Complete Valve-bag filling systems

Rotary Impeller PackerPneumatic Roto-PackerIn-line Packing Machine

Valve Bag Applicator

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designed silo cones, incorporated aeration cushions and thelarge inlet cross-section of the impellers, are an integral partof the design features of the Möllers packer. The impellers alsohave a second outlet for rapid emptying of the packer silo byremote control, which is particularly important in the case of frequent changes of product. With its highly developed dedusting system and optimized spillage return flow, the fillingmachines are designed for low-contamination packaging.

Service-friendly module design

The advanced modular construction of the Möllers impellerRoto-Packer is combined with exceptional ease of servicing.All components are readily accessible. The quick-swap construction of the impeller filling module makes replacing theimpeller wheel a matter of minutes. The machines are also easyand quick to adjust to different filling weights, bag dimensionsand product characteristics – all part of the high-performancedesign. The optimized flow path to the impellers, with specially

Advantages of horizontal filling impellers

The rotating impeller packer is the most advancedform of high-performance filling machine. It isused for filling cement, lime, gypsum and otherparticulate products into valve bags and is mainlyused where large quantities of product have to befilled in a cost-effective manner.

The distinguishing feature of the Möllers impellerpacker is the horizontally mounted filling impeller which is much more energy-efficient thana vertical impeller, with the added advantage ofgreatly reduced wear. The horizontal impeller caneven fill abrasive products efficiently, with its proven universal capability over a wide range ofgrain sizes from 4 mm to a Blaine fineness of20,000. The vertical configuration of the filling impeller motor with the directly mounted impellergives the Möllers impeller packer the additional advantage of a compact, space-saving format.

As one of the world’s leading suppliers of bag filling and packaging plant, Möllers produces valve bag filling machines with the most advanced engineering using almost all filling systems, configured as rotating packers, in-line packers and single packers, depending on the type of system. The Möllers range of bag filling machines is available with a wide variety of performance ratings, providing an efficient packaging solution for all materials.Electronic weighing systems are an integral component of Möllers packers, providing a high level of filling weight accuracy at high filling throughput rates,generally better than the calibration accuracy.

Automatic bag filling systems

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The filling module - basiccomponent of Möllers impeller packers

Packers of various sizes can easily be composed by means of the Möllers module system

Number of spouts

25 and 35 kg bags: 1 000 to 5 500 bags per hour

50 kg bags: 900 to 5 000 bags per hour

Impeller Roto-Packer output with 50 and 25/35 kg bags,

product CEM I 42.5 N

Filling rates just as required, also upgradeable

Möllers impeller Roto-Packers are fitted with three to 16 fillingspouts. The ingenious modular construction has resulted in anefficient, compact machine design that can be adapted precisely to the performance requirements of the operator. It isalso possible to buy just a packer with a partially equipped packer silo, and expand it later to double the number of spoutsas required for increased production output.

Filling modules form the basic components

The basic module of the Möllers impeller packer is the fillingmodule. It combines the filling impeller with the filling spout,the bag holder and the weighing electronics as a complete bag-filling unit. The filling modules are mounted on a packersilo from which the material flows. The filling rate of a moduleis about 350 bags per hour for medium fineness cement. Witha suitable number of filling modules on a packer silo, fillingrates of 1,000 to 5,500 bags per hour are achieved. To makeeconomic use of the high work rate of Möllers Roto-Packers,the empty bags must be fed by an automatic valve bag placingmachine to ensure a uniformly high bag placing frequency witha correspondingly consistent filling system output level.

Modular Impeller Roto-Packer

Example: 16 Spouts

Example 12 Spouts

Example: 8 spouts

Bag application

Taring

Coarse flow On-linecontrol

On-linecontrol

Fine flow

Tolerance

Printer

Bag discharge

- Vibration cut-out

- Setpoint/actual valuecomparison

- Broken bagcheck

- Coarse/fineflow change-over point

- Self optimization

- Optimizazion ofthe coarse/fineflow change-over point

- Run-oncorrection

- Vibration cut-out

- Setpoint/actual valuecomparison

- Run-on

- Weight checkand standarddeviation: ave-rage value from ten weighings

- Secondarymetering

- Self-optimization

- Run-oncorrection

Möllers Rotronic® packer control

Closed loop filling

A high filling rate combined with consistent filling weight metering – this isprincipally the function of the electronicweighing system independently fitted toeach filling module of a Möllers impellerpacker. The electronic filling system controls the entire filling sequence, performing several functions directly affecting the precision of the filling process. The electronics constantly measures the flow characteristics of theproduct by the millisecond, matching thefine/coarse filling switch-over point to adjust the filling weight to the nominalvalue as closely and as quickly as possible.

