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Bulk Processing Equipment Case Studies

Explore our case studies detailing how our bulk processing equipment has helped businesses streamline their operations and boost efficiency.

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Automated Rice Bagging Equipment for Rice Producer

View of Bagging Machine and High-Speed Bag Closer in an Automated Packaging System

Rice producers face several challenges when it comes to bagging and packaging their product. Manual bagging processes can be time-consuming, labor-intensive, and prone to errors. To overcome these challenges, a USA-based rice producer sought an automated packaging system that could increase production efficiency, reduce labor costs, and improve bagging accuracy. In this case study, we’ll examine how the company successfully implemented the system, resulting in significant time and cost savings.

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lowering stainless steel IBC bin onto discharge station above powder packaging machine

Stainless steel IBC (Intermediate Bulk Container) containers and systems are widely used in various industries for their durability and functionality in bulk powder handling. These containers are designed to store and transport large volumes of powders, liquids, and granules in a safe and secure manner. IBC systems are constructed using high-quality stainless steel, making them strong, corrosion-resistant, and easy-to-clean. They are available in various sizes and shapes and can be custom designed to fit specific material handling requirements. Stainless steel IBC containers and systems are a popular choice for industries that require powder blending equipment for the bulk processing of powders, such as chemical, pharmaceutical, nutraceutical, and food industries.

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robotic depalletizer and bag opening system for chemical powders

One of our manufacturers recently designed and implemented an automated robotic depalletizer and bag dump station for a customer in the chemical industry. The system involves a robotic depalletizer that unstacks 50 lb. bags of chemical powders from a shipping pallet located to the left and right side of the robot.  The bags are picked up 3 at a time and placed 1 at a time on a conveyor that transports them to an inclined belt conveyor that discharges them into automatic bag dump station. In this article, we’ll provide an overview of the system, explain how the automated system works using a vision system, and outline the features and benefits of the system.

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used robot bag stackerAutomating the stacking, or palletizing, of bags at the end of a packaging line with a used robot bag stacker can provide a fast return on investment.  Palletizing robots can be oriented in any direction to accept bag inflow from a new or existing bagging system.  They minimize the risk of repetitive injuries caused by stacking heavy bags on shipping pallets, while simultaneously reducing labor and staffing requirements.

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operator placing bags on valve bag filling machines

This valve bag filling system is used to fill 50 Lb. paper valve bags with different types of high-quality silica sand.  After filling, bags are conveyed to a robotic palletizer that automatically stacks the bags on pallet.

This type of silica sand is a high-quality round and sub-round silica sand with mesh sizes ranging between 8×16 and 100.  It has many uses including:

  • turf sand used for infill to protect artificial turf and increase its life expectancy
  • roofing sand for specialty roofing tiles, flooring titles, and colored grout
  • building and industrial sands as an ideal base for construction, concrete, bricks, foundry, and flooring
  • water filtration sand used in wells, filters, and other water fixtures
  • glass sand for large quantity glass production
  • oil and gas hydraulic fracturing sand

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deer corn bagging systemThe Grain and Corn Bagging System combines product storage, filling, and bag closing into one system.  Efficiently fill and close 30-50 lb. paper and poly-woven open mouth style bags.

The system has been engineered for bagging deer corn (whole corn), feed, seed, and other grains.  The manual, or mechanical, bagging option includes automatic weighing.  The system is upgradeable to a higher packaging speed with the addition of a high-speed bag sewing system to quickly close the bags.  Additional options are available including hand held bag sewing machines, bag flattening conveyors, and bag stacking systems.

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bagging machine fills 25 lb bags with horse pellets

Tinsley Equipment Company recently performed a test run for a new feed producer for filling 25 Lb. bags with horse pellets.

These type of supplement pellets were made of coastal hay and measured about ¼-1/2” in diameter and about 1 inch long.  The producer’s family farms different types of coastal hay and Bermuda grasses and wanted to learn more about the bagging and packaging process.

horse pellets or hay pellets for feed supplement

Horse pellets (or hay pellets) used for feed supplement

To run the test, Tinsley Equipment Company set up a 25 cubic foot bagger supply hopper, a digital gross weigh bagging machine with a pneumatic bag clamp, a temporary box platform under the scale to support the filled bag, and then a table for manual bag top folder over and handheld sewing.  Closed bags were manually transported and stacked on pallets resting on a truck trailer.  Finished pallets were manually wrapped and secured to the trailer before transporting them to a feed store for final sale.


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code printer for lot batch numbers and codes on bags

Lot / batch code and date printed on bottom part of bag after passing print head

This inkjet code printer was put to the test in an animal feed and minerals packaging line. Multi-wall open mouth paper bags, filled with animal feed are sewn shut.  Then, they pass in front of the code printer on a conveyor before robotic palletizing. As each bag passes the code printer, a lot code and date are printed on the bottom part of the bag.  Each of these unique codes helps to identify when the batch of product was produced and packaged.

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Plastic Compounding with an Intermediate Bulk Container IBC System

An Intermediate Bulk Container (IBC) System is used to prepare a homogeneous dry blend of base polymers and additives before the extrusion phase in a plastic compounding process.  Plastic compounding and toll processing companies first use an IBC system to create a lab formulation or test to confirm final product characteristics before creating a masterbatch.  Once a final product has been confirmed, the same IBC system is used to create a larger batch or production run.

IBC container being raised by forklift

IBC is easily transported by forklift to other discharge stations

This type of set up using an Intermediate Bulk Container (IBC) System is also known as a decoupled system because ingredients can be moved, mixed, and blended independently inside the IBCs.

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Alfalfa Pellets Bagging Machines and Systems for 20-110 LB Bags

Alfalfa Pellets

These alfalfa pellets bagging machines and systems are used to efficiently fill 20-110 lb. paper or plastic open mouth bags with a variety of alfalfa pellets and cubes.  Buy just a bagging machine or an entire bagging system that includes a free-standing hopper, bagging scale, conveyors, bag closers, palletizers, and more. These systems are designed to fill 20-110 lb. paper or plastic open mouth bags with alfalfa pellets, with the most popular bag size being 50 lbs.

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Newlong DS-9C Bag Sewing Head

Newlong DS-9C Bag Sewing Head

The Newlong Bag Sewing Machine DS-9C high-speed industrial sewing head is a popular choice for businesses seeking to improve their bag closing operations. In this article, we will explore the key features of the Newlong DS-9C, how it works in conjunction with a power infeed system, and the benefits it brings to bag closing processes.

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The video below shows a bag palletizing robot stacking 50 lb. paper valve bags onto a pallet located on the floor per the programmed bag placement design.  This robot was added to an existing bag filling system to reduce labor costs and increase automation.

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Bagging Livestock Minerals & Supplements into 25, 40, 50 Lb Bags

Robot Stacks Bags on Shipping Pallet

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