In modern manufacturing industries, greater emphasis and importance are placed on the packing of flour than in the past. Because by planning your packing, you will deliver positive results to your business. Select the requisite machinery carefully, choose reliable suppliers, make sure that you have additional capacity for the future within the machinery you invest in, and work to a practical layout, which avoids unnecessary expenditure. Getting an automated flour packing machine will help you meet the current demands and keep up with the tight competition in the market.
In today’s milling industry, particular emphasis and importance are placed on the packaging than has been the case in the past. The reason for this is good packaging, and innovative thinking will attract more customers and increase your profits. The key points to be addressed by any mill before starting a packaging product are:
- Selection of equipment- versatility, flexibility, and level of automation
- Tonnage capacity
- Layout of floor space
What is a flour packing machine?
It is a machine with a complete packing system that can weigh and pack the flour depending upon the information we provided. It has display screen and control buttons to manage it. You can input your needs, and the machine will produce the desired weight of flour packages.
Components of flour packing machine
The single unit of flour packing machine consists of many different parts, and all these parts work in harmony to produce a single package of flour. Before undergoing the packing device, the grains have to undergo the cleaning to wash out any impurities. After the cleaning part, the damped grains will experience the milling part. The mill breaks the grains into fine powder in which each particle will be of equal size. Now this powder will be loaded into the packing machine.
The flour packing machine has many components that all work together to produce a single package. But for this guide, we will focus on major ones. Keep in mind that the location of each component will vary according to the type of packing machine you are using. Following are some essential components packing machine has:
It has a control system to coordinate different components of the machine. The flour packing machine uses PLC control systems to coordinate the mechanical parts of the device. In some cases, the touching mechanism is also integrated with the PLC control system. Having a touch screen will help in efficiently controlling the machine.
This component consists of the power and motor system and other parts that work together to operate all the components in the packing machine. This system will provide energy for all other features to work correctly.
The dosing system is a crucial part of the flour packing machine because it is responsible for supplying and filling the flour in various packages. It is made of an auger filler that dispenses the flour products for loading purposes. This system is responsible for producing different sizes of containers.
The loading system of the machine is where the operator loads the packages for processing by the machine. It also can have feeding rollers and gripping arms to retain the packages stable.
Most fully automated flour packing machines use intermittently moving Conveyor belts to transfer containers from one place to another in the packaging line. It will separate the empty containers from the filled ones, and the sealed containers are then ready to go further into the packing line.
Some flour packing machines have Dusting systems in them. This system will remove any dust particles from the flour that may become incorporated during packing.
This section of the flour packing machine handles the completed flour packages transferred to another station for further processing.
The manufacturers of flour packing machines may customize the designs of the unit according to the customer’s demand. So before buying any packing unit, always ask for the user’s manual for that unit.
How to use a Flour Packing Machine?
Not everyone knows how to use a Flour Packing Machine. In this section, we will guide you on how to use the filling and sealing machine.
- Premade pouches will be loaded directly into the in-feed section. Carefully load the bags avoiding any folds for proper packaging.
- There is a vacuum suction arm in a fully automated machine that grasps each pouch and transfers it to the grippers from where the bags move onto the next section.
- The pouch grippers hold the pouch firmly on both sides of the top of the bag and transfer it to the following stages in line. The grippers are reinforced by stainless steel, making them capable of withstanding eights of even up to 10kg for quite some time.
- Optionally some machines have an inkjet or thermal printers for customization of pouches.
- A combination of opening Jaws will open the pouches, and a blower jet blast fresh, hygienic air into the bags to make them inflate.
- Now the auger filler will fill the inflated pouch with the exact quantity of flour needed. The operator can set the amount of flour by using a control panel.
- During the process, the dust hood present above the fillers will collect any dust particles present.
- Next, the full pouches proceed towards the deflator plates. These plates will smoothly squeeze the bag to expel the excess air.
- Now, a system of hot seals closes the top section of the pack.
- Then a cooling bar passed over the hot bar and straightened the sealed section of the bag.
- This package is now ready to be dispatched. The finished packages will track from the machine and drop onto the receptacle and move into the next for additional processing.
- Benefits of flour packing machine
- Flour packing machines are used widely for commercial purposes as it makes the job of packing easy. Following are some essential functions of flour packing machine due to which their use has been increased:
- Itself make bags or pouches for the flour
- Weigh the flour for filling
- Fill the flour into the bags or containers
- It can make both plastic or paper bags according to the demands of the target market.
- Seal the bags or containers
- It can count the number of packaged bags
- The new machine can make up to 20 packages per minute.
Where to install a Flour Packing Machine?
You should understand the correct use of flour packing machines before purchasing them. The following points will help you understand the importance of an ideal location for your flour packing unit and how to take care of your unit.
