Intake and Storage of Single Components

Individual solution for intake, screen cleaning and Box Filling

For this project, a compact special-purpose plant was implemented for the intake and storage of individual components. The objective was to receive product from bags and big bags, reliably separate packaging residues such as threads or paper pieces, and then fill the cleaned product into boxes.

The plant was adapted to very limited space conditions. In particular, the arrangement of the process steps across two levels placed special demands on layout planning, conveying technology and the operating concept.

The project shows how individual customer requirements can be implemented with adapted machinery, special solutions and compact plant integration.

Insights

The raw products can be fed into the system via two separate intakes. For bagged product, a bag intake with belt conveyor was provided. A vacuum bag lifter supports manual depalletizing. For big bags, a separate big bag intake is available. The big bag is opened above the intake hopper. The intake areas are connected to the aspiration system in order to capture dust directly at the point of feeding.

A gentle continuous bucket conveyor transfers the crops to a vibrating screen type RVK. There, unwanted foreign material, especially threads, paper pieces or parts of woven poly bags and big bags, is separated from the good product. The clean product passes through the screens onto the belt conveyor below, while the screen overflow is discharged separately as waste.

After the thread screening step, the product is routed to the lower level, where box filling takes place. A buffer bin holds the product before it is filled volumetrically into boxes. The filled boxes are weighed, and the box number can be recorded via barcode scanner and transferred to the control system.

A special solution is the box magazine with integrated box lift. Empty boxes are provided on an upper roller conveyor, transferred to the filling position and, after filling, discharged via the lower roller conveyor. This enabled a continuous box flow for empty and full boxes despite the limited space available.

The aspiration system with filter dedusting captures dust at intake, conveying, control screening and box filling. This supports clean operation on both plant levels.

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Highlights

The particular challenge of this project was not a high capacity, but the customized implementation of specific customer requirements while taking the spatial conditions into account. Product from different containers had to be received, control-screened, cleanly filled and stored for later process steps.

Due to the low available installation height, machines, conveying routes, product pipework, operating platforms and box handling had to be planned very compactly. The arrangement across two levels also required precise coordination of product transfers and box logistics.

The box lift is a central element of the solution. It allows empty and full boxes to be handled in a confined space and integrates the box filling system on the lower level into the overall process. This made it possible to create a functional solution without exceeding the existing structural limits.

The control screening step was also designed specifically for the task. The focus is not on classic cleaning based on grain characteristics, but on the reliable separation of packaging residues from bag and big bag intake. This prevents foreign material from entering the following processes.

Custom Solutions – end to end

Concept development and process design
Project planning and layout design
Mechanical and plant engineering
Delivery of machinery and plant components
Assembly and installation
Commissioning
Operator training
Service and support