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Sep. 09, 2024
Are you struggling with finding an efficient and reliable powder packaging solution?
Packaging flowing powder requires auger or gravity fillers. In contrast, you need volumetric or paddle fillers for non-flowing powder packaging. Thats why you must choose the powder packaging machine based on your applications, such as food, medicine, or industrial.
With my 20 years of experience in this field, Im here to guide you in picking the best powder packaging machine. So, lets begin-
The powder packaging machine automatically packs the powdered items into cans, bags, bottles, pouches, and other types of containers.
The key functions of these machines are filling, sealing, labeling, and weighing the powder quantity of each packet. These machines are used in different industries to ensure hygiene and efficient packaging. You will find them in manufacturing factories of food, medicine, cosmetics, etc., that produce powdered products.
Hooper is the large funnel-shaped container at the top of the machine. It contains the powdered product that goes through the packaging process. You can detach this part to insert/shift products or for cleaning.
The bottom of the hopper is attached to the fill head. It dispenses the powder from the hopper to the packets or containers. Based on the machine type, the fill head can be of two types: auger and volumetric.
Level-control sensors detect the quantity of powder inside the hopper. It gives refilling alters when the powder level is low. Thus, it maintains the continuity of the packaging process. Similarly, it notifies you when there are overfilling issues.
Agitator blades are stainless blades used to keep the powder inside the hooper in motion. It prevents powders from clogging. These blades can be of different types- flat blades, paddle blades, ribbon blades, or sweeping blades.
The auger is a spiral-shaped component that transfers the powder from the hopper into the packaging container, ensuring accurate filling. You can adjust the speed and direction of the augers rotation based on requirements.
The control system of the powder packaging machine contains the following-
The PLC acts as the brain of the machine. It manages various machine functions such as filling, sealing, weighing, and safety monitoring. The servo motor is also controlled by the PLC to ensure precise motion.
The HMI is a touchscreen display that monitors the machine. It provides real-time data on machine performance.
The dusting unit minimizes dust generation during the filling process. An enclosed dusting hood is attached to the powder filling station. As the powder is transferred into the packets or containers, it captures the flying dust particles. This can be later reintroduced into the filling process. Thus, you can reduce production waste.
The conveyor unit acts as a moving platform, ensuring a continuous flow of packaging materials. It carries the empty containers, bottles, or pouches from the infeed area towards the filling stations. Conveyor units can be of several types, such as
Powder packaging machines can be classified into different types. These are as follows-
Manual powder packing machines are manual devices, also known as hand-held machines. It has a handle to rotate to fill the powder containers. This kind of manual powder filling machine requires a lot of manual labor. However, it is cost-effective and good for small, home-based businesses. For example- you can use them as a powder masala packing machine or wet flour packing machine.
In semi-automatic powder packing machines, the filling task is automated, but other segments are manually operated. For instance, you need to fill the hopper, adjust the packets, or move them once filled. Therefore, a technician is required to operate the machine. You can purchase a semi-automatic powder-filling machine on a limited budget.
Automatic powder packaging machines are fully automated devices. You dont need any manual function to operate the device. It has sensors to detect product quality. Thus, the hopper filling procedure is also automated.
These machines are excellent choices for large-scale production. All you need to do is provide data to the device with appropriate parameters and it will do the rest on its own.
In inline powder packing machines, the process starts and ends in the same line. Here, filling, sealing, and packaging occur in a linear direction. These types of machines occupy large spaces but have maximum visibility for inspection.
Rotary powder packing machines use a rotary mechanism. In these machines, containers are filled, sealed, and labeled in a circular motion. It has a compact design, occupying little space. You will get one of the top four feeding lanes in rotary powder packing machines. So, these are ideal for large-scale productions.
Automatic can packaging machines are designed to fill powders in jars, cans, and bottles. They use a screw-type mechanism to dispense the powder into the cans. If you are working with free-flowing powders, automatic can powder packaging machines are a good option. They require no manual labor to fill or seal the cans after filling.
Based on packing style, automatic can powder packaging machines are composed of components such as powder filling, sealing, capping, and labeling machines.
