Are you struggling with finding an efficient and reliable powder packaging solution?
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Packaging flowing powder requires auger or gravity fillers. In contrast, you need volumetric or paddle fillers for non-flowing powder packaging. That&#;s 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, I&#;m here to guide you in picking the best powder packaging machine. So, let&#;s 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 auger&#;s 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 don&#;t 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 don&#;t 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 factory&#;s 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 machine&#;s daily production capacity.
You will find the production capacity in the machine&#;s 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. Don&#;t 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 company&#;s 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 machine&#;s 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 manufacturer&#;s 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, powder&#;s 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.
In modern manufacturing industries, automation of the whole packaging process of various products, including powder packaging, is widely implemented. Automated powder packing machine or packaging machines help manufacturers meet the current demands and keep up with the tight competition in the market.
Introdução
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Powder packaging machinery not only saves enterprises from the complex process of production but also improves production efficiency. Thus, saving time and operation costs. However, before you go on purchasing a powder packing machine for your business, you should familiarize yourself with the basics of powder packaging automation first.
So in this guide, we will be covering the core aspects of powder packing equipment for newbie packagers.
What is a Powder Packaging Machine?
A powder packaging machine refers to various packaging equipment used for automating the production of powder products in different industries. This equipment can automatically do the following:
Make bags/pouches for the powder products
Weigh the powder product for filling
Fill powder into the bags/containers
Seal the bags/containers
Count the number of packaged bags/containers
Moreover, depending on the powder packaging machine&#;s function in the production line, some also call them the following:
Without powder packaging machinery, there is no other way of packing your powder products in an efficient manner. Unless you do it manually, which is not a practical method especially if you have high production requirements.
What Products Can a Powder Packing Machine Handle?
You can use a powder packing machine for almost any type of powder product. The list we will provide below is only some of the common powder products under each manufacturing industry that use a powder packing machinery for the production process.
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#1 Food and Beverage Industry
Coffee powders,
Cream,
Starch,
Powdered sugar,
With competitive price and timely delivery, dahe sincerely hope to be your supplier and partner.
Carbonate,
Flour,
Milk powder,
Chocolate powder,
Chili powder,Condiments,
Additives,
Energy drinks,
Green tea,Protein powder
#2 Chemical Industry
Pesticides,
Feeds,
Detergent,
Laundry powder,
Powder coatings,
Non-liquid powder materials,
Veterinary powders
#3 Cosmetics Industry
Baby powders,
Cosmetic detergents,
Henna powders
#4 Pharmaceutical Industry
Powdered drugs
If you have other powder products you want to package aside from the ones mentioned above, don&#;t hesitate to ask your packing machine manufacturer.
Most manufacturers of packaging solutions offer consultation services for the creation of your ideal powder packaging machine to better suit your exact needs. Besides, no single machine can handle all types of powder products. So you need to make sure that your chosen machine is the most appropriate one for your product.
How Can a Packaging Machine Benefit Your Business?
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With the current competition in the market, various manufacturing industries need to find a way to make their brand stand out from their competitors&#; products on the shelves. Besides, consumers will likely prefer a product with a creative and appealing package design.
So, to help packagers increase brand awareness, they would need a more flexible means for the packaging process. This is where powder packaging machines come in. Aside from saving yourself from the exhausting process of manual packaging, automated packaging machines will give you the following benefits:
#1 Cost-Effective & Efficient Production
It is true that powder packing machines are a huge investment. But in the long run, these machines will help you reduce labor costs and eliminate human errors from the process. They can help you reach your required production demand with high efficiency.
#2 Improved Brand Value
With the help of flexible packages, it is easier to produce various product designs to make your brand noticeable by your consumers. In fact, the presentation of your product on the shelves is an important factor in attracting potential buyers.
#3 Extended Product Shelf-Life
Powder packaging machines are important in retaining the freshness of your products, which in turn extends the products&#; shelf-lives while still maintaining their inherent qualities.
#4 Increased Reliability and Functionality
Powder packing machinery can perform different tasks in the packaging process such as filling, capping, sealing, and labeling with little human intervention. Automated machines also ensure the reliability of the packaging process with the help of the latest technologies.
