Automatic pouch filling and sealing machines are gaining popularity due to their simplicity, user-friendly nature, and the exceptional aesthetics of the final product.
Whether you're new to packaging machinery or contemplating the inclusion of premade pouch packaging in your product range, you likely want to understand the operation of these machines.
Today, we will take a step-by-step look at the processes involved in transforming an empty premade pouch into a finished product ready for the shelf.
150ml~2000ml Liquid Packaging Machine ZV-520L
Bag filling and sealing machines can be configured in either an inline or rotary layout. For today's discussion, we will delve into the rotary layout, which is gaining popularity due to its space-saving design and ergonomic considerations compared to inline models.
In essence, rotary automatic pouch packing machines grasp a preformed pouch, fill it with the product, and seal it at speeds reaching up to 200 bags per minute. This process involves moving the bag in an intermittent rotary motion to various 'stations' positioned in a circular layout. Each station is dedicated to a specific packaging task, with typically 6 to 10 stations, with 8 being the most popular configuration. Automatic pouch filling machines can also be configured with a single lane, two lanes, or four lanes. Here is an overview of how the pouch packaging process unfolds:
Preformed pouches are manually loaded into the bag magazine at the front of the automatic pouch packing machine by an operator. Subsequently, a bag feeding roller conveys the bags into the machine.
Upon detection of a bag by a proximity sensor, a vacuum bag loader picks up the pouch and transfers it to a set of grippers. These grippers securely hold the bag as it progresses around the rotary packaging machine, visiting various 'stations'.
On top-tier bag filling and sealing machine models, these grippers can consistently support weights of up to 10 kg. For heavier pouches, an additional continuous bag support can be incorporated.
If printing or embossing is required, this equipment will be positioned at this specific station. Pouch fill and seal machines have the capability to use both thermal and inkjet printers. The printer is responsible for imprinting the desired date/lot codes on the pouches. Alternatively, the embossing option creates raised date/lot codes within the bag seal.
If the bag features a zipper reclosure, a vacuum suction pad initiates the opening process by lifting the lower part of the preformed pouch. Simultaneously, opening jaws grasp the top side of the bag. These opening jaws then expand outward to expose the top of the bag, and an air blower inflates the premade pouch. In cases where the bag lacks a zipper, the vacuum suction pads open the bottom part of the pouch, with only the air blower in operation.
Near the bottom of the bag, two sensors are positioned to detect its presence. If a bag is not detected, the filling and sealing stations remain disengaged. In instances where a bag is present but not correctly positioned, it will not undergo filling and sealing. Instead, it will remain on the rotary apparatus until the next cycle.
Grain / Solid Food Pouch Doypack Packing Machine with Zipper
Product is dropped down a bag funnel into the bag, usually by a multi-head scale. For powder products, an auger filler is used. In the case of liquid pouch filling machines, product is pumped into the bag by a liquid filler with a nozzle. The filling apparatus is responsible for the correct measurement and release of discrete quantities of product to be dropped into each premade pouch.
Options at the filling station include:
- Gas flush. This modified atmosphere packaging (MAP) process displaces oxygen within the bag by using a blast of gas, usually nitrogen. This is done immediately prior to filling the bag with product to ensure maximum displacement.
- Dust collection. For dusty or messy products, a dust hood is placed above the filling station that collects airborne particles.
At times, loose contents may need to settle at the bottom of the bag before sealing. This station facilitates this process by gently shaking the premade pouch.
Additional options available at this station include:
a. Second Liquid Seal: In configurations involving liquid or water pouch filling machines, this station can be utilized for a second liquid seal, enhancing seal integrity.
b. Second Filling Station: For products comprising both solid and liquid components, an additional filling station can be incorporated at this stage.
c. Load Shelf: In cases where heavy fills exceeding 10 kg are required, a shelf can be added to bear the extra weight and alleviate stress on the gripping arms.
Before sealing takes place, two deflator components expel any remaining air from the bag.
A hot seal bar descends onto the upper part of the pouch. Utilizing heat, pressure, and time, the sealant layers of the premade pouch are fused together, creating a robust seam.
A cooling bar passes over the seal to enhance and flatten it. Subsequently, the completed bag is discharged from the packaging machine into a receptacle or onto a conveyor, ready for transport to downstream equipment such as check weighers, x-ray machines, case packing, or carton packing equipment.
Pouch packing machines exhibit versatility and can cater to a diverse range of products, spanning liquids, powders, solids, and everything in between. At Viking Masek, we have successfully implemented pouch fill and seal machines for various projects, including:
1. Packaging fresh coffee into stand-up pouches for a coffee roaster.
2. Filling and sealing premade pouches of cannabis gummies for a leading Canadian producer.
3. Packaging bulk pre-workout powders.
4. Filling and sealing bags of shredded cheese with a nitrogen gas flush for freshness.
5. Packaging premium dog food and treats.
6. Filling and sealing stand-up pouches of dishwasher pods at a contract packaging facility.
Interested in learning more about how automatic pouch filling and sealing machines can increase the diversity of your operations, help appeal to a new consumer demographic, and improve your bottom line? Contact us!
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