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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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fanuc robot picking up 100 lb. bag of minerals using a bag gripper tool

Robotic bag handling equipment picking up 100 lb. bag of minerals using a bag gripper tool

A contract packaging company recently added robotic bag handling equipment to their existing valve bag filling system.  The new palletizing system includes bag handling and robotic pick conveyors, a Fanuc robotic arm that has been reconditioned with a bag gripper tool, and an automated pallet and slip sheet dispenser.

With the added automation, the entire system is now able to fill and stack 100 lb. paper valve bags at a rate of 10-12 bags/minute.  The company can also quickly swap out settings to fill and stack 50 lb. valve bags at a rate of 15-16 bags/minute.

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box palletizing robot stacks multiple boxes at once on a palletThis box palletizing robot can pick up multiple boxes at once and stack them on a shipping pallet.  It can pick up different sized boxes from multiple infeed conveyors on both sides of the robot.  An automatic pallet dispenser can line up multiple pallets at once to reduce downtime as full pallets are discharged from the box stack zone.  Choose from different stacking patterns to fit your specific box and pallet sizes.

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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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automatic bag opener and emptying system

This automatic bag emptying machine with opener can slice and slit open 20-110 pound bags and empty their contents into downstream conveyors or processing equipment. It opens and empties various bag types including multiply / multiwall paper bags, polywoven bags, and burlap bags containing but not limited to coffee, flour, grains, nuts, sugar, spices, beans, seeds, salt, oats, corn, cocoa, peanuts, mustard, peppercorn, whey powder, corn flour (starch), chemical powders and granules, as well as active pharmaceutical ingredients (APIs).

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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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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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Filling Bulk Bags with Feed or Seeds

Filling bulk bags with animal feed or seeds can range from a semi-automatic to a fully automated process.  These types of bulk bag filling machines are designed to fill an open spout or duffel top bulk bag with granular, free-flowing, or semi-free flowing materials like corn, grains, nuts, rice, fertilizer, salt, dry sand, plastic pellets, and more.

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automatic nut bagging system with robotic bag placer

An automatic bag placer machine picks up, hangs, and clamps an empty open mouth bag onto a bagger before product is discharged into the bag.  20+ bags per minute are possible and it works with both new / existing net weigh and gross weigh bagging scales.  With this type of automation, one full-time operator can be removed from the bagging system. Two operators can be removed if you including the automatic bag sewing or bag heat sealing system.

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