Control from the central terminal

The messages of all the filling modules feedin to the monitoring function in the centralterminal of the Möllers Rotronic® packercontrol unit. All the modules can be individually set from here, or jointly set todesired values, weighing parameters andtypes of product. All filling weights arecontinuously displayed on the central monitor. Default settings such as the switchover point can be first transferred toone module, adjusted as necessary, thencopied to the other filling spouts at thepress of a button when the start-up checkhas been successfully completed. Fillingparameters for up to 99 types of productcan be stored in the Möllers Rotronic control unit.

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Efficient filling weight mean adjustment

The sophisticated weighing electronics of the Möllers Rotronic® control unit fills the valve bags with a precision significantly above the calibration accuracy. However, separation loss is one of the unavoidable characteristics of thevalve bag and its filling technology. It refers to the amount ofproduct spilt from the valve when the bag is separated from thefilling spout. It varies from bag to bag, it is compensated in thefilling process by a set degree of product overfill.

When variations outside the normal distribution

The weight is monitored by the checkweigher, which has thefunction of correcting the filling weight setting of the weighing electronics, as well as rejecting off-weight bags, in order tocounteract the variations in filling weight. In combination withthe Rotronic® packer control unit, Möllers has refined the filling weight adjustment for individual bags for mean valueadjustment. This significant improvement determines the meanvariation over a particular number of weighings, and onlymakes adjustments to the settings when the variations fall outside the normal distribution. This way the mean adjustmenttakes account of the fluctuations in separation loss, and at thesame time avoids constantly adjusting the filling weight value.

The checkweigher eliminates off-weight

bags, performs themean value adjustment,

and collects statisticaldata

The bag discharge station removes the

off-weight bags, controlled by the

checkweigher

1 Vertical double rotary feeder2 Rotary impeller packer with bag

applicator3 Spillage collection system4 Bag discharge belt5 Bag cleaning station6 Bag checkweigher7 Bag removal device8 Bag ripping machine with drum

screen9 Spillage return screw

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The Möllers rotary packer with air filling system can be used formany bulk materials with poor flow properties and mixtures ofcoarse and fine particles or of particularly heavy and light components. Each filling module consists of a pressurized filling chamber with a cone-type closure valve, a level indicator, a pivoted filler pan bottom and the Möllers Rotronic®weighing system.

A flow of fluidizing air passing through a mesh aeration basegenerates flowable two-phase mixture in the chamber, whichis driven into the bag in an even flow by the constant air pressure level in the chamber. The advantages of the Möllers

Pneumatic rotary and in-line packers

pneumatic filling system are that blends to be filled do not separate, the elimination of mechanical strain on the product,low-dust filling due to low feed pressure, and the ease ofcleaning and maintaining the filling modules. In combinationwith automatic bag placers, Möllers pneumatic rotary packerscan also be operated fully automatically.

For low and medium filling rates, the Möllers packer range includes stand-alone and in-line pneumatic packers that haveproved effective in the special vibro pneumatic packer versionfor filling difficult materials that are extremely prone to bridging.

Four-spout vibro-pneumatic in-line packer withautomatic bag applicator. With its vibrating pressure chamber this type of packer is also designed for filling materials that are highly proneto bridging

Eight-spout pneumaticRoto-Packer with automatic empty-bagapplicator and emptybag cassette magazine

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Ultrasonic bag sealing

Bag sealing before bag discharging

The increasing demand for bag packs that can be handledwithout dirt requires hermetic sealing of the bag valves. Thebag sealing system developed for this by Möllers seals thevalves by ultrasound , to ensure clean handling along thesupply chain. Each filling module is fitted with its own sealing unit. The sealing process comes immediately after thefilling process and before the bag is discharged. The cleanlyfilled valve bag is removed from the filling spout, the valve isgripped by the sealing device and ultrasonically sealed. Thebag is then transferred to the discharge conveyor.