- Position the packing machine as near as possible to the incoming flour. That is, it should be near the milling unit of the flour machine.
- Make sure that the directional flow of the packed bags is the same in all lines.
- Avoid long conveyors when and where possible
- Avoid bends in conveyors when and where possible
- Ensure that adequate free space around each machine is available
- Ensure that sufficient free passage for forklifts is available
- Make sure that all finished products have the minimum distance to reach the warehouse
How to Choose a Flour packaging machinery
Before choosing the flour packing machine, one should consider all of the following factors into consideration:
- The capital cost of the packing machine itself
- Cost of the packaging material per piece
- Secondary packaging costs (for example for putting packs into boxes)
- Estimated additional costs for other items to be used as hot melt glue, shrink film, boxes, labels, cartons, etc.
- Technical capabilities
- Labor requirements
- Worker safety
- Floor space
- Return on investment
How can a packing machine benefit your business?
In today’s competitive market, where there are many manufacturing industries, one needs to make its brand stand out. For this purpose, modern and creative packing design is necessary. Attractive packaging will attract customers and increase your brand awareness in the market. Buying a packing machine will save you from the exhausting process of manual packing. An automated packaging machine will give you the following benefits.
Cost-effective and efficient production
A single unit of flour packing machine costs a tremendous amount of money, which is a significant investment. But in the long run, the investment will help you reduce the labor costs and eliminate human errors from the process. It can help you reach the high production demand efficiently in a short amount of time. Efficient production of flour packages is necessary in today’s competitive world.
Improved Brand value
Automated packing machines can produce flexible packages. It is easier to create various packages designs with your brand logo on them. It will help your brand to be recognized by your customers and warn trust of your target market. The presentation of your product on the supermarket shelves is an essential factor in attracting potential buyers.
Extended products shelf life
Flour packing machines are essential in retaining the freshness of your flour and increase its shelf life. The material of packages made from these machines is environment-friendly and does not react with your product, keeping it safe and preserving its quality.
Increase reliability and functionality
The automated flour packing machine can perform different packaging processes, like filling, capping, sealing, and labeling, with little human intervention. This automated machine can ensure the reliability of the packaging process with the help of the latest technologies. Also, it can produce an increased number of flour packages per minute compared to manual packaging, helping in fulfilling the market demands.
Improved Ergonomics and lowered risk of employee injury
In manufacturing and packaging industries, where it is common for employees to perform highly repetitive tasks over long shifts, it’s not uncommon for employees to get injured during this process. This injury may vary from superficial skin injuries to work-related musculoskeletal disorders. These sometimes are called ergonomic injuries.
By automated flour packing machines, employees’ workload will decrease, and naturally, the ratio of employees getting injured or suffer from musculoskeletal disorders will also decrease. Process automation systems are already an exceptional fit for repetitive and tedious tasks because these tasks often benefit from consistency. By swapping machines with workers for highly tedious and repetitive tasks, it is possible to increase productivity and reduce workers’ risk of injury.
With automatic packaging, you can be sure that every package is well protected through a standardized packing process. Using a flour packing machine, each product will have a tailored packing design and shape so that you can be sure that the level of protection is the same for every package.
Flour packing machine also has following benefits along with the ones as mentioned earlier:
- It will eliminate potential bottlenecks
- It will eliminate downtime
- It will increase the production speed
- Better customer service
- Types of flour packing machine
- Generally, the flour packing machine can be classified based on the following categories.
- The design of the flour packing machine
- The automation level of the flour packing machine
- Based on flour packing machine design
Inline flour packing machine
The type of flour packing machine which uses an Inline design will pack products in straight and orderly lines. This means that the starting and finishing points of the operating machine are located at the lines opposite end. This type of packing machine design has only single input and output lanes.
The major drawback of this type of design is that it requires ample floor space for its installation. But some packagers still prefer the Inline packing machine because it is easier to inspect each packaging station in these designs. This type of design enhances visibility and makes it easier to check all packages.
Rotary flour packing machine
This type of machine has circular designs; the operation is performed in a circular motion, giving the operator an ergonomic format. Therefore, the Rotary flour packing machine does not occupy ample space to operate. It can easily be confined to a small area without affecting the outcome of the product. Also, the starting and ending points of the operation in the Rotary machine design are close to each other.
For higher production requirements, Rotary flour packaging machines are vastly used. They feature one to four in-feed lanes, but the one-lane machine design is more common and used mainly by entrepreneurs.
Apart from the lanes, there are permanent stations in the rotary flour packing machine. These permanent stations are embedded circularly. Each station performs a selected procedure within the packaging process. These stations can vary from one machine to another, but there will be eight stations.