Form Fill Seal (FFS) machines fill powder, creating bags/ pouches from a roll of film. These machines can be of two types-
Vertical Form Fill Seal machines use film sheets to produce tube-like packaging bags. They take up little space for their vertical design and are ideal for small floor areas. These machines can be of different types based on packaging style-
As the name suggests, these machines produce pillow-shaped packages. These are sealed from three sides. Pillow powder packing machines are widely used to pack powdered milk, coffee, flour, etc.
These machines produce small, single-use packets or sachets. They should be used for packing small-quantity powder products. Sachet packaging machines can be used for both flowing and non-flowing powders. You can use these machines as small spice packing machines or milk powder packaging machines.
The stick pack machine is a versatile option for packing single-serve products. It produces three-sided sealed long narrow packs made of plastic, aluminum, or paper, suitable for nutritional powders, instant coffee powders, spices, etc.
A Horizontal Form Fill (HFFS) packaging machine uses film rolls to produce packets for filling powders. These films move in the horizontal direction, which is why they are known as HFFS machines. Here, packet manufacturing, filling, and sealing occur within a single machine.
Different from roll forming, premade pouch packaging machines use pre-made pouches, offering a more modern and convenient powder packaging solution. These machines use premade pouches to fill powders in various styles, such as doy-pack, quad, stand-ups, 4-side seals, etc.
Note down some facts that you must consider before purchasing a powder packaging machine:
Powder can be of two types: free-flowing and non-free-flowing. Free-flowing powders such as sugar and salt do not get sticky. On the other hand, powder that tends to stick together is called non-free-flowing powder. The filler type of the powder packaging machine differs for free-flowing and non-free-flowing powders.
Powder TypeRequired Filler Free-flowing powderAuger FillersCalculating the bulk density of the powder is essential to determine the ideal pouch size for the powder. It determines the compressibility and flowability of powder under pressure.
But how to determine the bulk density of powder?
The formula for bulk density, (ρ) = M / V
Here,
ρ = Bulk density (g/cm3)
M = Mass of the powder (g or kg)
V = Volume of the powder (cm³ or m³)
High-bulk-density powders generally take up less space than low-bulk-density powders. For example, brown sugars or sands are high-bulk-density powders. They can be easily compressed. So you can fit them into small pouches. But low-density powders like roasted coffee dont compress much. They are to be packed in larger pouches.
Besides, flowability is also a crucial factor here. Even with similar bulk densities, free-flowing powders will naturally pack denser than non-free-flowing powders.
Powder PropertySuggested Pouch Size High Bulk Density + High CompressibilitySmaller pouches might suffice(Example: brown sugar)High Bulk Density + Low CompressibilityYou might still need larger pouches due to particle shape. (Example: some metal powders)Low Bulk Density + High CompressibilityConsider a pouch size that allows for some compression. (Example: instant coffee)Low Bulk Density + Low CompressibilityLarger pouches are likely needed to accommodate the powder volume. (Example: ground coffee)You must consider your factorys area and vertical space size to pick the right machine size. HFFS machines or in-line machines take up large spaces. Meanwhile, VFFS or rotary powder packing takes up less space than other variants. So, if you have a small production area, go for these machines.
Powders are filled in different types of powder packaging bags or pouches. And the machine type differs for the style of bag you use. For example, for single-use packs you will need powder sachet packaging machines. Whereas for bulk packaging powder box packaging machines are essential.
Therefore, you should first decide what type of bag you want to pack the products in, then decide on the machine type. The chart below will help you with selecting the right powder bag filling machine-
Powder Packaging MachineType of bagApplication Vertical Form Fill Seal (VFFS)Sachet BagsThe speed of a machine is the number of packets it can fill in a minute. It is calculated as Packs Per Minute (PPM), which helps you track the machines daily production capacity.
You will find the production capacity in the machines manufacturer specification. A small-size powder packaging machine has a lower production capacity. Calculate your daily production requirement and purchase one accordingly. The chart below gives you an idea about the industrial production capacity of powder packaging machines:
Production Line SizeProduction Capacity (units per day)Recommended Speed (PPM)Small1,000 5, 100Medium5,000 20, 200LargeOver 20,+Powder packaging machines are made of stainless steel, aluminum, carbon steel, plastic & polymers. Among all these construction materials, stainless steel machines are the most durable. Though expensive, they are best for industrial-level production.
