How Powder Filling and Sealing Machines Work

If you are manufacturing or producing powder products, definitely you need a reliable packaging solution. That is where powder filling and sealing machines comes in.

But, how can you achieve an effective packaging solution for your powder products.

Well, this guide takes you through all the fundamental aspects in powder willing and sealing process.

Take a look:

Parts and Working of Powder Filling and Sealing Machines

Powder Packaging Machine
Powder Packaging Machine

A. Filling Process

The filling process in powder packaging and sealing equipment ensures the right amount of product is dispensed into a container. The filler constitutes different parts playing a specific role in the filling operation.

i. Powder material in the filling process is held in the hopper before entering the filling system. Hoppers are designed to accommodate different powders and can have agitators for the very cohesive powders.

ii. Material from the hoper is metered accurately into the filling system via precise measuring and dispensing. Depending on the powder material, there are different approaches used to draw the powder in the desired amount. All these methods ensure there’s low product wastage.

  • Auger Filling: This approach is suitable for different powder types, that is, free and non-free flowing powders. Here, an auger screw is utilized in drawing the powder from the hopper, before dispensing in desired volumes.
  • Gravity Filling: When filling powder into containers using gravity filling, it is allowed to flow naturally under gravitational pull. Best suited for free-flowing powders, gravity filling can implement vibrating trays for enhanced filling process.
  • Volumetric Filling: With this approach, the metric of powder measurement is volume instead of weight. This is typically when dealing with powders where weight is not a concern. Different mechanisms can be used to measure volume including using pistons, cups or rotary valves.
  • Weight-Based Filling: As opposed to volumetric filling, with this filling approach, controlling the product weight is necessary. Powder filling machines utilize scales to measure the container weight as the powder is dispensed until the desired figure is achieved.

iii. The measured powder is thereafter dispensed through the filling nozzle ideally equipped with a valve to control powder flow. Controlling powder flow ensures accurate filling by preventing overfilling or underfilling of containers.

iv. Powder filling and sealing machines utilizing volumetric filling can also include a leveling device to ensure even powder distribution in the container. This is also useful in ensuring the fill level is consistent for every other container.

Powder Auger Filler System
Powder Auger Filler System

B. Sealing Process

The sealing mechanism in powder filling and sealing machines serves to ensure the integrity and safety of the powder product. This is by creating an air/watertight seal preventing leakage or contaminant entry thus preserving product freshness.

The sealing process is undertaken by the sealing head as the primary component. The sealing head typically utilizes pressure or heat to seal the container. It employs sealing die or jaws to adhere the seal upon interaction with the surface of the packaging material.

Packaging material used in the sealing process include laminates, plastic film and aluminum foil. Depending on the industry requirements, packaging material and desired seal strength you can choose from a host of sealing methods.

Carton Case Sealing Machine
Carton Case Sealing Machine
  • Adhesive Sealing: Here, adhesives are applied to the packaging before being activated to result in a strong bond that seals the package.
  • Heat Sealing: Heat application on the packaging material creates a bond sealing off the packaging. There are variants to heat sealing including induction sealing, impulse sealing and continuous heat sealing.
  • Mechanical Sealing: Mechanical force and pressure through methods like folding, crimping, or rolling are utilized in sealing the packaging material.
  • Ultrasonic Sealing: High-frequency ultrasonic vibrations bond packaging materials by generating friction and heat in between.

Control and Monitoring Powder Filling and Sealing Machines

Control and monitoring systems in powder filling and sealing machines ensure the packaging process is efficient, accurate and safe. These systems are useful in regulating process parameters, monitor performance, and also provide feedback for real-time adjustments.

· Filling Control

During the filling process, some of the control elements you observe include:

  • Auger Speed Control: Where auger screws are utilized to dispense powder, there is need to control their rotation speed. Controlling speed ensures the filling process is precise and consistent and depends on the powder properties.
  • Volume/Weight Control: For powders being dispensed by virtue of their volume or weight, control elements are necessary to determine the desired values.
  • Feedback Mechanisms: These employ sensors to monitor the process of filling while providing real-time data making adjustments possible via the control panel.

· Sealing Control

The sealing process entails different mechanisms with which to securely enclose products for quality and safety purposes. Certain elements require close control during the sealing process:

  • Temperature Control: When using heat sealing methods, the temperature should be just enough to actualize the fusion of the packaging material. It should not be too little to cause a weak fusion or too much to damage the package or product by overheating.
  • Pressure Control: Where pressure is utilized in sealing packages, control maintains consistent and standard pressure on for strong and uniform seals.
  • Timing Control: Timing is everything especially when using automated powder filling and sealing machines. Control systems determine how long the sealing process is carried out to effect an effective seal.

· Monitoring Systems

Monitoring systems are relevant to powder filling and packaging machines ensuring aspects like fill level and seal integrity are appropriately checked. With regard to fill level, monitoring systems utilizing sensors or cameras ensure the fill is as expected.

Departure from the desired fill by over/underfilling is communicated for manual intervention or automatic adjustment. Additionally, monitoring systems inspect seal integrity ensuring the package is not damaged in the process.

Control systems feature a host of sensors, motor and actuators to aid in fault detection. Monitoring systems keep track their performance such that a non-ideal response is checked for recalibration or programming.

· Human-Machine Interface (HMI)

The human-machine interface is where you interact with the powder filling and sealing machines. On this platform, you respond to alerts, correct errors and adjust parameters via push-buttons and touchscreen displays.

Conclusion

Some industries in which powder filling and sealing machines find use include pharmaceuticals, chemicals, cosmetics and food and beverage. These machines streamline the production process while ensuring product quality and safety.

At JOCHAMP, we have a range of powder filling and sealing machines you can easily integrate to form a complete production line. The top-selling machines include carton box packing, pouch packing machine, and case sealer, among other machines.

 

More resources:

6 Critical Powder Packaging Points to Consider – Source: Jochamp

Milk Powder Packaging Guide – Source: Jochamp

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