FFS – IMPORTANT ELEMENT OF EFFICIENT PALLET LOGISTICS
Industriesäcke sind in der Feindistribution von Massenschüttgütern nach wie vor unverzichtbar, unter wirtschaftlichen Gesichtspunkten aber nicht immer beliebt. Moderne Absackverfahren wie FFS (Form, Fill, Seal) aber zeigen, daß es noch immer Kostensenkungspotentiale zu erschließen gibt. Neueste maschinentechnische Entwicklungen verschieben bisherige Grenzen der Anwendbarkeit des Verfahrens in Bereiche, die ihm bisher verschlossen waren.
Windmöller & Hölscher based in Lengerich, Germany is the number one address world-wide, when it comes to machinery and equipment for the production of industrial sacks out of paper, film and woven tape material. The company is, however, equally versed in packaging technology and offers the market a complete program of FFS bagging systems suitable for handling pelletized, granular and coarse- as well as fine-grain powdery products with maximum reliability and commercial efficiency. The acronym FFS stands for a cost-optimized bagging method with bag making, filling and sealing taking place in-line, eliminating the need for the procurement, storage, and filling of pre-made sacks. In addition, the all-around closed, durable, and waterproof bag provides perfect protection of the filled product, combined with optimum utilization of transport and storage space as a result of the brick-type shape as well as a highly attractive presentation of the product thanks to the brilliantly printed surface of the packaging film used.
Unlike the known tubular bag making machines, which work from the flat web, W&H bagging systems are designed to use exclusively heavy-duty tubular film, sometimes pre-made out of flat webs. For this reason, there is no need for longitudinal seam welding, with a resulting positive effect on film usage and bagging speed. As an added benefit, the FFS process is specially suited to produce gusseted sacks – with or without corner sealing – which offer notable advantages in regard to stacking quality.
Boasting a market share of markedly over 40 per cent and around 700 references world-wide, W&H is the uncontested market leader in this segment. Main applications of the process include the bagging of plastic resins, pellets, and granules such as PE, PP, PC, PA, PS or S-PVC. Apart from this, W&H packaging systems have been successfully used in the bagging of other products such as fertilizers, salts, special sands, vitamins, sugar, pet litter, etc.
The following presentation briefly describes the market position of the individual machines which are marketed by W&H under the names of gems:
TOPAS® is the FFS bagging system covering the broadest application spectrum. From the point of view of operating principle a drop chute packer, the machine excels with a large size range and plenty of product-related engineering solutions such as, for instance, bypass hopper, dust removal system or clean-up capability. The machine can therefore be adapted to the most diverse bagging requirements with filling weights ranging from 5 to 50 kg. In addition to the classic product weighing concept, volumetric dosing is available as well.
The reliable bagging of dusty and heavy-flowing bulk goods is the special forte of the OPAL®.
Automatic roll change, air evacuation assemblies, corner sealing, edge sealing, handle die-cutter or explosion-proof design in full compliance with ATEX standards – are other examples documenting the flexibility as well as productivity of TOPAS® and the high functional quality of the packages it produces. Special attachments comprised in the "dust package" even allow for highly dusty products to be bagged reliably and with ease.
Because of its compact design, the TOPAS® also lends itself as a portable unit for use in bagging terminals where it can be docked to the specific silo as need be. Rails, wheels, or air cushion systems are available for this.
The extraordinary versatility, capability and reliability of the TOPAS® have made it the most widespread bagging system in the world for handling standard and engineering resins, PVC powder, chemical base and intermediate products, food and pharmaceutical products, fertilizers, filter sands, wood pellets and a lot more.
RUBIN®, like its big sister TOPAS®, is suited to free flowing products, including fine- to coarse-grain structures, such as salt, sand, plastic resins, fertilizers, wood pellets, animal feed and pet food, food and feed additives as well as fine chemical products.
TOPAS® with edge sealing capability, specially suited to the bagging of consumer products.
Designed for bagging speeds up to 400 bags/h, the machine was specially designed for applications not justifying FFS technology from the economic point of view so far, i.e. small batches or non-continuous operation.
Completely pre-tested and featuring a highly compact design with integrated electrical cabinets, it will easily fit into existing filling infrastructures. Its low design height is the result of the integrated gross weighing system (which comes, of course, with European MID calibration approval).
Delivered as a pre-assembled unit ready for hook-up, the only things to do on site is power and air connection as well as the equipment for product feeding and filled bag removal. Installation on site is done so quickly and easily that bagging can mostly start right away.
Even the RUBIN® in standard specification provides an amazingly broad flexibility with regard to products versatility. Package sizes can be individually adjusted to the bulk weight of the product, pallet dimensions, and market requirements. A comprehensive range of add-on modules are available to extend and enhance the machine's application spectrum.
