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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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fertilizer bagging system using buckhorn centerflow seed boxes

This fertilizer bagging system is used to fill poly bags with granular, free-flowing fertilizer. It includes a specially designed discharge stand and stainless steel hopper for Buckhorn CenterFlow seed boxes, a stainless steel digital gross weigh bagging scale with pneumatic bag clamp, a stainless steel mesh belt bag closing conveyor, and a hot air bag sealer.

The same type of system could be used to bag other types of free-flowing products like animal feed, plastic pellets, grains, seeds, wood pellets, and more. Multiple bag filling recipes are stored and easily swapped out via the digital scale controller.

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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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used robot bag stackerAutomating the stacking, or palletizing, of bags at the end of a packaging line with a used robotic palletizer can provide a fast return on investment.  Robotic palletizers 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

These valve bag filling machines are used to fill 50 Lb. paper valve bags with different types of high-quality silica sand.  After filling, bags are conveyed to an automatic palletizer that stacks the bags on a 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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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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bulk feed tote bag unloaderThis simple system is used to safely unload bulk feed tote bags (also called FIBC, bulk bags, Super Sacks®, or jumbo sacks) containing dry, free-flowing products by gravity into an open mouth bagging machine and scale.  The bagging machine would then weigh out a desired amount of feed into each open mouth bag, with 40lb. and 50lb. bags being the most popular.

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intermediate bulk containers or ibc

Blend metal powders evenly inside a stainless steel intermediate bulk container.

Prevent powder bridging, rat holing, or segregation with a cone valve that is integrated into the bottom of each IBC container!

Stainless steel intermediate bulk containers and IBC blending systems are a special type of custom blending equipment that are widely used in various industries for their durability and functionality in bulk powder processing. These containers are designed to store and transport large volumes of powders, liquids, and granules in a safe and secure manner.

These types of powder blending systems are constructed using high-quality finished 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 metal powder handling requirements. Stainless steel IBC containers and systems are a popular choice for industries that require powder mixing solutions for the bulk processing of powders, such as powder metallurgy, chemical, pharmaceutical, nutraceutical, toll blending, 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 automatic depalletizer and bag dump station for a customer in the chemical industry. The system involves a robot 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 robot depalletizer system works using a vision system, and outline the features and benefits of the system.

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What is ratholing in powder flow?

rat holing of powder in hoppers bins ibc containerRatholing occurs in hoppers, bins, and intermediate bulk containers when cohesive powders with interlocking particles build up or cake on the walls or sides of the container.  This occurs more frequently when powders are discharged using a butterfly valve or slide valve and the powder flow takes place directly above the outlet.  This creates a funnel flow effect where the cohesive powders flow directly above the outlet, but eventually build up on the sides reducing or stopping flow and powder discharge all together. This results in increased processing time including container disassembly and cleaning.

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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 that was interested in bagging horse pellets into 25 lb bags.

These type of supplement horse pellets were made of coastal hay and measured about ¼-1/2” in diameter and about 1 inch long.  The producer 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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