Digital Re-print

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September | October 2014
Choosing the right bagging system
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Innovations for a better world.
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while boosting line capacity to up to 80 tons per hour. With the Kubex™ T you save costs, reduce the release of CO2 and
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For more information visit us at the EuroTier 2014 in Hanover, Germany from November 11 - 14 in hall 23, Booth G15 or
www.buhlergroup.com/kubex-t.
DPEF_plant_2014_de_en_fr_es_it.indd 1 11.09.2014 12:41:14
Innovations for a better world.
Built by feed millers for feed
millers.
Equipped with the industry‘s most efficient drive system, the new Bühler pellet mill Kubex™ T saves up to 30% of energy –
while boosting line capacity to up to 80 tons per hour. With the Kubex™ T you save costs, reduce the release of CO2 and
make your operation even more productive. Gaining competitive advantages has never been easier.
For more information visit us at the EuroTier 2014 in Hanover, Germany from November 11 - 14 in hall 23, Booth G15 or
www.buhlergroup.com/kubex-t.
DPEF_plant_2014_de_en_fr_es_it.indd 1 11.09.2014 12:41:14
T
he configuration of a packaging plant
for a milling business depends on
various factors. The packing of the
final product is one of the most labour
intensive steps in the process of grain
milling. That is why this part of the system
should be as automated as possible. The
capacity of the bagging line is simultane-
ously connected to the processes ahead
and afterwards. This requires a very close
connection and co-ordination between the
bagging and the production logistics and
the subsequent storage and distribution
management.
In Europe, North America and Australia
the majority of milled products are loaded
in tankers as bulky loads. In Latin America,
Africa and Asia the load is overladen through
packing in open sacks or ventilated bags.
Around the world the open sacks are most
commonly used because this packaging has
advantages for milled products. In addition
to the pure function of packaging, more
and more mills are using grain packaging
as a marketing instrument. The surface of
the sack, the means of sealing it and/or the
material used, allows the company to bring
up the value from an undistinguishable grain
product that could be exchanged for any
other, to a unique and un-mistakeable brand.
Bagging material
The woven plastic sack and the paper
bag have largely replaced the traditional
jute or cotton sacks. As a disposable bag,
the paper sack conforms to the hygienic
standards required today. The costly clean-
ing work and the removal of bugs and
impurities are no longer necessary. Whereas
in Europe, North America and Australia,
paper-packaging material is generally used as
packaging material, woven polypropylene is
mostly used in Latin America, Asia and Africa
for 10 - 50 kg bags. Apart from simple retail
practice, climate conditions or the less than
careful handling of the sacks favour a packag-
ing of inexpensive woven polypropylene.
Environmental balance also influences
the discussion in Europe about packaging
material. Since the production of paper is
very energy intensive, environmental balance
favours the use of plastic bags if correctly
disposed.
Open or ventilated sacks?
Ventilated sacks are the simpler solu-
tion for automated bag attachments, going
without sealing up bags in small packaging
plants or with low hygiene requirements. In
favour of packaging in open bags not only
is there better hygiene, more exact weight
and increased flexibility in relation to bag
sizes and the bulk density of the product,
there is also easier opening of the bags
by the final customer. These advantages
explain the trend towards bagging in low
cost, open sacks for the bagging of milled
grain products.
Manual or automatic?
The choice between manually operated
or automatic equipment depends directly on
the products, the local conditions and the
size of the different systems of the business.
Criteria such as the weight of the sack, sack
sizes and quality, the required performance
of packaging, the closing mechanism and
logistics can be used for the lay out of a
bagging plant. Single nozzle packing stations
are suitable for paper, plastic and textile bags
with a capacity of 10 -50 kg. Depending
on the performance of the bagging station,
the packaging of grain in 25 kg bags can be
around seven bags per minute. For higher
performance, packing machines can be used
with several filling nozzles. These can also
work with different bagging materials. If
these are used with woven polypropylene
bags, a suitable sack quality is needed for
greater reliability with an automated system.