Based on automation of flour packing machine
Fully automatic flour packing machine
In this design of flour packing machine, the machine will not need monitoring or operation from a human being throughout the whole procedure. The operator just had to enter the appropriate parameters in the machine, and it will do the rest of the job. Moreover, these machines have sensors that help different coordinate pieces of equipment of the machine during the whole packaging process.
For example, the sensor detects if a predetermined fill level is reached, and then it signals the machine to stop the further filling of the package. With the help of these sensors, the whole process of filling and packaging will run automatically and continuously. It will also reduce the human errors caused by manual packaging.
Semi-automatic flour packing machine
This packing machine needs the operator to manually put the pouch or bag in the machine and initiate the packaging process. As the name suggests, some procedures of Semi-automatic machines will work automatically, but the majority of the processes still rely on the operator.
Things to consider before buying a Flour Packing Machine
Buying a Flour Packing Machine that will suit your business is not as easy a task as it seems. You have to do complete research on the qualities each type of machine has to offer before selecting a suitable one for you. The key aspects one should consider are the following:
The type of packaging you will be using will determine the kind of machine appropriate for your brand. Different machines are needed for different packages; for example, bags, pouches, containers all will require different types of machinery.
You have to consider your budget before buying any machinery. Your profit should be your priority, so you should pick the machine that will require less investment and give more profit. For example, a fully automatic packing machine will require massive investment and may not be practical if your business has low production requirements.
Which design will suit your business better Inline or rotary? You should decide that after examining your comfort level with each type of machine. You should also carefully pick the design of your machine, keeping in mind the available floor space in your factory.
You should know your daily production requirements. If you are a small or medium-sized business owner and your business does not require a large amount of production, you can go for semi-automatic machines as they will be more practical. For large productions, a fully automatic packing machine will be more suitable.
VFD, servo motors, electric motor, and vacuum suctions are among the several options you could choose from for your business. You should consult with the manufacturer and explain your demands to them. They can tell you which driving mechanism will be suitable for your factory. As one driving mechanism may be better than another depending upon the product, you needed to be packed. For instance, servo motors will be more effective for filling systems.
Machine control system
The perfect and easy-to-handle control system is necessary to operate the packaging machine efficiently. An integrated PLC and man-machine interface in the fully automated machine is considered the ideal control system for any machine. This type of control system is easier to operate and enhances the efficiency of the packaging machine.
Dust management system
During the whole packaging process of flour, flour has to go through different packaging lines components before reaching the endpoint. The flour may become contaminated with dust during this process. This is a common problem in every packaging industry. This is why dust collectors, dust hoods, dust vacuum stations, scoop feeders, and load shelves are all needed to minimize dust pollution and keep the package free from dust particles. You have to carefully choose your packing machine, keeping this point in mind. As dust-contaminated flour will give your brand a wrong impression in the market, you may lose customers.
It is also a crucial factor to consider before purchasing a new packaging machine. You have to select a material that is least likely to corrode. For this purpose, stainless steel grades 314 and 316 are recommended for the machine’s structure to minimize the possibility of rusting and corrosion.
Machine’s quality standards
On top of your priorities, you should include the quality standards of your packaging machine manufacturers regarding their products. Always pick the product which has satisfied different standards criteria and has certification like CE, CGMP, and ISO. Packaging machinery can be:
- Purchased as standard, off the shelf equipment
- Purchased custom-made or custom-tailored to specific operations
- Purchased refurbished and upgraded
- It was manufactured or modified by in-house engineers and service staff.
- You have to consider all these options before selecting a suitable one for you.
This parameter is different for different machines. Usually, flour packing machine manufacturers will clarify the production capacity of their machines to you. You should select the one which would meet your production requirements. For example, if you own a large flour industry that requires numerous packages to deliver to the market every day, you have to go for the machines that can produce 20 packages per minute. As you already know, the number of packets per minute is different for every type of packaging machine; the prices of these machines may also vary. So carefully choose the one keeping in mind all the aspects that the machine is offering.
Types of packages for the storage of flour
Two types of packages are common in the market for flour packaging- Paper bag or plastic bag. You have to do complete research on the trends in your target market. Generally, if the paper bag is used in flour packaging, it will be sealed in a brick shape, and if the plastic bag is used for packaging, it will be packed in a cushion or pillow shape. If you are storing the flour in a plastic bag, you have to make sure that the material of the plastic will not react with the flour. After you have decided the type of material for your packaging, you will select your machine depending on that.
An automated flour packing machine is a virtual machine that every packager should improve the packaged products’ efficiency, reliability, and quality. Being familiar with a flour packing machine’s essential aspects will help you choose the right one ideally. As you already know, today’s world is a world of technology and automation. An automated machine can help you achieve your target efficiently in a short amount of time without any errors. These machines are better than manual packaging as there is a high risk of human error in manual packaging. Also, manual packaging will take a lot of time, and you may face difficulties with supplying the package within time.