Medicinal Powder Packaging machines must adhere to Good Manufacturing Practices (GMP) regulations. This ensures product safety and quality. Again, if the machine is for food-grade powder packaging, it must meet strict hygiene standards like the FDA and USDA. So, before you purchase any machine, research industrial standards. However, always look for a fully automatic filling and sealing machine for bulk production.
IndustryIndustry Based Feature Example Of Application Pharmaceutical Precise measurement of unit doseLook for quality powder packaging machines with better brand value. Dont always look for a low cost powder filling machine. Before purchasing any devices, do a competitive price comparison. Also, long-term cost-effectiveness and spare part availability should be considered.
A good warranty policy ensures the security of your investment. You should purchase from powder filling machine manufacturers that offer extended warranty facilities. Also, check the companys presale and post-sale services.
Step 1: Site Preparation
Decide on a space where you want to place the powder packaging machine. Make sure the space is well-ventilated and dry. Also, consider a level floor that can support the machines weight.
Step 2: Unpacking and Inspection
Use a lifting tool to unpack the machine with care. Look for any missing or damaged parts. If you find any issues, immediately contact the supplier or packaging machine manufacturer.
Step 3: Positioning the Machine
Move the machine to the selected location, ensuring leveled placement on the floor. Use lag bolts to secure the device on the ground firmly. This will prevent unnecessary movement of the machine while operating.
Step 4: Electrical and Pneumatic Connections
Connect the machine to the power supply following the manufacturers instructions. Ensure the machine and power source are voltage-compatible. However, if it requires a compressed air supply, connect the device to a pneumatic system.
Step 5: Initial Setup and Calibration
Adjust settings such as fill weights, sensors, and machine control systems. Also, the rotation of the motors must be fixed. The filling motor must be directed counterclockwise. In contrast, the agitator motor should be directed clockwise.
Step 6: Test & Run
Power on the machine and text if all the parts are moving correctly. You can do a small test run to optimize performance by filling the hopper with powder and snake adjustment. Also, check for consistent filling and sealing, as well as any signs of clogs or leaks.
Dust generated during packaging can cause health risks and affect product quality.
Solution:
Powders with varying bulk densities cause flow issues. This leads to inconsistent filling and operational disruptions.
Solution:
Inappropriate sealing lets air enter inside the packaging. This damages the product and lowers its quality.
Solution:
Clogs in the feed mechanism hinder the production flow. On the other hand, leaks in packaging lead to product wastage. It also creates hygiene issues.
Solution:
Variations in powder density or improper machine calibration can cause inconsistent filling.
Solution:
Always consider the industry-specific requirements and powder type for the best powder packaging machine. Production capacity, bag style, powders bulk density and installation are also essential factors. But whatever machine you purchase, always give preference to brand reputation. For this, the Honor Pack powder packing machine is your go-to solution!
What are the advantages of a powder packaging machine?
Powder packaging machines provide a quick and effective solution to the powder filling system. They also maintain consistency and accuracy and reduce manual labor.
How much does a powder packaging machine cost?
The price of powder packaging machines differs depending on their type, production capacity, and features. For instance, an automated machine can range from $20,000 to $100,000+. On the other hand, manual powder packaging machines cost between $1,000 and $5,000.
How do I prevent clogs or leaks in my powder packaging machine?
Use a hopper vibrator to prevent feed clogging in the powder packaging machines. However, to prevent leaks, check the feed rates and pressure levels. Also, look for unwanted substances in the feed or machine that can cause leakage.
How To Choose The Right Filling Machine Type For Your Business
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Are you new to the world of packaging or an intermediate folk?
Or you are looking to get the best liquid filling machines. Again, it requires a significant amount of research, especially when plenty of options are available in the market.
Dont worry, and we understand how important it becomes to choose the right decision at the right time. Hence, we guide you to take accurate information and then invest.
Now, one question arises: Who needs to invest in a filling machine?
The answer is if you have a business that needs filling bottles with food, beverages, water, juice, or other products. Then, it is a perfect fit for you to invest.
We need to see various factors when getting started with filling machines.
It would be best if you looked for
These are only the intro of a book. Lots of reliability to come within this article.