Limitations of a Powder Packing Machine
If you want to purchase a powder packing equipment, you should also know the limitations that come with it aside from its benefits. These limitations include the following:
Fully automatic powder packaging machines cost more compared to semi-automatic and manual ones. So if your production demands are not that high, you should go for either a manual or semi-automatic powder packing machine.
Some machines can only handle powder products with a particular
powder flowability
level.
Despite the fact that versatile powder packaging machines exist, most powder packaging machines are made for specific applications only, depending on what kind of powder product is being packaged.
However, do note that the above limitations will be determined by the powder packing machine&#;s design and automation level.
Types of Powder Packaging Machine Solutions
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Various packaging machines exist for different types of packaging &#; pouch, bag, cartons, bottles, etc. Below are some of the most common ones.
#1 Automatic Can Packaging Machines
Packagers use automatic can packaging machines to automate the powder packaging process. Powder filling, sealing, capping, and labeling machines exist under this category. They can handle a wide variety of containers (bottles, jars, cans, etc) and closures in different shapes and sizes.
#2 Cartoning Machines
Cartooning machines can create cartons of various types including closed, erect, folded, and side-seamed ones. They can be in vertical or horizontal designs depending on the type of product.
Aside from milk cartons, many other products including cosmetic and pharmaceutical retail goods are packaged in cartons.
#3 Form Fill Seal Machines
Like cartooning machines, form fill seal machines also come in horizontal and vertical orientations. In addition to powder products, these machines can also be used for various snack foods. They form the package before filling it with the product and sealing it closed.
Moreover, form fill seal machines can handle any bag or pouch style, saving you from the costs of purchasing premade bags.
#4 Stick Pack Machines
These machines fill powder products into sachets/sticks using multiple lanes. They are suitable for packaging food, dietary, and cosmetic products among others. Stick pack machines are used for single-serve products and are popular with modern consumers because of their convenience and portability.
Types of Powder Packaging Equipment Based on Machine Design and Automation
Generally, powder packaging machinery can be classified based on the following categories:
The design of the powder packaging machine
The automation level of the powder packaging machine
Under these two categories, there are still other subcategories that will be discussed in the following sections.
Based on Powder Packing Machine Design
Inline Powder Packing Machines
Powder packing machines in inline designs pack products in straight and orderly lines. This means that the starting and final processing points of the operation are located at the line&#;s opposite ends. Typically, inline machine designs only have single infeed and output lanes.
The major drawback of these designs is that the machines will require a reasonable floor space before they can operate. Nevertheless, some packagers still prefer inline powder packaging machines because it is easier to inspect each packaging station in these designs. In short, inline machine designs enhance visibility.
Rotary Powder Packing Machines
These machines have circular designs which means that the operation is performed in a circular motion, giving the operator an ergonomic format. Therefore, the rotary powder packaging machine does not need to occupy a large space to operate. Also, the starting and ending stages of the operation in rotary machine designs are close to each other.
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For higher production requirements, rotary powder packaging machines are widely used. They feature one to four in-feed lanes, but the one-lane machine design is the most popular one and is used by medium-sized enterprises.
Aside from the lanes, rotary powder packing machines are also composed of permanent stations which are separately embedded in a circular manner. Each station performs a specific procedure in the packaging process. Normally, these machines will have 8 stations but this number can vary from one machine to another.
Based on Powder Packing Machine Automation
In fully-automatic machine designs, the machine will not need constant human intervention throughout the whole operation. The operator just needs to enter the appropriate parameters in the machine and it will do the rest of the job. Furthermore, these machines are composed of sensors that help coordinate the parts of the machine during the packaging process.
For instance, a sensor detects if a predetermined fill level is reached then it signals the machine to stop the filling process. With the help of these sensors, the packaging process runs automatically and continuously. Also, it reduces human errors caused by manual packaging.
&#;&#;
Semi-Automatic Powder Packing Machines
Semi-automatic machine designs need the operator to manually put the pouch/container into the machine and initiate the packaging process. Though some procedures in the semi-automatic packaging are done automatically, the majority of the processes will still rely on the operator.
