Are you considering upgrading or expanding your bulk bag-filling line? Not all FIBC (Flexible Intermediate Bulk Container) bag fillers are the same. To assist you in choosing the right equipment, the team at Spiroflow prepared a thorough bulk bag filler customization guide to tailor your solution for the best results. Explore the world of bulk bag-filling customization and make informed choices with confidence.

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Bulk bag filler customization involves tailoring bulk bag filling equipment to your specific needs and requirements. It includes the selection of components, features, and configurations to optimize the filling process. Customization ensures that your bulk bag filler is efficient, accurate, and perfectly suited for your materials and applications, reducing waste and increasing productivity.

Step 1: Narrow Selection: Bulk Bag Filler Frame Or Station

First, narrow the equipment selection to one of the following: a simple, stand-alone bulk bag filler frame or a more sophisticated filling system. To get the bigger picture, make sure you check out the options below:

Low Cost, Volumetric Filling for Simplified Operation 

Bulk bag-filling frames are most suitable for low-rate applications, typically involving ten or fewer bulk bags per hour. This cost-effective choice is practical when weighing and densification aren&#;t necessary. However, it&#;s important to consider this option only if you have an operator consistently monitoring the filling progress and your material readily deaerates, making volumetric filling acceptable.

These frames typically feature a base plate with two vertical legs, allowing for vertical adjustment of the horizontal loop support arms. The filling nozzle support frame is positioned above the two loop arms, while locking pins ensure the secure positioning of the two sliding sections. 

To remove filled bags, you deflate the inflatable collar, manually pull the neck from the filling spout, and then lift the pallet and the bag a few inches using a forklift or pallet jack. Finally, you can back the bag out of the filler.

C Series &#; Medium to High Volume Filling Minimizes Product Loss

C Series are bulk bag filling stations that cater to medium to high-volume applications where precise weight measurements or increased productivity are essential. They accommodate both forklift and semi-automatic bag removal via a motorized belt conveyor system. Unlike basic frames, complete filling stations often feature load cell weighing systems (either hang weighing or base mounted) and can incorporate vibration capabilities for efficient product densification, reducing overfill and minimizing product loss.

These stations comprise a support frame, bag support arms, fill head, dust extraction, weighing (load cells or platform scale), vibration table, and, in semi-automatic setups, a bag removal system. Additionally, customization options abound, allowing you to tailor your bulk bag filling station to specific application requirements, including automated conveyor systems for pallet feeding, shrink wrapping, or bag labeling.

Step 2: Define Bulk Bag Filling Requirements

Before starting to specify the filler type, options, and customizations, first consider the material, process needs, bag requirements, and any seamless conveyor technologies to ensure a streamlined and efficient filling process.

Master Material Handling: Customization for Varied Material Characteristics

Choosing the right material-handling equipment is essential to ensure the success of your operation. Each material has unique characteristics, and customization is key to meeting specific requirements and challenges.

Choose the Perfect Option With Bag Type Customization

Selecting the right bag type is another critical aspect of bulk bag filling customization. The choice of bag dimensions, style, lifting loops, and liner/sealing requirements can impact efficiency and safety.

Process Customization for Precision and Efficiency

Customization is integral to fine-tuning the bulk bag-filling process to your specific needs. This involves assessing various factors, such as bagging rate, weighing accuracy, duty cycles, and space/storage requirements. 

Step 3: Select Bulk Bag Filling Station Components

Based on your requirements definition, start to select each component of your bulk bag filling station. Selection of individual components that make up your bulk bag filling station. These components collectively determine how efficiently and accurately your system operates.

Support Frame Builds the Foundation

The support frame is the backbone of any bulk bag filling station, providing stability and structure to the entire system. It&#;s a critical component that influences accessibility, safety, and overall functionality. Customizing the support frame allows you to tailor your bulk bag filling station to your specific requirements, ensuring that it efficiently and securely handles your materials.

Filling Nozzle or Fillhead Enhances Precision and Efficiency

The filling nozzle or fillhead is another essential component in the bulk bag filling process. It not only facilitates the controlled flow of material but also contributes to the efficiency and precision of your operation. Here are all the options you need to be aware of:

Weighing or Scale Type Options

In a base-weigh system, both the entire bulk bag filler and the product in the bag are weighed throughout the filling process. Conversely, hang-weigh systems weigh only the weight frame, fill head, hanger arms, and the bulk bag itself during filling when it&#;s suspended from its loops. This hang-weigh arrangement minimizes the dead load on the load cells, enhancing weighing resolution for improved accuracy and consistency.

Vibration Compaction and Deaeration

Achieving a homogeneous fill while removing trapped air and promoting material flow are essential steps in bulk bag filling. Vibration compaction, deaeration, and a top-notch flexible screw conveyor play a crucial role in optimizing these processes.