There are a plethora of options available when it comes to filling machines. Various types of filling machines provide you with different functionality. In addition, you know that different types of filling machines handle different viscosity.
Lets go through them one by one
Here are the three types of Filling Machines -
This article goes through 3 types of machines and their applications.
We are going to look for a machine that works on operational efficiency. Works as a device that is in direct contact with your liquid product. That needs to handle our product with care, obviously without degrading the product quality and hampering hygiene.
And here we are with our first machine
01.
Liquid Filling Machines
Some people know Liquid filling machines with their alternate names. Like people will often tell you this as flow filling machines. These liquid fillers are very common in the beverage industry. Their primary work is for filling, which includes viscous and non-viscous liquids.
It is essential to mention what type of container you will work with because this will consider our liquid filling machine.
And here comes the perfect role of liquid filler. It distributes the exact amount of liquid-based products. In addition, you can classify the products needed for different containers, such as bottles cups.
Lets dive into our application part for this filling machine
Applications
There are several common types of liquid filling equipment. Lets discuss them in detail to find out the details in the kit.
We can further classify these common types of liquid filling equipment. But I think you get the crux of the main types of essential equipment. Now the time has come to discuss our following kind of filling machine. Let me introduce you.
02.
Vibratory Weigh Filling Machines
As the name suggests, this machine is a structure with many vibrating trays. Every tray present over here builds such that it can handle the weight. With the customized elements present in this filling machine, it becomes controlled. Like hopper and feeder pan techs provide you with the perfect blend of speed and accuracy.
With these elements, you can feel the versatility across the line of net weight. It is the ultimate source of speed and accuracy. This filling machine provides you with two fillers mentioned below
Suppose you are one of those enterprises that require high rates of speed in their application. Then Auger fillers are the best choice for you. However, opposite this, if your main focus is on the product, then Vibrator fillers work idle.
Now, we can shift our discussion to the application part
Applications -
The principle on which this weigh filler machine works is straightforward to digest. What it does is that it dispenses products into the weight bucket. And then, it measures the weight if it is the required weight. Afterwards, the bucket will empty the product into a container.
I hope you get the idea of how this machine works. Now lets dive into our next type of filling machine. Now we will talk.
03.
Powder Filling Machines
You must face challenges when filling powder products if you own a businessthese machines helps to provide you with high filling accuracy. In addition, with their spiral feeding and light control technology, you can maintain zero-drip operation.
It is okay, but some machines only work with free-flowing products. But these conditions become apparent when you use a powder filling machine. It works fine with both free-flowing powdered and granulated products.
Its okay if you dont know what free-flowing means. When I started my business, I also didnt know about the same. But we are going to cover everything here only.
The powered product didnt change its shape when we applied some extra pressure. The most common example in our daily life is table salt. Now, let me tell you what non-free-flowing products are? These products can be compressed and keep their shape like brown sugar.
Now, let us discuss how powder filling machines boost your business.
How can a Powder Filling Machine boost your business?
There are lots of hustle going on in the market right now. Everyone is preparing themselves to beat their competitor. If you want yourself to be in the top 2-3% of the market, you must formulate strategies. Not very hi-fi but going with the current technology. We need to start opting for modern packaging solutions. I am mentioning the benefits of using a powder filling machine below
We have now seen great ways how power-filling machines can boost your business. Let us discuss some of the silent features of the powder filling machine.
Silent Features
04.
Conclusion
We have studied lots of things about power filler machines. So lets try to summarize the main key points. But If you missed the upper part of this section, you would miss lots of good information. So I encourage you to spend some time above to get a detailed analysis. So you can know what type of machine provides which functionality.
After analysis, it is found that Power Filling Machines are commonly used in pouring additives. In addition, they were used in starch, feed, pesticides in different types of packaging. As such, they can be easily seen in the food and beverage.
Now, I hope you get a detailed answer of what you are expected from us. We tried to put on all the necessary information in the blog itself. If you find any good news related to these, we are happy to accept it. Please share your opinions with us.
I hope that this overview article has helped you figure out the three types of filling machines. Please do share if you feel that this article can assist others and make their desire. Let us know your opinions in the chatbox below.
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