Major Components of a Powder Packing Equipment
Powder packing machinery has a lot of components that are all essential in the packaging process. But for the purpose of this guide, we will only focus on the major ones. Do take note that the location of each component that will be discussed in the following sections will vary depending on the type of the machine.
#1 Control System
Powder packaging machines use PLC control systems to coordinate the mechanical components of the machine. In some cases, the PLC control system is also integrated with a touch screen interface for easier control.
#2 Driving Mechanism
This component consists of the power system and motor system along with other parts that work together to drive the components of the packaging machine.
#3 Dosing System
This is an important component of the powder packing machine as it is responsible for supplying and filling the powder products into various packages. It is composed of an auger filler that dispenses the powder products for the filling process.
#4 Loading System
The machine&#;s loading system is where the operator loads the packages for processing by the machine. It can also have feeding rollers and gripping arms to keep the packages stable.
#5 Conveyor Belt
Most fully-automatic powder packing machines use intermittently moving conveyor belts for transferring the empty and filled containers from one place to another in the packaging line.
#6 Dusting System
There are powder packaging machines that incorporate a dusting system in the machine design. This can be a combination of a dust hood, dust nozzle, dust collector, and others.
#7 Discharge System
This section of the powder packing machine handles the completed powder packages which are transferred to another station afterward for further processing.
As mentioned earlier, powder packaging machine manufacturers may customize the design of the machine to suit the customer&#;s unique application. So when you intend to buy a packaging machine, always ask a user manual for that machine.
Things to Consider When Buying a Powder Packing Machinery
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Buying a powder packaging machinery that will suit your business&#; specific needs is not as simple as you think it is, given the many aspects you need to consider during the process. These key aspects include the following:
#1 Your Bag/Container Type
The type of packaging you will be using will determine the type of machine appropriate for your application. Different machines are needed for different packages &#; bags, pouches, and containers.
#2 The Price of the Machine
Consider your allocated budget for the machine. After all, your profit should be your priority so be careful about your quotations. Fully-automatic packaging machines are a huge investment and may not be practical if your business only requires low production requirements.
#3 The Machine&#;s Design
Inline or rotary packaging machine? Choose which one would suit your factory&#;s available space and which one would you be more comfortable with.
#4 The Machine&#;s Automation Level
What are your daily production requirements? For larger productions, fully automatic powder packing machines would be more ideal. Otherwise, semi-automatic machines would be more practical.
#5 The Machine&#;s Driving Mechanism
Electric motors, VFD, servo motor, and vacuum suction are among the several options you will have for the machine&#;s driving mechanism.
Consult with your manufacturer which driving mechanism would best suit your application. Because one driving mechanism would probably be more suitable over another depending on what packaging machine you are looking for. For instance, servo motors would be more ideal for filling systems.
#6 The Machine&#;s Control System
The perfect control system for any machine is an integrated PLC and man-machine interface, especially for fully-automated processes. This type of control system is easier to operate and enhances the efficiency of the whole packaging process.
#7 The Machine&#;s Dust Management System
When packaging powder products, dust pollution is a common problem every packager has to deal with. This is why dust collectors, dust hoods, dust vacuum stations, scoop feeders, and load shelves are all needed to minimize dust emission during the packaging process.
#8 The Material From Which The Machine Is Made Of
Stainless steel grades #314 and #316 are recommended for the machine&#;s structure to minimize the possibility of rust and corrosion.
#9 The Machine&#;s Quality Standards
One of your top priorities should include the quality standards of your packaging machine manufacturer regarding their products. Check if they satisfy various standards and certifications like CE, cGMP, and ISO standards.
#10 The Machine&#;s Production Capacity
This parameter is different for each type of machine. Normally, powder packing machine manufacturers will specify the production capacity of their machines. Choose which speed would meet your production requirements.
Conclusion
An automated powder packing machine is absolutely an important machine that every packager should have to improve the efficiency, reliability, and quality of the packaged products. Being familiar with the core aspects of a powder packaging machine will help you find a machine guaranteed to perfectly fit your application.
Choose the powder packing equipment that suits your project best. But if you are looking for a way to automate the powder packaging process using automatic can packaging machines, Levapack can help you create a machine tailored to your specific needs. Feel free to contact us for a perfect packaging solution!