Download - Filling Solutions for Flexible Packaging
PPC 2011 Filling Solutions for Flexible Packaging
Steve Gosling
Introduction
Quick overview of rigid containers
Range and styles
Filling equipment
Considerations when filling rigid containers
Flexible filling review
Types of flexible packages
Types of filling equipment
Considerations when selecting flexible packaging
Considerations when selecting filling equipment
Assorted Rigid Containers
1200 liter plastic tote
Assorted drums
Assorted Rigid Containers
Cubitainer
Jug in Box
20liter pail
Tight Head Pail
Typical Rigid Filling Equipment
Multi-head filler Single head drum filler
Quick Overview of Rigid Filling Equipment
Single and multi-head depending on package size and
filling speeds required
Speed of filling is somewhat limited by the amount of splashing and foaming that may
occur
Typically multi head fillers are used to increase speed (slower flow rates)
Techniques that are used to overcome the problems with filling rigid containers
Anti-foam additives
Nozzle designs
Filling equipment modifications
Multiple filling heads
Flexible Packaging
Cheertainer 3 liter to 25 liter
Cheer Pack 70ml to 1000ml
IBC 55 gallon to 330 gallon
Automatic Single Head Filling Line
Semi Automatic Single Head Filler
Filling Equipment Controls
Control System
The filling equipment is supplied with a very simple control
system
Pump on/off
Safety start
E Stop
CIP
Sample
Encoder/counter for setting the fill volume
Fault code display
Filling Metering Systems
Turbine
Mostly used on non-viscous products
Used for wines, water, milk and oils
Will not handle viscous and particulate
Electromagnetic Flow meter
Most common and simplest design
Wide range of products
Not as accurate on small fills less than 5 liters
Mass Flow
Will handle almost all products
Very expensive
Very accurate
Weigh Scale
Used on high viscosity products
Not as accurate
Slower
Can be used inline with the other systems for verification
Flow Meters
Mass Flow
Turbine
Typical Filling Valve
Filling nozzle Cap pick up
Cap in gland prior to filling
Semi automatic filling head
The Filling Valve Operation
Steps
1..The filling head automatically removes the cap
from the gland
2…The filling nozzle seals off on the top of the
fitment or gland
3..The nozzle will first draw a vacuum ensuring that
there is no air in the bag prior to filling
4..The large orifice nozzle will then open and accurately flow the product into the bag
5..Once filled, the cap will be replaced and pushed to the final shipping position
Semi Automatic Filler
Selecting Flexible Packaging
What type of dispensing is required?
Select at tap or bung
What is the expected shelf life?
Does the product require a barrier film structure?
Is the product light sensitive?
Is the product hazardous?
What is expected from the carton design
Shipping
Environment
Cheertainer® Fitments
Filler Production Data
Filler 20L 10L 5L Labor Price
Manual 2/min.,
210,000/yr.
3/min.,
315,000/yr.
4/min.,
420,000/yr.
1 person $18-$20,000 USD
+ Freight
Semi-auto 3/min.,
315,000/yr.
4/min.,
420,000/yr.
5 min.,
525,000/yr.
1 person $30-$35,000 USD
+ Freight
Twin-semi 6/min.,
630,000/yr.
8/min.,
840,000 yr.
10/min.,
1,050,000/yr.
2 people $70-80,000 USD
+ Freight
Fully-auto 6/min.,
630,000/yr.
8/min.,
840,000/yr.
10/min.,
1,050,000/yr.
1 person $140-$155,000
USD +
Freight
Notes: (1) Annual bag production is based on one 7-hour shift per day, 250 days per year taking into account 10 holidays. (2) Prices shown are
based on British £ currency rates as of March 2008.
Filling Equipment Considerations
What type/range of products are to be filled?
What flow meter will work the best for the application ?
Filling range 3-1200 liters
What taps, caps and bungs need to be handled?
What is the annual volume?
What floor space is available?
Filling Equipment Considerations
Carton Erector System
Size range
Closure required
Local supply/service
Hot melt system
Local supply/service
Ink jet system
Carton labels
Carton closure
Palletizing
Cheertainer Automatic Filler
Single Head Automatic Filling line
Three Up Automatic Filling Line
Conclusions of BIB Filling Equipment
Accurate, repeatable fill based on volume or weight
Safer fill due to seal of nozzle on fitment
No foaming or overflow because there is no air in the bag
Less labor - no manual cap application or equipment
Fast setup and change over from one size to another
CIP and SIP system using one fill head reduces product waste
Requires much less floor space than other traditional nozzle fillers
Wide range of taps and fitments for dispensing
Why consider a flexible packaging solution?
Lower costs
Faster filling speeds per single head
No air on the product at fill or dispense
No glugging during the dispense
Sustainable
Fewer in-bound trucks
Less warehouse storage
Takes up less volume in the landfill site
Carton is 100% recyclable
THANK YOU