efficient, one area of a feed feed factory where its relatively easy to reduce the cost of production - is in the bag packaging department.

Currently, China is the world's leading fish feed producer and as of 2015 accounted for 49 percent or 35,5 million tonnes of the world's total production. Vietnam is estimated to follow with a production volume of 2,9 million tonnes in 2012. This is followed by Thailand with 1,6 million tonnes, Indonesia with 1,3 million tonnes, India with 1,2 million tonnes and the USA at 1 million tonnes, followed by South American countries, Australia, Norway and Scotland.

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As marine resources become more finite and fish farming becomes more commonplace, it’s anticipated that 60% of global seafood production will be farmed by 2030. This also should give producers more control over the health and wellbeing of their fish. Demand for fish products are set to increase as the world's population grows and becomes more urbanised and incomes rise in developing nations. As fish tends to be lower in fat and has a smaller carbon footprint than other protein sources, it’s also expected to become more popular as it’s healthier and more sustainable. This will continue to drive demand to levels that current supplies can’t meet. This demand will be concentrated specifically in Pacific Asia, Latin America, North America and Europe.

In 2020, Covid-19 temporarily slowed down fish feed imports as borders closed and food service businesses shut down. This temporarily decreased demand for fish products and by extension fish and fish food. As lockdowns start to lift globally, demand is expected to rise again. However, manufacturers are expected to face many unique challenges such as staff shortages and more stringent sanitary guidelines when producing and packaging the product.

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What’s The Best Way To Package Fresh Feed Pellets?

The majority of extruded fish feed is predominantly sold in pellet or granular form, filled into woven polypropylene bags of 25 to 50 kg - and Bulk or Jumbo Bags of 850 - 1100 Kg.

This woven polypropylene fabric or outer material is strong and robust, meaning it can travel long distances without ripping or tearing — ensuring it protects its contents.

However ,although the empty bags have many secondary uses, the polypropylene cannot be recycled - hence the desire to move to more environmentally friendly packaging materials - in particular recyclable PE plastic film.

In the case of Big Bag filling it is desirable to minimise the size and cost of the bag by implementing various techniques to settle the contents of the Bulk Bag as it’s being filled.

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The Big bag filling machine is equipped with a load cell weighing system to ensure that each bag weighs the same amount., and so that the weight  evey bag filled can be logged. When  moving to recyclable PE film it is now cost effective to fully automate your packing process. 25 - 50 kg bags  can be packed on a low cost fully automatic, hygienic Form Fill Seal (FFS) Bagging machine, connected by belt conveyors to a compact bag palletising robot, which sacks the full bags of salmon feed in ann interlocked  pattern onto wooden or plastic pallets. The palletised loads can then be automatically stretch wrapped, which will stabilise and protect the product during transport and distribution to the fish farm.

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Fish Feed Is Packed Into Different Sizes Of Bags, Depending Upon The Type Of Customer Or End Consumer:

  1. Retail clients and fisheries — Small plastic bags weighing 1 kg - 5kg. 
  2. Small industrial fish farms — 25 - 50 kg PE plastic bags (previously woven polypropylene fabric bags).
  3. Large industrial fish farms — Bulk Bags ranging from 500 - 1500kgs - manufactured from woven polypropylene fabric. 

For larger feed manufacturers, who need to fill  25-650 kg bags, FFS bagging technology  is becoming a popular choice for bagging Salmon Feed - because  the empty bags made on a form seal seal bagger are  much less expensive than 'pre-made' polypropylene fabric bags so the factory saves on packaging material costs as well as the cost of labour - because it requires fewer workers to operate the machinery in the bagging line. The FFS machine automatically forms bags out of a continuous roll of flat or tubular polyethylene film at a rate of 500 to 1200 bags an hour. 

Talk to Webster Griffin about installing a high speed, automated Bulk or Big Bag packing machine for fish feed, or how ask us how you can cut packaging material costs and reduce the number of operators you employ on your 25kg sack packing line for salmon or prawn food. 

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Staying Up To Date With Tomorrow’s Fish Feed Packaging Options 

If your business is looking for a fish feed bagging machinery packaging option that can keep up with future market developments, it needs to consider an automated solution that can fill products around the clock with less labour required and no pauses in operation necessary. Webster Griffin has decades of experience in helping businesses package their fish feed on a large scale and can advise you on what your best options are.

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Our Experience Supplying Big Bag Filling Machines

EWOS (Cargill) Scotland - Big Bag Filling System for Pelletised Salmon Food

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Ewos Innovation is part of Cargill, the world’s largest commercial fish farming feed food manufacturer with a global presence. They contacted Webster Griffin for a Big Bag system that fills FIBC’s with salmon feed at hourly rates of 25- 30 x 1000kg bags/h or 30-35 x 500kg bags/h. The Big Bag Filling system was designed to be compact and fit into the limited space available within an existing factory.

