20.09.2024 | Our new ‘Tower 12’ spray drying plant has two self-sufficient and largely automated packaging lines for tubular bags. Packaging options include 5 kg, 15 kg, 20 kg and 25 kg tubular bags made of aluminium composite film. Filling takes place from big bags and is therefore decoupled from the actual spray-drying process. This means that we can also use the system for products from our other spray towers from the existing plant in order to pack them under high-care conditions.
The powder is filled into the tubular bags within the high-care zone in a dust-free environment (OEB Level 3) and at the highest level of hygiene. The big bags are connected to a buffer container via a special liner connection system. This allows the product to be emptied without coming into contact with the environment. It is then conveyed one level down into another, smaller buffer container, from which it is then filled into the tubular bags via a dosing screw. Thanks to the special routing of the continuous film when forming and sealing the bag, the product has no contact with the surrounding air.
The sealed bags fall into a carton and pass through a double-gate airlock to the packaging lines, which are located in the grey hygiene zone. The cartons, which have previously been automatically unfolded in the grey zone, are also fed to the flow-wrapping system via double-gate airlocks. In the packaging line, the bag-in-box packs are closed fully automatically, labelled and weighed and x-rayed for inspection. They are then transported to the neighbouring high-bay warehouse via a roller conveyor and palletised there by a robot.
Before packaging, both the product and the packaging material must be scanned for verification. Only if everything matches the production data stored in the control system and networked with our SAP system will the packaging line be released for the packaging process. In addition to the sophisticated hygiene measures, this ensures a high level of product safety. Regular sampling takes place automatically and securely in sealed aluminium bags. During the packaging process, both bags and cartons are labelled with a product label and, if required, with an additional hazardous substance label, which is also automated and database-controlled.