Sealing units for rotary and in-line packers

All paper bags with film liner or with sealable internal coatingare suitable for ultrasonic sealing, apart from plastic bags. TheMöllers ultrasonic valve sealing devices are available for impeller and pneumatic packers, of rotary and in-line configuration. The practically dust-free filling operation generates much less meal spillage, with less contamination ofnearby plant. For different filling weights from 10 to 50 kg, thebag rests can be infinitely adjusted to the allocated bag lengthsmanually and automatically.

Ultrasonic valve bag sealers make bag valves dust tight

Ultrasonic valve sealer on a singlespout packer

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Output of Möllers in-line bagging machines with one to four spouts,bags per hour

Four-spout in-line packer in accordance with the Möllers module system

Impeller in-line packers

1 Dedusting system2 Aeration cushion3 Impeller filling module4 Bag holder with vertical

discharge5 Weighing electronics

Valve bag filling machines in in-line formation aremade up with one to four filling spouts from thesame filling modules as impeller Roto-Packers. Themachines can be operated with manual bag feedand fully automatically with specially developedbag applicators. Their compact format providesgreat planning flexibility, with modest requirements in terms of building structure.

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Automatic valve bag applicators

High speed and reliability of application are features of the Möllers rotarypacker bag applicators

The mode of operation of the Möllers valve bag applicators forrotating filling machines has been matched to the high bag filling rate of the Roto-Packer. Designed for a throughput of upto 4,500 bags per hour, it combines a high work rate with greatprecision – which is essential for intact application of the bagsto the filling spouts passing in rapid succession in front of thebag applicator. The bag applicator can be fed with empty bagsfrom various types of bag magazine. Cassette magazines andbundle magazines have special advantages, especially whenchanging bag type frequently, and can be used as well as reel magazines, which provide the highest degree of filling plant automation. Filling magazines of this type with depalletizing robots likewise largely eliminate the manpower required to operate the filling plant.

Cassette magazines allow rapidchanges between different

types of bag

Bag with fitted valve ready for application to the filling spout Reel bag magazines configured as double magazines provide outstandingly fast changeover times

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Exemplary packaging plants from a single source

Bag loading machines and equipment for loadingtrucks, railway wagons and ships

Auto loaders for loading bagged goods directly ontotrucks

Machines for filling all kinds of bags and bulk packaging units

Silo filling and discharge equipment. Mechanicaland pneumatic conveyors

Palletizing equipment for bags and other containers.Stretch and shrink wrapping equipment for pallets

Palletless shrink packaging equipment using theMöllers reverse hood shrink system

knowledge of the relevant product characteristics and the operating conditions on site. As an engineering company withmore than five decades of experience in this specialist field,Möllers gives an assurance of robust packaging and loading systems ideally adapted to the particular production environment, and perform their function reliably at the lowestpossible cost: Complete packaging solutions from a singlesource.

Filled materials still have to be packed. An industrial packingprocess requires additional downstream operations to load andhandle products efficiently and bring them to market quickly.Palletizing, pallet stretch and shrink wrapping and palletlessstretch / shrink packaging using the extremely cost-effectiveMöllers reverse hood system are essential elements for efficient freight movement worldwide. Packaging plant for thiscomprehensive process capable of satisfying industrial demands in terms of integrability, functionality and availabilitymust be planned and built thoughtfully, with a thorough

Complete packaging systems

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The Producat® process control system

Producat® records the machine data at control level and prepares it for the datamanagement level

Order Processing module: Complete product data records are accessed by clicking, then all the necessary machine settings proceed automatically

In the graphic overviews of the Plant diagnosis module the sensors and actuatorsare displayed as coloured signals that facilitate location of faults by changingtheir colours or flashing

For highly automated palletizing and packaging plant tofunction smoothly, it must have an impeccable central controland monitoring system to reliably support the supervision functions with minimal manpower. The Producat® computer-based control and visual display program developed for thispurpose by Möllers provides all the dialogue tools essential foroperation, housed in a central terminal:

1. Quick overview of the process structure and insight into the sequence of operations.

2. Simple, intuitive operation and easy, error-minimized input of order data.

3. Diagnostic routines immediately and directly availableif there is a fault, with optional link to the Möllers Producat® remote service. Records all system data and prepares it for data management.

