Whether it be spices, protein or milk powder, drink mixes, or pharmaceutical/nutraceutical products, powder packaging remains Viking Masek's largest packaging equipment market, comprising almost a third of our packaging machine installations.
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With convenience products becoming increasingly popular, we expect the powder packaging market to grow even more in areas like pre-packaged spice blends to add to meals, instant coffee and drink mixes, legal cannabis products, and portable protein powders.
When it comes to powder packing, there are three main things your packaging equipment manufacturer needs to know to provide the best powder packaging solution for your specific application.
Planning a powder packaging equipment project?
A powder product is considered free-flowing when its particles are not cohesive. Examples of this are granulated sugar or table salt, which 'flow freely' when dispensed. Adding extra pressure usually will not compact these types of powders, and they usually don't hold their shape when manipulated.
A powder product is considered non-free-flowing when the particles are cohesive. Examples of this are brown sugar or powdered milk, which tend to hold their shape when manipulated and can be compacted under pressure.
A (very unscientific) way to determine if something is free-flow or non-free-flow is "the finger test". Simply poke your finger into a container of the powder product. If the product compresses and still shows the indentation of your finger after you remove it, then it is likely non-free-flow. If, when removed, your finger leaves no lasting indentation, it is likely a free-flow powder product.
Determining whether your product is free-flow or non-free-flow is vital to the success of your powder packaging project. In particular, it affects the type of filler your product requires to properly dispense your powder product into its packaging.
Free-flowing product easily falls with the force of gravity while non-free-flowing product needs to be properly compacted and 'helped along' during packaging because of its cohesive properties, necessitating entirely different filling systems to convey the products properly. In general, free-flow powder packing projects can utilize volumetric or free-flow auger product fillers, while non-free-flow powder packaging necessitates an auger filler specialized to properly dispense cohesive products.
Consider a non-free-flow powder product like flour. When flour is dispensed, inevitably a dust cloud is formed. Anyone who has ever worked with this type of product knows how far these particles can travel, and how they cling to almost any surface.
Now consider this in the context of powder packaging machinery; serious mechanical issues can occur as a result of loose airborne particulates. Thus, certain powder packaging machinery options are recommended when a powder product is dusty:
The bulk density of a powder product conveys both the 'flowability' of the powder and how much it may compact when under pressure. A basic formula used to compute bulk density is total mass divided by total volume, although there are other methods and devices that can compute bulk density to a higher accuracy. Bulk density is customarily represented as g/cm3.
Free-flowing, dry powder products like granulated sugar usually will not compress very much and have a low bulk density. Non-free-flow, cohesive products like brown sugar have a higher bulk density that will get even higher when compacted.
So what does bulk density have to do with powder packaging machinery? As an extreme example: Consider packaging 50g of moist sand vs. 50g of roasted coffee beans. Both weigh the same at 50g, but the package dimensions and types will be vastly different because of the amount of empty space around and inside of the products. The sand contains less empty space and is more compressed within the package, allowing for a smaller pouch. The coffee beans contain much more empty space and do not compress much at all, necessitating a much larger pouch.
This is where bulk density becomes an important consideration when packaging powders: It has a direct influence on pouch sizes and attributes, the type of filler required, as well as the packaging speeds that can be attained.
As our number one application, we consider powder packaging machinery one of our areas of greatest expertise. We have successfully installed our packaging equipment in plants with powder packing projects like:
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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. 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.
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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.
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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.
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Variations in powder density or improper machine calibration can cause inconsistent filling.
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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.
Are you interested in learning more about Powder packaging machinery? Contact us today to secure an expert consultation!