Step 4: Customize Bulk Bag Filling Station With Additional Options

In this step, we delve into the realm of customization, where the versatility of bulk bag-filling stations truly shines. Beyond the fundamental components, a world of additional options awaits, designed to tailor your equipment to your unique operational needs. Whether it&#;s enhancing safety and productivity or even extending the shelf life of your products, these supplementary features can make a world of difference. This being said, here are some of the options conveyor systems manufacturers recommend to keep in mind:

Step 5: Test, Test, and Once Again Test

Before purchasing bulk bag filling equipment, it is recommended to first run the material on the equipment in the bulk bag equipment manufacturer&#;s test lab. Replicating the filling conditions allows analysis of specific characteristics, including how the material interfaces with industrial conveyor systems, to avoid production challenges later.

Use Spiroflow&#;s Bulk Bag Filler Customization Guide for Seamless Operation 

Making the Leap to Automated Packaging: 5 Factors for Choosing a VFFS or Premade Pouch Machine for Your Coffee Roastery 

Kristi Anderson-Runge

In the dynamic world of coffee roasting, where precision, flavor, and presentation matter, every decision can have a profound impact on the success of a roastery. As the demand for quality coffee surges, the choice of commercial coffee packaging equipment becomes crucial. And as a result, coffee roasters are increasingly considering the switch to automatic coffee packaging machines to streamline their operations, increase shelf life, and promote consistency in their branded packaging. 

We&#;ve written about factors to consider when selecting a manual or automatic packaging machine, so if you decide to take that leap, your next decision will involve exactly what kind of coffee packaging automation is best for you. There are a number of automated packaging options to choose from, but this article focuses on the two most popular options: the Vertical Form Fill Seal (VFFS) machine and the Premade Pouch machine.

Let&#;s consider five factors to aid in your decision-making: 

1. Speed and efficiency
2. Product line variety
3. Sanitary considerations
4. Aesthetic appeal
5. Sustainable packaging

Speed and Efficiency

When considering the speed and efficiency of Premade Pouch machines and VFFS machines, it's important to match your roastery's production volume, capacity for skilled labor, and budget with the capabilities of each machine type. 

While Premade Pouch machines offer flexibility and cost-effectiveness for smaller operations, VFFS machines excel in high-speed, large-volume production environments.

Premade Pouch machines are relatively quick to set up and switch between different bag sizes, making them ideal for small to medium production runs with frequent product changes. These machines can handle various bag styles, including stand-up pouches, flat pouches, and more, providing flexibility in packaging options to cater to consumer preferences.

However, Premade Pouch machines may have limitations in terms of speed, especially for high-volume production. They can also be more labor-intensive, as operators need to load bags onto the machine and perform quality checks, potentially increasing labor costs.

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VFFS machines are known for their high-speed capabilities, making them ideal for large-scale roasteries with significant production volumes that demand rapid packaging. They&#;re also masters of efficiency when it comes to continuous and large production runs, minimizing downtime between batches and maximizing output.

On the other hand, VFFS machines require a more complex initial setup, including film roll loading, forming tubes, and aligning sealing jaws, which might demand skilled operators. You also have to consider changeover challenges: Switching between different bag sizes and styles can be time-consuming and complex, potentially causing production interruptions during frequent product changes.

Variety in Product Line

The variety in your coffee product line plays a significant role in determining whether to opt for a Premade Pouch machine or a VFFS machine for packaging. Here's how this might impact your decision:

Premade Pouch Machines

1. Flexibility in Bag Styles: As we&#;ve already noted, Premade Pouch machines are versatile and can accommodate different bag types and sizes.

2. Quick Changeovers: These machines allow for relatively quick and easy changeovers between different bag sizes and styles. This is beneficial if your product line frequently introduces new variations or limited-time offerings.

3. Small to Medium Batches: If your product line features a range of small to medium-sized batches, Premade Pouch machines can efficiently handle the diversity in packaging requirements without excessive downtime.

VFFS Machines

1. High-Speed Performance: VFFS machines are designed for high-speed packaging, making them suitable for coffee product lines with large-volume items that require quick and efficient packaging.

2. Consistent Quality: Automated sealing and cutting in VFFS machines ensure uniform packaging quality, which is crucial if your product line needs a standardized presentation across various packaging sizes.

3. Efficiency in Large Runs: If your coffee product line consists primarily of popular, high-demand items, a VFFS machine can handle continuous large production runs with minimal interruptions. 

Sanitary Considerations

Both Premade Pouch machines and VFFS machines offer sanitary benefits, but there are differences to consider.

Premade Pouch machines often feature stainless steel construction, which is easy to clean and sanitize, reducing the risk of contamination and rust. The flat, horizontal orientation of Premade Pouch infeed can aid in preventing dust or debris accumulation, ensuring a clean filling process. Additionally, Premade Pouch machines may have fewer exposed moving parts, minimizing potential contact points for contaminants.