Graphic displays and table views make it easier to understandthe system functions and input requirements. Producat® isready for linking to higher-level systems (host computer) andto subsequent plant extensions. Producat®’s Internet capability enables other computers on the company’s intra-net to be used for order processing and system diagnosis. Forthe man-machine dialogue Producat® provides the modulesA) Order processing, B) Plant diagnosis and C) Program maintenance. A is the standard module for inputting andhandling production orders. Module B monitors the state ofthe plant and is used for locating and rectifying faults. Module C is used by IT staff to make basic adjustments to thesystem and for online updating of the system software usingthe Möllers remote service.

Filling plants for bulk, liquid andpasty products

Palletizing plants

Palletizing and depalletizing robots

Stretch filmpackaging plants

Machines · Plants · SystemsPlanning, development and manufacture of complete plants

Everything from a single source

Maschinenfabrik Möllers GmbH · 59269 Beckum/Germany · Sudhoferweg 93-97 • 59247 Beckum/Germany · Postfach 1764Telephone +49 (0)2521 88-0 · Fax +49 (0)2521 88-100 · info@moellers.de · www.moellers.com

Manufacturing plants of the Möllers Group:

Mollers North America Inc.5215 – 52nd St. S.E., Grand Rapids, Michigan 49512 / USATelephone +1 (616) 9 42-65 04, Fax +1 616 9 42-88 25mollersna@mollersna.com, www.mollersna.com

GREIF-VELOX Maschinenfabrik GmbH / Logdos P.O. Box 12 11 51, 23532 Lübeck / GermanyKronsforder Landstraße 177, 23560 Lübeck / GermanyTelephone +49 (0) 451 53 03-0, Fax +49 (0) 451 53 03-233webmaster@greif-velox.de, www.greif-velox.de

Logdos Liquid FillingP.O. Box 12 11 51, 23532 Lübeck / GermanyKronsforder Landstraße 177, D-23560 Lübeck Telephone +49 (0) 451 53 03-0, Fax +49 (0) 451 53 03-233logdos@logdos.de, www.logdos.de

Librawerk Maschinenfabrik GmbHVossenkamp 1, 38104 Braunschweig / GermanyTelephone +49 (0) 531 370 98-0, Fax +49 (0) 531 370 98-88info@librawerk.de, www.librawerk.de

NATRONAG Maschinenfabrik GmbHVossenkamp 1, 38104 Braunschweig / GermanyTelephone +49 (0) 531 370 98-0, Fax +49 (0) 531 370 98-88info@natronag.de, www.natronag.de

Subsidiaries of the Möllers Group:

000 „Möllers INTERTEC“, ul. Giljarowskogo, d 39, office 301-304Moscow, RussiaTelephone/Fax +7 495 780 97 50moellers-intertec@umail.ru

Möllers Singapore, Singapore Representative Office, # 10 – 09 Golden Mile Tower6001, Beach Road, Singapore 199 589 / Singapore Telephone +65 6 298 9860/9817 6880, Fax +65 6 298 9289 moellers@singnet.com.sg

Möllers France, 14, rue de la Papeterie 67310 Wasselonne / FranceTelephone/Fax +33 3 88 87 29 00, Mobil 33 632 98 2452moellers-france@orange.fr

Möllers (UK) Ltd., Maxron House, Green Lane, Romiley, StockportCheshire SK6 3JQ / Great BritainTelephone +44 161 406 9824, Fax +44 161 494 5982, info@moellers.co.uk

Möllers Prague, Nad Rokoskou 14,18200 Praha 8 / Czech Republic Telephone +420 2 8468 2462, Fax +420 2 8468 0499, bartosm@czn.cz

Möllers Brazil, Via Anhanguera km 14,5 - Vila Mangalot, 05000 São Paulo / Brazil

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Fully automatictruck loading systems

Conveyor and loading systems

Controland visualizationsystems

Shrink filmpackaging plants

Palletless shrink/stretch packaging plants

Bag loading machines

Bag loading systems

FillingShrink-

wrappping Loading

PalletizingPalletlesspackaging Conveying

Stretch-wrapping Loading

MonitoringControl