New and old combine to bag success. New and old combine to bag success. New and old combine to bag success. New and old combine to bag success.

New and old combine to bag success.

24th January 2008

Supplying a comprehensive range of quality products in varied packaging sizes to both trade and retail stores, Tarmac Trupak is the UK's leading supplier of pre-packed building and decorative aggregates.
At the company's new site in Scorton, North Yorkshire, Trupak bags the full range of building and decorative aggregates for delivery to builders merchants, DIY stores and garden centres in the North East. Scorton would need to combine the business from two Trupak plants, one at Blaydon and the other at Farnham, which closed due to expiry of planning consent.

With the help of Haith Industrial, Trupak transferred its existing bagging line from Blaydon to Scorton where the line was installed along with a new control panel, bag kicker transfer conveyor and weigh conveyor.
However as Cliff Ogden, director at Trupak explains: "With the combination of business going through both Blaydon and our Farnham Bagging plant we required the output available from two bagging machines."
So a brand new form fill and seal bagging line was installed including a new robot for palletising the bags. Haith Industrial sourced the bagging machine from Premier Tech in Canada, "because of the success of a previous PremierTech machine installed by Haith Industrial at our Sevenoaks bagging plant," says Cliff.

Scorton's PremierTech Line

Material is fed to the PremierTech bagging line at Scorton, via a 10 cubic metre end-loaded bulk holding hopper with a 14.3 m long x 0.6 m wide discharge conveyor. The Premier Tech FFS-200 automatic bagging machine was supplied by Haith with a volumetric feeder for rocks and aggregates to provide a horizontal form, fill and seal process that is supplied complete with dust collecting ports. In this application, the PremierTech equipment will produce 25 kg bags of aggregate at the rate of 1200 bags per hour.

The FFS-200 Series Horizontal Form, Fill and Seal Bagger is an automatic system that makes its own bags from rolls of polyethylene pre-printed center-folded film. The combination of a non-stop operation and the horizontal configuration allows the use of a large film roll providing a continuous operation for many consecutive hours. The filled aggregate bags are weighed on a standard, totally enclosed Haith weigh belt conveyor that sits on a set of four load cells.

A 2 m long x 0.45 m wide transfer / kicker rubber-belt conveyor unit sends the bags to a flattening conveyor. The flattener has three powered rollers driven by a shaft mounted geared motor all mounted into a common frame, supported on adjustable legs fixed to the conveyor. The bags continue to a powered roller pick up table with powered rollers ready to be picked by the robot for palletising. Reject bags from the kicker conveyors go to pallet waste trays.

It's a Haith - Kawasaki ZD 130-S robotic stacking machine that is used to stack the 25 kg plastic bags at a rate of up to 20 bags per minute. A fresh pallet on which the robot can build a stack of bags is issued from a pallet magazine that holds fifteen 1200 x 1000 x 100 mm pallets. Once stacked with bags, the pallets are taken on an 8 m long x 1.3 m wide powered roller conveyor. This conveyor is constructed with heavy duty powered rollers, seven geared motor drives down the length of it and sets of control beams on each of the powered sections to enable accumulation of the full pallets, which are then collected by forklift truck to be taken to storage.

The bagging line's control panel utilises a PLC controller for full automatic and manual control and can be accessed via a step over platform that bridges the plant.
To ensure safety the robot stacking cell compound is secured with light guards across each of the forklift trucks access openings, while two man-access gates with Castel key system are also provided. There is also a compound guard unit with 2 man access gates with Castel key system interlocked into the panel for the bag kicker and flattener

Moving Trupak's Blaydon bagging line

Haith travelled to Tarmac Trupak's Blaydon site to strip out the bagging line located there and transferred it to Scorton where it received upgraded wiring, a new control panel fitted to control the new bag kicker and a new transfer conveyor and weigh conveyor.

The existing bagging line comprises a Haith 10 cubic metre end loaded bulk holding hopper with a 7.2 m long x 600 mm wide discharge conveyor to send material for bagging to Haith's high throughput, 10-50 bagging machine used for fill granular or fibrous materials. A manually set control gate is fitted into the mouth of the hopper. Fitted over the head pulley is a pneumatic trickle gate to reduce material flow for topping up. Rubber skirtings are fitted around the hopper and there is an automatic control system to start/stop the bag filling and clamp/unclamp the bags. A pair of cut off doors to reduce the in-flight material and increase bag accuracy is fitted above the bag clamp. Material is fed through the machine by a rubber belted conveyor, which is driven by an adjustable speed geared motor unit.

An auto infeed device presents the bags automatically to the Saxon SH1000 continuous hot air heat sealer, which seals the bags.
The weigh belt conveyor is again Haith's standard totally enclosed type with the conveyor being sat on a set of four load cells that are controlled by a single controller with LED readout. The readout is fed into the PLC that controls the 10-50 weigher to control the in flight materials.
Bags then travel down a 3.6 m long x 0.45 m wide bag transport conveyor to the palletising robot that came with the line.
This line that Haith has upgraded and reinstalled at Scorton will bag at the rate of 600 bags per hour.

Bulk Bagging

Haith also installed a bulk bagging facility at Scorton. Three Haith 10 cubic metre end loaded bulk holding hoppers, each with a 7.2 m long x 0.6 m wide discharge conveyor to serve three Haith bag support frames for loop or tunnel bulk bags. The machine is made from channel and box section with the inner frame having two formed up-turned channel sections to support the bags. This frame has four wheels fitted to it, which run on the inside of the outer support frame. Also fitted to the inner frame is a manually operated screw jack to adjust the position of the bag relative to the floor and feed conveyor. A load cell fitted into the mechanism is wired to the weigh controller, which will stop the feed conveyor at the pre-set weight. The programmable controller has an LED readout showing the weights and settings.

Cliff Ogden concludes: "The new equipment is working very well. We also took the opportunity to build some ‘just-in-time' production features into the bagging process which includes the pre loading of parked trailers so that the delivery HGV tractor only has to carry out a trailer swap (i.e. swap an empty trailer for a pre loaded trailer). We are very happy with the new equipment installed by Haith Industrial and the overall operation of the new site, which is achieving all the designed production efficiencies."

Article courtesy of the HUB magazine