PPC 2011 Filling Solutions for Flexible Packaging

Steve Gosling

Introduction

Quick overview of rigid containers

Range and styles

Filling equipment

Considerations when filling rigid containers

Flexible filling review

Types of flexible packages

Types of filling equipment

Considerations when selecting flexible packaging

Considerations when selecting filling equipment

Assorted Rigid Containers

1200 liter plastic tote

Assorted drums

Assorted Rigid Containers

Cubitainer

Jug in Box

20liter pail

Tight Head Pail

Typical Rigid Filling Equipment

Multi-head filler Single head drum filler

Quick Overview of Rigid Filling Equipment

Single and multi-head depending on package size and

filling speeds required

Speed of filling is somewhat limited by the amount of splashing and foaming that may

occur

Typically multi head fillers are used to increase speed (slower flow rates)

Techniques that are used to overcome the problems with filling rigid containers

Anti-foam additives

Nozzle designs

Filling equipment modifications

Multiple filling heads

Flexible Packaging

Cheertainer 3 liter to 25 liter

Cheer Pack 70ml to 1000ml

IBC 55 gallon to 330 gallon

Automatic Single Head Filling Line

Semi Automatic Single Head Filler

Filling Equipment Controls

Control System

The filling equipment is supplied with a very simple control

system

Pump on/off

Safety start

E Stop

CIP

Sample

Encoder/counter for setting the fill volume

Fault code display

Filling Metering Systems

Turbine

Mostly used on non-viscous products

Used for wines, water, milk and oils

Will not handle viscous and particulate

Electromagnetic Flow meter

Most common and simplest design

Wide range of products

Not as accurate on small fills less than 5 liters

Mass Flow

Will handle almost all products

Very expensive

Very accurate

Weigh Scale

Used on high viscosity products

Not as accurate

Slower

Can be used inline with the other systems for verification

Flow Meters

Mass Flow

Turbine

Typical Filling Valve

Filling nozzle Cap pick up

Cap in gland prior to filling

Semi automatic filling head

The Filling Valve Operation

Steps

1..The filling head automatically removes the cap

from the gland

2…The filling nozzle seals off on the top of the

fitment or gland

3..The nozzle will first draw a vacuum ensuring that

there is no air in the bag prior to filling

4..The large orifice nozzle will then open and accurately flow the product into the bag

5..Once filled, the cap will be replaced and pushed to the final shipping position

Semi Automatic Filler

Selecting Flexible Packaging

What type of dispensing is required?

Select at tap or bung

What is the expected shelf life?

Does the product require a barrier film structure?

Is the product light sensitive?

Is the product hazardous?

What is expected from the carton design

Shipping

Environment

Cheertainer® Fitments

Filler Production Data

Filler 20L 10L 5L Labor Price

Manual 2/min.,

210,000/yr.

3/min.,

315,000/yr.

4/min.,

420,000/yr.

1 person $18-$20,000 USD

+ Freight

Semi-auto 3/min.,

315,000/yr.

4/min.,

420,000/yr.

5 min.,

525,000/yr.

1 person $30-$35,000 USD

+ Freight

Twin-semi 6/min.,

630,000/yr.

8/min.,

840,000 yr.

10/min.,

1,050,000/yr.

2 people $70-80,000 USD

+ Freight

Fully-auto 6/min.,

630,000/yr.

8/min.,

840,000/yr.

10/min.,

1,050,000/yr.

1 person $140-$155,000

USD +

Freight

Notes: (1) Annual bag production is based on one 7-hour shift per day, 250 days per year taking into account 10 holidays. (2) Prices shown are

based on British £ currency rates as of March 2008.

Filling Equipment Considerations

What type/range of products are to be filled?

What flow meter will work the best for the application ?

Filling range 3-1200 liters

What taps, caps and bungs need to be handled?

What is the annual volume?

What floor space is available?

Filling Equipment Considerations

Carton Erector System

Size range

Closure required

Local supply/service

Hot melt system

Local supply/service

Ink jet system

Carton labels

Carton closure

Palletizing

Cheertainer Automatic Filler

Single Head Automatic Filling line

Three Up Automatic Filling Line

Conclusions of BIB Filling Equipment

Accurate, repeatable fill based on volume or weight

Safer fill due to seal of nozzle on fitment

No foaming or overflow because there is no air in the bag

Less labor - no manual cap application or equipment

Fast setup and change over from one size to another

CIP and SIP system using one fill head reduces product waste

Requires much less floor space than other traditional nozzle fillers

Wide range of taps and fitments for dispensing

Why consider a flexible packaging solution?

Lower costs

Faster filling speeds per single head

No air on the product at fill or dispense

No glugging during the dispense

Sustainable

Fewer in-bound trucks

Less warehouse storage

Takes up less volume in the landfill site

Carton is 100% recyclable

THANK YOU