VFFS machines also frequently come with stainless steel construction, and their vertical design can contribute to maintaining a cleaner environment by allowing gravity to assist with preventing debris buildup. However, the vertical movement and complex mechanisms involved in the VFFS process may require more meticulous cleaning to prevent residue accumulation.

Aesthetic Appeal

Both Premade Pouch machines and VFFS machines contribute to the aesthetic appeal of your packaging, but they do so in different ways.

Premade Pouches can have a sleek, modern, or even artisanal look that resonates well with contemporary consumers. They also allow for ample space to display vibrant labels and branding, creating eye-catching packaging that stands out on the shelves and aligns with your branding.

VFFS machines, on the other hand, typically produce vertically oriented bags. While they may not offer as much surface area for label display as Premade Pouches, their compact design can create a minimalist and sleek appearance. While this can be appealing to certain demographics, others might associate it with a lack of visual excitement or vibrancy that they expect from more elaborate packaging formats. 

An expert weighs in:

"Choosing an automated packaging machine isn't just about convenience; it's about crafting an aesthetic experience. We&#;re finding that there is increasing demand for the premium quality of premade pouches, as it resonates with customers who appreciate authentic and artisanal designs evocative of their coffee-drinking experience,&#; said Jacob Resnick of Viking Masek. &#;That said, if you demand high-production throughput and only have one or two product lines, VFFS machines can produce sleek, minimalist bag designs that will impress your customers &#; and for less per bag (or impression) than premade pouches." 

Sustainable Packaging

Both Premade Pouch machines and VFFS machines offer unique advantages when it comes to sustainable, eco-responsible packaging. 

Premade Pouch Machines:

• Use pre-formed pouches, often designed to minimize material waste.
• Use pouches often made from recyclable materials, such as paper, kraft paper, or biodegradable plastics, reducing their impact on the environment.
• The process of using premade pouches in these machines can be energy-efficient, as it requires less heat and energy compared to forming and sealing pouches on-site.
• Printing directly on premade pouches can reduce the need for additional labels or coatings, minimizing the use of inks and chemicals.

VFFS Machines:

• Can create pouches with custom sizes, reducing excess material usage and ensuring a snug fit for the product. This customization minimizes waste.
• Can use recyclable plastics or compostable films, aligning with eco-friendly practices. (Film manufacturers are working hard to constantly improve eco-friendly film options that don&#;t impede packaging quality.)
• Enable on-demand packaging, reducing the need to transport premade pouches, which can decrease carbon emissions associated with transportation.
• Often include printing capabilities, allowing roasteries to print labels and graphics directly on the packaging. This minimizes the need for additional labels and their associated waste.

SUSTAINABILITY SIDE-NOTE: Regardless of the machine type you select, roasteries can contribute to sustainability by selecting recyclable, biodegradable, or compostable materials for their packaging. Additionally, by optimizing the sizing of pouches and minimizing excess material, coffee roasteries can reduce their environmental footprint and promote responsible packaging practices.

So, How Do You Choose A Premade Pouch or VFFS Packaging Machine?

We've given you a lot to consider and only focused on five key factors. This &#;at a glance&#; scorecard should help you quickly size up the qualities of each option &#; offering a quicker reveal of the choice that might be the best fit for you.

Just check off the considerations that mean the most for your coffee roastery and then tally them up at the end to get a sense of which option might be more viable for your roastery operations.

Coffee Equipment Pros Can Help

The decision to switch to automated packaging is a significant step for any coffee roastery. Both VFFS and Premade Pouch machines offer unique advantages, with VFFS machines excelling in practicality, speed, and cost-effectiveness (over time) and Premade Pouch machines showcasing more aesthetic packaging options and suitable for smaller production runs.

Coffee Equipment Pros can help you carefully assess your roastery's needs, budget, and long-term goals so that you can choose the packaging solution that aligns with your brand's vision and aspirations &#; ensuring that your coffee products stand out on shelves and delight consumers worldwide.

And it might just be that this isn&#;t an either-or decision. Some roasteries find a need for a Premade Pouch machine for their smaller, more specialized product lines and a VFFS machine to handle higher output for one or two higher-demand product lines.

Our partnership with Viking Masek means we can connect you with multiple packaging options like their 4SC-235 Rotary Premade Pouch Machine, 8S-235 Rotary Premade Pouch Machine, M250 Vertical Form Fill Seal (VFFS) Machine, and ST800 Multilane Stickpack Machine.

Plus, Viking Masek has just introduced the VFFS Velocity, billed as the fastest VFFS machine in the world, with its 300 bag-per-minute capability.

And at the time of this writing, we also have a Used Elite 8S-235 Single Lane Premade Pouch Machine available to ship to you immediately. 

For more information and details, call us @ 855.585. or call/text Rick direct @ 949.289..

Remember, we&#;re here to find the right commercial coffee equipment for you &#; quickly and affordably. 
Because Roasters Need To Roast&#;.

Contact us to discuss your requirements of Bag Filling Machine. Our experienced sales team can help you identify the options that best suit your needs.

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