How Does the Powder Filling and Sealing Machine Work?

Today, we will delve into the process of packaging powder products into pre-made bags using a pouch filling and sealing machine.

The Powder Packing Machine mainly accomplishes two things: distributing the product into prefabricated bags, and then sealing the bags.

There are two main designs of this machine type: rotary and in-line. The difference between the two lies in the machine layout.

Powder Packing Machine

The in-line bag making machine packs products along a straight line, and the starting and ending points of the process are at opposite ends, requiring more floor space.

The rotary bag packaging machine is arranged in a circular pattern, which means that the starting point of the packaging process is right next to the end point. This creates a better ergonomic setting for the operator and requires a minimal footprint. Since they are very popular in powder packaging, we will only take a closer look at the rotary design in this article.

The rotary bag filling and sealing machine can be equipped with one-bag, two-bag or four-bag feeding "channels", among which the simplex (single channel) model is the most needed for powder packaging. When the packaging speed requirements exceed single-channel output, the company can upgrade to machines with additional feed channels to meet throughput requirements.

On the rotary bag packaging machine, independent static "stations" are arranged in a circular manner, and each station performs different steps in the bag packaging process. Rotary sachet filling and sealing machines usually have 6 to 10 stations, of which 8 stations are the most popular configuration. The inside of the machine moves counterclockwise, stopping briefly at each station.

1. Bagging

The staff will manually load the prefabricated bags into the bag feeding box regularly, and they must be carefully folded to ensure that they are correctly loaded into the bag packaging machine. Then, these small bags will be conveyed one by one into the inside of the machine through the bag feed roller.

In 2018, Viking designed a proprietary bag feeding device, which features a robotic arm that uses vacuum suction to grab each bag and transfer it to the bag holder. This innovative technology effectively eliminates the manual labor involved in loading and folding bags. Contact us today to watch an exclusive video about the practical application of this technology.

2. Bag Clip

A set of bag clips, one on each side, grasp the loaded bag and hold it consistently as it passes through each station on the powder packaging machine. On the best automatic bag filling and sealing machines, these grippers are mounted on stainless steel arms and can easily support fillings of up to 10 kg, even with frequent use over long periods of time.

3. Optional printing or embossing

If you need a date or batch number on the finished bag, you can add printing or embossing equipment at this station. Both inkjet printers and thermal printers are available, and inkjet printers are preferred. The embossing device creates raised characters in the sealed area of the bag.

4. Opening and testing of zippers or bags

The powder bag is usually equipped with a zipper to reclose. To fill the bag with products, this zipper must be fully opened. To do this, the vacuum suction cup grabs the lower part of the bag, and the open jaw grabs the top. The bag is opened gently, and at the same time, the blower blows clean air inside the bag to ensure that it is fully opened. If the bag does not have a zipper, the suction cup will still engage with the bottom of the bag, but only the blower will engage at the top of the bag.

5. Powder product filling

The most commonly used to dispense powder into bags is the auger filler. This filling device uses a long spiral type mechanism to dispense discrete amounts of powder into each pouch. Depending on whether your powder product is free-flowing or non-free-flowing, different auger configurations are required.

Dust is most often released at the transfer point of the powder packaging system. For this reason, it is recommended to use a dust cover (pictured on the right), which is placed directly above the filling equipment to help control the diffusion of particles in the air.

In powder packaging, there will always be some loose particles that end up on the surface of the machine. It is important to clean the pouch packaging machine regularly to prevent accumulations that may hinder operation or affect product quality.

6. Dust removal, sedimentation or other options

During the powder packaging process, several options are available at this time:

Dust collection. Before sealing, a dust collector can be used at the station to remove any additional airborne particles from the bag seam area.

Product settlers. In order to encourage the powder product to settle to the bottom of the bag, the settler can gently shake the bag.

Spoon feeder. Some powder products require a measuring spoon in the packaging. The bag filling and sealing machine can be equipped with a bowl feeder and chute, and a spoon is distributed to each bag at this station.

Loading shelves. For heavier powder filling, a loading rack can be added after filling to support the extra weight of the bag and eliminate some pressure on the bag holding arm.

7. Seal the bag and deflate

To ensure that all remaining air is expelled from the bag before sealing, the two air release plates gently squeeze the bag.

In order to seal the bag, a pair of heat seals are enclosed in the top area of the bag. The heat from these rods causes the sealing layers of the bag to adhere to each other, forming a strong seam.

8. Sealed cooling and discharge

In order to flatten and strengthen the seam, a cooling rod is passed through the heat-sealed area of the bag. The finished powder bag is then discharged from the machine and placed in a container or transported down the production line for further processing.