The system is able to fill three sizes of single loop bags. The operator applies the empty bag and bag sizing technology automatically self adjusts the machine to fill the bag size in question . The empty bag is always inflated to prevent the inner bag from rupturing during filling.

The two stage bag filling process with ‘coarse’ and ‘dribble’ feed combined with a self optimising digital weighing controller provides very good  weighing accuracy and prevents product ‘give away‘ The filled and settled bags are then  discharged and accumulated on conveyors before being removed by forklift.

The new big bag line has reduced the number of operators involved in bagging and therefore  boosted productivity, it has minimised the amount of valuable fish feed ‘given away’ in every bag, and also allowed bagging machine operators the chance to take on other vital production tasks within the factory.

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Our Experience Supplying Big Bag Filling Machines

Biomar, Scotland - High Speed Big Bag Filling System For Extruded Salmon Feed

BioMar is a Danish sustainable feed manufacturer that operates in over 80 countries to create high performance feed for over 45 species of fish and shrimp. They boast a production volume of 1.25 million tonnes and it's estimated that one in five fish farmed in Europe are fed BioMar feed.

BioMar needed a new system that could boost productivity and fill 6 different bag types and could withstand abrasive and oily products. It would also need to package 25-30 bags an hour at weights of 500, 1000, 1050 and 1250kg.

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After several consultations with the customer, Webster Griffin We installed a Big Bag filling system for them, complete with a product dosing system and electronic load cell weighing system to ensure consistent weighing and filling of free flowing fish feed products into bags. A bag inflation device keeps each bag fully open to receive product from the feed valve and has a height adjustable filling spout and bag loop support arms included.

An inflatable spout, external clamping ring and angled chute ensured accurate and dust free product filling. A heavy duty belt conveyor would transport move the filled bags for discharge and offloading. The system allowed BioMar to accurately fill a range of bag sizes at high speeds with less product and packaging wastage than ever before.

The system allowed BioMar to more easily trace their products after distribution using ‘passport’ tickets and they were also able to cater to more customers by offering a bigger range of bag shapes and sizes. The increased accuracy of the filling meant that customers could be confident they were getting what they paid for and ensured that BioMar wouldn’t lose was losing any capital from

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Our Experience Supplying FFS Bagging Machines

Cargill, Ecuador - Fully automatic Bagging System For Prilled Shrimp Feed 

 

Ewos contacted Webster Griffin seeking a fully automated bagging system that could run continuously and pack 10 to 25 kgs around the clock  with minimal operator intervention. It would need to bag salmon pellets 24/7 and produce compact bags suitable for robot palletisation.

Webster Griffin designed a system integrating an Form Fill Seal FFS bagging machine that could use gusseted and non-gusseted tubular film rolls to decrease downtime between film changeovers. The  system also incorporates a single high accuracy net weigh scale with a servo motor driven ‘cam shell’ weigh  dosing technology - which can pre weigh up to 1800 x 25 kg charges of fish feed per hour. This weigh scale is self checking and monitoring, each 25 kg weighment is dropped via a special stainless steel ‘accelerator’ chute onto the newly formed bag waiting below.

As with all Form Fill Seal bagging installations from Webster Griffin, the machine produces bags  in a continuous uninterrupted flow - it only being necessary to stop the line once per shift to reload a new roll of pe bag film

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As a result of the new system, Ewos dramatically improved the productivity of their bagging operation and eliminated the need for operators to carry our arduous manual labour around the clock  - releasing them to work on more productive tasks in the factory. Because the system is controllable and automated it delivers maximum operating efficiency. Since then, Ewos has ordered additional bagging lines from Webster Griffin.

Why Choose Webster Griffin?

Not many packaging machinery experts have the technology combined with years of experience in working with large scale fish feed bagging projects. Webster Griffin understands the problems, and the challenges of packing a wide range of oily, dusty fish feed pellets.

They use only the best quality components, sourced from the original, European, Japanese and American manufactures thereby ensuring spare parts are available from local distributors. Data logging, packing line performance monitoring and CCTV remote support are all features pioneered by Webster Griffin - to ensure your bagging operation keeps running - and you keep delivering fish feed to your customers.

Their technology is up to date yet, robust - built to operate reliably in inhospitable remote locations. If you’re looking for a partner who will design and build a Turn Key solution that will grow with your business, contact Webster Griffin today.

Fish Feed Market Round Up

The fish feed market is estimated to be valued at USD 112 million by 2032. Recording a CARG of 8% in terms of value.

The rising global fish feed consumption and increase in processed seafood consumption are due to rising middle class affluence in developing countries.