DIAMANT® is the high-performance counterpart of the RUBIN® within the FFS program, since it is designed for continuous operation and high speeds of up to 2,000 bags per hour. Main uses include the bagging of fertilizers as well as chemical and petrochemical complexes, i.e. applications demanding perfectly reliable and commercially efficient packaging of bulk products.
High-performance DIAMANT® FFS system – the ideal packaging system for continuous high-speed operation as required in the petrochemical industry.
The rotary operating principle of the filling section provides ideal conditions for longevity even in the rough environment of the bagging plant. Intermediate storage of empty sacks in a cooling section prior to filling guarantees high strength bottom seals, while at the same time ensuring the shortest possible filling cycles. Minimized film overhangs at the top and bottom seals give maximum film utilization and reduced film costs. Automatic roll change increases the effective up-time for greater productivity.
Like with TOPAS® and RUBIN®, the optional corner sealing unit for the top and bottom seals enhances the stability and gives a perfect shape to the filled sacks, essential for neat stacking and an attractive presentation of the individual bag. As an added benefit, residual product left in the sacks after emptying is eliminated.
OPAL® is the packaging system for products making more exacting demands on the bagging process – i.e. heavy flowing and dusty of the type frequently used in the chemical industry, the building material sector and also in the food and feed industries.
To handle such products, the OPAL® uses an auger feed system which allows not only to bag very fine free-flowing products but also ensures the same perfect handling of products that tend to stick, clog or bridge and so far not suitable for FFS application. The product is fed into the bag from the bottom up (under-level filling), which eliminates dust during filling to the greatest extent possible. This gives the best protection against contamination in the sealing area of the sack mouth – essential for high-strength, reliable top seals.
The reliable bagging of dusty and heavy-flowing bulk goods is the special forte of the OPAL®.
Thanks to the special layout of the OPAL® with a filling section that can be offset laterally relative to the bag making section, the product feed assembly becomes easily accessible – a major advantage when it comes to clean-up or product changeover.
A comprehensive selection of optional units is available also for the OPAL® to adapt it to specific filling situations and requirements, including an air evacuation system, corner sealing, and an explosion-proof package in full compliance with ATEX standards.
Efficient Pallet Logistics
FFS – IMPORTANT ELEMENT OF EFFICIENT PALLET LOGISTICS
Industriesäcke sind in der Feindistribution von Massenschüttgütern nach wie vor unverzichtbar, unter wirtschaftlichen Gesichtspunkten aber nicht immer beliebt. Moderne Absackverfahren wie FFS (Form, Fill, Seal) aber zeigen, daß es noch immer Kostensenkungspotentiale zu erschließen gibt. Neueste maschinentechnische Entwicklungen verschieben bisherige Grenzen der Anwendbarkeit des Verfahrens in Bereiche, die ihm bisher verschlossen waren.
Windmöller & Hölscher based in Lengerich, Germany is the number one address world-wide, when it comes to machinery and equipment for the production of industrial sacks out of paper, film and woven tape material. The company is, however, equally versed in packaging technology and offers the market a complete program of FFS bagging systems suitable for handling pelletized, granular and coarse- as well as fine-grain powdery products with maximum reliability and commercial efficiency. The acronym FFS stands for a cost-optimized bagging method with bag making, filling and sealing taking place in-line, eliminating the need for the procurement, storage, and filling of pre-made sacks. In addition, the all-around closed, durable, and waterproof bag provides perfect protection of the filled product, combined with optimum utilization of transport and storage space as a result of the brick-type shape as well as a highly attractive presentation of the product thanks to the brilliantly printed surface of the packaging film used.
Unlike the known tubular bag making machines, which work from the flat web, W&H bagging systems are designed to use exclusively heavy-duty tubular film, sometimes pre-made out of flat webs. For this reason, there is no need for longitudinal seam welding, with a resulting positive effect on film usage and bagging speed. As an added benefit, the FFS process is specially suited to produce gusseted sacks – with or without corner sealing – which offer notable advantages in regard to stacking quality.
Boasting a market share of markedly over 40 per cent and around 700 references world-wide, W&H is the uncontested market leader in this segment. Main applications of the process include the bagging of plastic resins, pellets, and granules such as PE, PP, PC, PA, PS or S-PVC. Apart from this, W&H packaging systems have been successfully used in the bagging of other products such as fertilizers, salts, special sands, vitamins, sugar, pet litter, etc.
