We were approached by an existing client with a “greenfield” project involving four packaging lines designed to fill valve bags with various building materials and palletize them at the end of each line. The primary challenge was achieving the right balance between throughput required for both the filling and palletizing processes on each line for the entire product range.
The Solution
Following our initial meeting with the customer, we began collaborating with the team responsible for constructing the new facility to gain a comprehensive understanding of the design and placement constraints for each packaging line. In parallel, we conducted a detailed product analysis across all materials to be packaged, ensuring each line was tailored to meet the customer’s specific requirements.
After engaging with all stakeholders and completing a thorough product analysis, we finalized a solution consisting of three packaging lines, each powered by a four-spout INTEGRA air-packer, and a fourth line utilizing a twelve-spout ROTO-PACKER. Each line is also supported by its own ARCUS High-Level palletizer, ensuring consistent, high-capacity performance from filling through to palletizing.
The three packaging lines featuring INTEGRA IVL4 Air Packers are each outfitted with our Flying Dutchman bag applicator, horizontal bag magazines, and paired with dedicated ARCUS High-Level palletizers capable of handling up to 2,000 bags per hour. These valve bag packers also incorporate a range of components including aeration chambers, filling spout blowout devices, and more—designed to facilitate quick product changeovers and enhance filling speeds. Additionally, each ARCUS palletizer includes a spillage trough that collects excess material from the conveyor belt, contributing to a cleaner and more efficient production environment.
To support the highest-capacity packaging line, we supplied a twelve-spout ROTO-PACKER featuring a customized RADIMAT® bag applicating system with an extended magazine for increased bag storage and automated adjustments for varying bag sizes. Additionally, a residual emptying and cleaning system was outfitted with this machine to support quick and easy product change. An additional feature on this ROTO-PACKER is the option to toggle on and off the sealing units on each spout to allow filling of various recipes featuring both sealed and non-sealing bags. The palletizing portion of this line is managed by an ARCUS palletizer engineered to palletize up to 4,000 bags per hour. Like the other lines, it includes a spillage trough to capture excess material from the conveyor belt, promoting a cleaner and more efficient production environment.
As part of this large-scale project, we are delivering a complete turnkey installation across all four packaging lines. This comprehensive approach underscores Haver & Boecker’s engineering expertise, from initial concept through to final implementation, and reflects our commitment to seamless, plug-and-play automation.