https://rutube.ru/play/embed/d613cbca309e363b083cdd5d37a1b912
In modern industrial production, the competitiveness of an enterprise is determined not only by the quality of the product, but also by the speed, accuracy and cost-effectiveness of its shipment to the consumer. This is especially true for enterprises producing bulk materials such as cement, gypsum, sand, dry building mixes, mineral fertilizers and other types of products. One of the key links in the logistics chain of such industries is the packaging of finished products. It is here, in the packaging sphere, that modern technologies demonstrate their maximum efficiency. A striking example of the implementation of such solutions is the automated big-bag packaging line installed at the production site of ZVO LLC.
What is a big bag and why is it so important?
A big bag (from the English Big Bag — «large bag») is a modern universal container for the transportation and storage of bulk and granular materials. These are durable soft containers made of polypropylene fabric with a load capacity of, as a rule, 500 to 2000 kg. Their main advantages:
- Economy: Significantly cheaper and lighter than metal or plastic containers.
- Convenience: Easily stacked and transported folded, taking up minimal space.
- Safety: Ensures the safety of products from moisture, dirt and leaks.
- Ergonomics: Equipped with slings for quick and easy gripping by a forklift or crane.
For a manufacturer such as ZVO LLC, the transition to shipping products in big bags means the opportunity to offer customers a more convenient and modern delivery format that meets international logistics standards.
From manual labor to full automation: the evolution of packaging
Historically, the packaging of bulk products was one of the most labor-intensive and «dirty» processes in production. It required the participation of several operators, it was difficult to control the accuracy of the weight, and the packaging speed was directly limited by the human factor.
An automated line similar to the one that operates at ZVO LLC changes this picture dramatically. It is a set of interconnected equipment operating as a single organism under the control of a programmable logic controller (PLC).
Key elements of the automated packaging line at ZVO LLC
Accumulative and dosing bin: The line starts with a receiving bin, where the product comes from the storage silo. Here it undergoes preliminary accumulation and stabilization, which eliminates freezing and ensures uniform feeding.
Automatic scales: The heart of the entire line is a high-precision strain gauge scale. The product enters the weigh bin, where it is weighed with minimal error (usually ±0.1–0.5% of the norm). Modern multi-component weighing systems provide ultra-high dosing accuracy.
Filling unit (bag filler): This is a mechanism that directly fills the big bag. The operator or robotic manipulator manually places the empty bag on the loading nozzle (manual manipulator). Then the process occurs automatically:
- The system fixes the bag with special clamps.
- The aspiration system is turned on, which sucks air out of the bag, creating a vacuum and straightening it.
- The dispenser valve opens, and the product, under its own weight or with the help of a vibration compactor, enters the big bag.
Conveyor system: After filling, the bag is released by clamps, and it moves along the conveyor belt to the next section. The conveyor can be equipped with control scales to control the weight of already filled big bags.
Sewing/sealing unit: At this stage, the filled bag goes to the operator or to the automatic sewing machine, which hermetically sews the neck of the big bag, ensuring the safety of the product during transportation.
Aspiration and filtration system: The most important element responsible for the environmental friendliness and cleanliness of production. It captures dust that inevitably forms when loading bulk material, preventing it from entering the workshop. This protects the health of employees and equipment, and reduces product losses.
Control system: The entire process is controlled using the operator touch panel (HMI). All parameters are set here: package weight, operating speed, number of cycles. The system displays all stages of work in real time, signals errors (for example, the absence of a package on the nozzle) and keeps records of manufactured products.
Advantages of automation for ZVO LLC
The implementation of an automated packaging line brought the company a number of tangible advantages:
High productivity: The line is capable of packing up to 20-30 or more big bags per hour, which is several times greater than the capabilities of manual labor.
Unprecedented accuracy: Human errors in dosing are excluded. Each client gets exactly the weight they paid for, which strengthens the company’s reputation.
https://rutube.ru/play/embed/a40cabd4df450e5b8e34fe9db22ad8b5
Cost minimization: Reduction
https://rutube.ru/video/d613cbca309e363b083cdd5d37a1b912/?r=wd
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