The following presentation briefly describes the market position of the individual machines which are marketed by W&H under the names of gems:
TOPAS® is the FFS bagging system covering the broadest application spectrum. From the point of view of operating principle a drop chute packer, the machine excels with a large size range and plenty of product-related engineering solutions such as, for instance, bypass hopper, dust removal system or clean-up capability. The machine can therefore be adapted to the most diverse bagging requirements with filling weights ranging from 5 to 50 kg. In addition to the classic product weighing concept, volumetric dosing is available as well.
The reliable bagging of dusty and heavy-flowing bulk goods is the special forte of the OPAL®.
Automatic roll change, air evacuation assemblies, corner sealing, edge sealing, handle die-cutter or explosion-proof design in full compliance with ATEX standards – are other examples documenting the flexibility as well as productivity of TOPAS® and the high functional quality of the packages it produces. Special attachments comprised in the "dust package" even allow for highly dusty products to be bagged reliably and with ease.
Because of its compact design, the TOPAS® also lends itself as a portable unit for use in bagging terminals where it can be docked to the specific silo as need be. Rails, wheels, or air cushion systems are available for this.
The extraordinary versatility, capability and reliability of the TOPAS® have made it the most widespread bagging system in the world for handling standard and engineering resins, PVC powder, chemical base and intermediate products, food and pharmaceutical products, fertilizers, filter sands, wood pellets and a lot more.
RUBIN®, like its big sister TOPAS®, is suited to free flowing products, including fine- to coarse-grain structures, such as salt, sand, plastic resins, fertilizers, wood pellets, animal feed and pet food, food and feed additives as well as fine chemical products.
TOPAS® with edge sealing capability, specially suited to the bagging of consumer products.
Designed for bagging speeds up to 400 bags/h, the machine was specially designed for applications not justifying FFS technology from the economic point of view so far, i.e. small batches or non-continuous operation.
Completely pre-tested and featuring a highly compact design with integrated electrical cabinets, it will easily fit into existing filling infrastructures. Its low design height is the result of the integrated gross weighing system (which comes, of course, with European MID calibration approval).
Delivered as a pre-assembled unit ready for hook-up, the only things to do on site is power and air connection as well as the equipment for product feeding and filled bag removal. Installation on site is done so quickly and easily that bagging can mostly start right away.
Even the RUBIN® in standard specification provides an amazingly broad flexibility with regard to products versatility. Package sizes can be individually adjusted to the bulk weight of the product, pallet dimensions, and market requirements. A comprehensive range of add-on modules are available to extend and enhance the machine's application spectrum.
DIAMANT® is the high-performance counterpart of the RUBIN® within the FFS program, since it is designed for continuous operation and high speeds of up to 2,000 bags per hour. Main uses include the bagging of fertilizers as well as chemical and petrochemical complexes, i.e. applications demanding perfectly reliable and commercially efficient packaging of bulk products.
High-performance DIAMANT® FFS system – the ideal packaging system for continuous high-speed operation as required in the petrochemical industry.
The rotary operating principle of the filling section provides ideal conditions for longevity even in the rough environment of the bagging plant. Intermediate storage of empty sacks in a cooling section prior to filling guarantees high strength bottom seals, while at the same time ensuring the shortest possible filling cycles. Minimized film overhangs at the top and bottom seals give maximum film utilization and reduced film costs. Automatic roll change increases the effective up-time for greater productivity.
Like with TOPAS® and RUBIN®, the optional corner sealing unit for the top and bottom seals enhances the stability and gives a perfect shape to the filled sacks, essential for neat stacking and an attractive presentation of the individual bag. As an added benefit, residual product left in the sacks after emptying is eliminated.
OPAL® is the packaging system for products making more exacting demands on the bagging process – i.e. heavy flowing and dusty of the type frequently used in the chemical industry, the building material sector and also in the food and feed industries.
To handle such products, the OPAL® uses an auger feed system which allows not only to bag very fine free-flowing products but also ensures the same perfect handling of products that tend to stick, clog or bridge and so far not suitable for FFS application. The product is fed into the bag from the bottom up (under-level filling), which eliminates dust during filling to the greatest extent possible. This gives the best protection against contamination in the sealing area of the sack mouth – essential for high-strength, reliable top seals.
The reliable bagging of dusty and heavy-flowing bulk goods is the special forte of the OPAL®.
Thanks to the special layout of the OPAL® with a filling section that can be offset laterally relative to the bag making section, the product feed assembly becomes easily accessible – a major advantage when it comes to clean-up or product changeover.
A comprehensive selection of optional units is available also for the OPAL® to adapt it to specific filling situations and requirements, including an air evacuation system, corner sealing, and an explosion-proof package in full compliance with ATEX standards.
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