The new Bühler bagging station Maia for
bags of 10 to 32kg offers an alternative with
a low energy requirement for the packaging
of milled products. It is known for high
reliability and sanitation with fully automated
bagging of powdered, free flowing and fragile
products.
Pre-storage processes
Consideration of the pre-storage ele-
ments such as the silos, product supply and
weighing is important for the configuration
of the bagging plant. In many plants they
are the limiting factors in the bagging perfor-
mance and must be adapted to the desired
performance. The right layout is a condition
for a high degree of accurate weighing and
replication of the bagged goods. A higher
productivity through reduction of person-
nel costs, tracking system and availability of
products as well as permanent stock control
are becoming increasingly important.
Post storage processes
Completion of direct embarkation of the
sacks to lorries through the use of pallets
increases the productivity of bagging plants
because the bagged goods can be stored in
pallet warehouses. This increases the pro-
Choosing the right bagging system
by Thomad Ziolko
14 | September - October 2014
GRAIN
&
FEED MILLING TECHNOLOGY
F
ductivity of the bagging process because the
waiting times at bagging plants decrease.
In addition to this, the pallet warehouse
complements the storage capacity of ready
made products in storage silos. Block stor-
age is advantageous due to very low logistic
costs, spaciousness or as ready made areas
for pallet embarkation. Rack storage can
be accessed on each pallet. Set up costs
for the storage facility are huge as the
requirement for personnel and space is
high. Conveyor belts are suitable for the
milling industry and excel by an ideal price
performance ratio with a high turnover.
Pallet storage plants for the milling industry
are run on the FIFO-principle (First in - First
out). High bay warehouses offer many pos-
sibilities through use of space and require
a preventive maintenance for trouble-free
service.
Control of the bagging system
A reliable control system guarantees efficient
running of a bagging plant. The ability of the
service personnel needs consideration. A hard-
ware which is unaffected by the influences such
as dust and temperature are crucial for good
relaiability. An integrated control system allows
all the process units to be centrally controlled
from bagging silo to the waiting pallet. The
module makes a flexible and user friendly plant
operation: this includes the discharge of the silo
and the supply of the product, weighing, filling,
the packing stations and sealing of the sacks as
well as the sack transport and the automation
of the pallets.
Closing systems for open sacks
Sewing, welding, gluing or combined sys-
tems can come into play for the sealing of
open sacks. Depending on the sack mate-
rial used the bagging performance and level of
auomation, different systems can be used for
the manual or automatic sewing up of filled
sacks. For the sealing of sacks with pre-applied
glue (Pinch bag) no consumer materials are
needed and a highly reliable process is neces-
sary to supply the sacks. Sack closing with hot
sealant is very user friendly (tear opening, seal
tape) and suitable for conventional open sacks.
The right layout of an automated bagging
plant for milled products in the range of 10
to 50 kg requires skilled advice. On the one
hand there are the planning questions such
as sack performance, distribution factors,
weighing systems, sack types, the means of
closing the sacks, the use of pallets, storage
logistics etc, on the other hand considera-
tion of the pre-and post storage steps in the
process are crucial. The customer should
also think more about the desired sack
performance per shift or day in the deci-
sion, instead of the short term per minute
performance. Very close compatibility and
co-ordination of bagging with production
logistics and the consequent storage and dis-
tribution logistics is only possible by carrying
out a thorough practice run through.
More information:
Thomad Ziolko
Product Manager, Grain Milling
Bühler AG in Uzwil/ Switzerland
Tel: +41 71 955 16 82
Email: thomas.ziolko@buhlergroup.com
16 | September - October 2014
GRAIN
&
FEED MILLING TECHNOLOGY
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mail: info@oj-hojtryk.dk
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INCORPORATING PORTS, DISTRIBUTION AND FORMULATION
S
e
p
te
m
b
e
r - O
c
to
b
e
r 2
0
1
4
first published in 1891
In this issue:
• STORAGE
Silo design &
construction
• Weighbridges
crucial
factors and
considerations
• Irish Flour
Milling and
the German
connection
• Bagging systems
chosing the right
one for your needs
• Burundi’s
women of war
turn to rice
• A new dawn for
GFMT
Our history and
our future!
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