The limited availability of marine feed resources as there is a growing demand for fish feed, results in a growing demand for fish farming and in turn fish feed products.

Seafood consumption in China accounts for more than 45% of the global volume. China consumes around 65 million tons of seafood out of 144 million tons and is also the biggest exporter internationally.

 

India, China, Japan, US, Brazil are all the biggest consumers of fish feed.

The Asia Pacific region has the leading market share in the global fish feed market, widely considered that by 2022 this region will account for over 50% consumed fish feed products.

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Big Bag Filling Machines

What Industries Are Palletisers Used In Most?

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What Industries Are Palletisers Used In?

As a business owner, you’re always looking for ways to make your operations more productive and cost effective. With technology advancing rapidly, investing in the right equipment can help you achieve these goals. You might have read about palletisers or seen them in action, but aren’t sure if they can meet the needs of your product and business. The global palletiser market is expected to grow by almost 5% by 2028 and reach a value of USD 3.27 billion by 2026 — demonstrating that many businesses have realised its value.

Today’s palletisers take up less floor space, can be fully automated, offer unprecedented productivity, and can palletise (and depalletise) complex and heavy loads quickly and without error. Here are two examples of different industries that robot palletisers can successfully operate in.

Packing

Food & Beverages 

The world’s food and beverage industries are set to grow, with middle class populations increasing in many countries. In the USA, the packaged food industry is set to exceed 3 trillion revenue by the end of this year.

Proper palletisation helps ensure food packages reach their destination in great condition. It offers a high throughput rate at a relatively low cost. It also has a small environmental footprint as it takes less energy to operate and reduces packaging and product damage due to mishandling.

 

Robotic palletisers are a superior solution when it comes to preventing food contamination and ensuring cleanliness. Due to the Covid-19 pandemic, government health and safety regulations are more stringent than ever. Robot palletisers and their selective compliance assembly robot arms eliminate external interference. It prevents damage and keeps the packaged food from being compromised due to human error. Robot palletisers can also work efficiently with plastic pallets, which are used when handling food products to discourage bacterial growth.

Pharmacuticals2

Pharmaceuticals

The regulatory requirements for packaging pharmaceutical products (including medication and medical or laboratory equipment) has become more rigorous due to the Coronavirus.

As these types of products are smaller, more fragile and easier to damage they need secure palletisation and careful handling. Robot palletisers can manage frequent product and format changeovers.

They also use pneumatic gripping and vacuum technology to precisely control and handle products with different packing densities and weights. Certain models can be equipped to help dispense, count, cap and package products.

Robot-Palletising

Modern palletisers are made of modular stainless steel components which are more hygienic and easier to keep clean. Robot palletisers can stack pallets to ensure no space is left between packages, reducing vibrations. It can also integrate stretch wrapping to protect each pallet from water and other external elements.

Designing & Installing Your Robot Palletiser 

To ensure your investment in a robot palletiser will offer you the maximum benefits with the fastest possible return on investment, you’ll need to ensure it’s designed to meet your specific needs and operate within any constraints you might have. Webster Griffin can design the perfect palletising system for your production needs as well as install it and train your staff members on how to use it. For more information, contact us today.

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Robot Palletisers

How Webster Griffin’s FFS Machine Installation Increased Harringtons Pet Foods’ Productivity and Automated Their Throughput

How-Webster-Griffin’s-FFS-Machine-Installation-Increased-Harringtons-Pet-Foods’-Productivity-and-Automated-Their-Throughput

Who Are Harringtons And What Product Do They Sell?

Harringtons Pet Food is a family operated business that manufactures a range of cat, dog and small animal food. They sell adult, puppy and senior dog wet and dry dog foods in sizes ranging from 150g to 15kg, including grain free and hypoallergenic options. They also produce dry and wet food for adult and senior cats in sizes ranging from 32g to 2kg and rabbit and guinea pig food in 2 and 10 kg sizes.

Open-Mouth-Bagging-Harringtons

What Kind Of Solution Did Harringtons Call For?

Harringtons approached Webster Griffin to design and install a high-speed packing line. It would need to fill 650 to 900 big bags hourly (24 hours a day) all fully automatic — from the bag filling to the dispatching stage. It would also need to be able to work with different bag weights and package sizes, including their 10, 12, 15, 17 and 20 kg pet food bags.

After packaging, Harringtons needed their products palletised into neat, square and compact pallets for storage in their clients’ automated high bay warehouses. As they sold their products in the UK and Europe, the pallets would need to be stacked and wrapped

onto mini supermarket shelf retail pallets and standard UK and European shipping pallets. Webster Griffin recommended the installation of a versatile Modulo Bagging machine, Okura palletiser with OXPA self teaching software and Uniwrap pallet wrapping machine. The palletiser and pallet wrapping machine would collate, wrap, and label the pallet and bags and roller conveyors would transport the pallets through the warehouse to an automatic truck loading dock. An automatic pallet collating machine would then combine two mini retail pallets and load them onto a standard distribution pallet to make it suitable for delivery to supermarket chains.

