This project features a fully automated form, fill, and seal (FFS) packaging line designed to package PVC powder into 25 kg polyethylene bags at 500+ bags per hour. The system integrates precise net weighing, dust-controlled filling, automated bag forming and sealing, downstream inspection, robotic palletizing, and pallet protection to deliver consistent bag quality, high accuracy, and reliable operation for powder packaging applications.
Powder Packaging Process
- Bulk PVC powder is conveyed into the feeder hopper.
- Material flows by gravity into the net weigher for accurate dosing.
- Weighed product is discharged into the FFS bagging machine.
- Bags are formed from PE film, filled, cleaned, and heat-sealed.
- Filled bags are conveyed through metal detection and check weighing.
- Accepted bags accumulate and are robotically palletized.
- Full pallets are stretch-hooded for protection and conveyed to the end of line.
Watch a Video of an Automated Form, Fill, and Seal (FFS) Packaging Line
Ask a Question or Get a Price Quote!
Speak with one of our sales engineers today.
Call: (979) 217-1480
Equipment Descriptions
Product Reception and Dust Control
Bulk PVC powder is conveyed into a stainless steel feeder hopper designed with rounded internal geometry to minimize product retention. A vibrating fork level detector monitors material presence, while a dedicated cartridge dust filter with automatic compressed-air cleaning captures airborne fines generated during bagging.
Dosing and Weighing
The system uses a gravity-fed net weigher equipped with a dual cut-gate for coarse and fine dosing. Product is metered into a weigh hopper suspended on load cells, providing tight weight control before discharge into the bagging machine. The weighing cycle is managed through an HMI-based control system with recipe management and production data monitoring.
FFS Bagging Machine Forms Polyethylene Bags from Film Roll
Form, Fill, and Seal Bagging
A tubular FFS bagging machine forms polyethylene bags with side gussets directly from film rolls. The system cuts and seals the bag bottom, transfers the formed bag to the filling station, and clamps the bag tightly to prevent dust escape during filling.
After filling, bags are cleaned at the mouth, sealed using hot-bar corner sealing for improved bag shape, and discharged onto the conveying system. Integrated static elimination reduces powder adhesion at the filling spout.
Bag Handling, Inspection, and Control
Filled bags are conveyed through an inline metal detector to identify ferrous and stainless contamination, followed by a checkweigher to verify final bag weight and ensure compliance. Alarms or rejection logic can be added to prevent off-spec bags from reaching palletizing.
Filled Bag Exiting Inline Metal Detector and Checkweigher
An inkjet bag printer adds lot codes and other information before the bags are conveyed into a bag flattener conveyor and onto a robot bag pickup conveyor.
Palletizing
A robotic palletizer arranges bags into a stable pallet pattern. The system supports slip sheet insertion, empty pallet handling, and accumulation conveyors to maintain continuous operation.
Pallet Protection and Discharge
Completed pallets are transferred to a stretch hooding system, where a fitted plastic sleeve is applied to protect the load from moisture, dust, and handling damage. Finished pallets are then conveyed to the pickup area for removal by forklift.
Stretch Hooding System
Typical Products for This Type of System
While designed for PVC powder, this packaging line configuration is also well-suited for other free-flowing and semi-free-flowing products, including:
- PVC compounds and resins
- Plastic pellets and regrind
- Polymer powders and granules
- Chemical powders (non-hazardous)
- Fertilizers and mineral powders
- Additives and fillers
- Agricultural powders
Ask a Question -or- Get a Price Quote
If you need a dependable and automated form, fill, and seal (FFS) system to increase packaging speed, improve product consistency, or reduce labor costs, our sales engineers can help size the correct system for your product and throughput requirements.
Call: (979) 217-1480