Harringtons-Palletiser

Why Was A High Speed Packing Line An Appropriate Solution For Harringtons?

The bagging system installed by Webster Griffin provided time savings by integrating functions such as an automated film loading system to eliminate downtime during film reel changes. The automatic loaded pallet collating machine came with built-in palletising programmes that could be modified to the client’s satisfaction. It automatically switches between pallet sizes to accommodate mini retail, Dusseldorf, Euro, or red or blue UK standard shipping pallets.

The pallet wrapping machine waterproofed each pallet in preparation for transportation through a national logistics network.

A high speed pallet conveying system accepted the loaded pallets from various automatic packing lines, transporting them to the dispatch zone using an automatic truck loading system. From here the pallets moved to IPN’s new distribution centre and warehouse.

Harringtons-Palletiser

Did The Commissioning Deliver Any Long Lasting Benefits For The Customer? 

Upon the client's approval, the bagging and palletising system was commissioned and installed by Webster Griffin’s site engineers. It immediately provided them with their desired benefit of an increased throughput of between 650-900 bags of 17 kg each, every hour. By automating the packing lines and warehouse duties it freed up their employees for other tasks within the business and reduced manual labour. The system was so successful that the client went on to order two more palletising lines.

IPN-Headquarters

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The Modulo Bagger

What Are The Disadvantages Of Using A Robot Palletiser?

What-Are-The-Disadvantages-Of-Using-A-Robot-Palletiser

Here's What You Can Expect From Your Average Robot Palletiser

Ideally, a single compact machine would be able to perform all your production tasks. While a machine like this could be created in the future, current models will perform certain tasks better than others. When combined in a production line, they’ll achieve a higher overall throughput rate than an ‘all in one’ packing machine. If you’re in the market for a robot palletiser, knowing its disadvantages will allow you to customise it to your needs or find a better performing model.

Palletising

Disadvantage #1 — A Higher Initial Investment Cost

A well installed and maintained robot palletiser will have a long working lifespan but a high initial investment cost. Its cost will go beyond what you pay for the machine upfront or every month.

You’ll need to consider the time you’ll spend installing the machine and any other delays or costs it might involve. If your usage won’t recoup your costs in a certain period, you might be better off renting one.

 

Disadvantage #2 — More Skilled Staff Members Required

Operating a robot palletiser requires a specialised skill set. Usually the palletiser’s supplier will organise training for your staff when it’s installed and tested. However, human resource problems that impact your operations could include dealing with ill or absent trained operators or product size or production process changes. A costly programmer may have to be employed to reconfigure the palletiser. Fortunately, recent technological advances mean that most modern modular palletising systems can be re-programmed by factory floor staff when production processes change.

A palletiser might put a few staff members out of work if it takes over their work. If these people have a versatile skill set and are knowledgeable about your company, you could retrain and restructure their day so they can take on more pragmatic management duties instead of making them redundant.

Disadvantage #3 — Not Suitable For All Situations 

Robot palletisers can adjust to most warehouse and factory settings, but you might need additional equipment or tools for unusual sized pallets or products.

For example, pallets over two metres high will require a pallet scissor lift table. You could also face extra costs if you often work with different product sizes or change your production processes. Some palletisers require external assistance should you need to move or reconfigure them.

LKAB-Stockton

How Can You Determine Your ROI With Robot Palletisers? 

To determine if your palletiser will provide you with a ROI you’re happy with you’ll need to calculate if it can facilitate a long term cash flow. It will also need to be integrated into your business in a way that meets your strategic goals for growing your company’s position and equipping it with a competitive advantage — while also meeting the short term goals that guarantee your financial survival.

The general payback time for a robot palletiser is between one and two years, based on several factors. The fact that it offers 24/7 production will help you keep up with demand and you’ll also save money because there will be less damaged products you have to write off due to human error. One the other hand you’ll also need to include what you’ll pay your operators, your insurance costs, as well as the cost of any sick leave they might take into your ROI calculations.

Robot-and-Pallet-Dipenser

The disadvantages considered above don’t necessarily have to disadvantage your business. Knowing what each one involves will help you integrate your palletiser into your production processes with as little disruption as possible. The key to getting this right is working with a supplier that understands your unique needs and is willing to help you integrate, service and maintain your robot palletiser. Webster Griffin can help you do this, so contact us today for assistance.

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About Robot Palletisers