Our nine packing lines package a range of products ranging from 50g to 25kg. Each packing line has its own computer that informs the Line Leader of the current and subsequent productions, providing full details of the product, packaging and stacking requirements. Each production run has its own unique works order traced by RFID (Radio Frequency Identification), preventing any unforeseen human error and offering full traceability for the partner.
Before the line is run, the Line Operator checks the product is correct as per the specification, using a reference photo on the screen. Should the product not be the exact standard, it is rejected, and a quality investigation commences. The bags are also placed horizontally into the machine and passed through a camera that checks the imagery of the bag, confirming it is correct.
Next, the bags are laser coded prior to filling. Various information is being etched onto the bag in exactly the same place every time, offering a guarantee that nothing will be missing or unreadable.
Weighing System & Quality Control
Meanwhile, the product is fed onto a weighing system into an arrangement of small buckets. After the weighing system has calculated the desired weight, it releases a number of the buckets, dispensing the desired weight. Should the machine calculate an incorrect weight, a bypass system operates, and the product is diverted away from the filling tube. If the weight is correct, the product travels down a feeding tube and, on its journey, will pass through a metal detector.
Should the machine detect a foreign object, the machine will sound an alarm, and a quality system process will begin an investigation into the source of the object. Once removed, the machine will restart, and filling will resume.
Sealing the bag
The bag travels past a Thermal Camera which is used to guarantee the bag has been sealed. The camera uses thermal imagery to inspect the seal integrity. If the bag seal is faulty, the machine automatically rejects the bag, removing it from the process.
On-Line Weight Checking System
Every bag passes across an On-Line Weight Checking System that weighs every single bag, guaranteeing the weight. The same system will automatically reject any bag found to be under or overweight.
The bag travels through an x-ray system to check for metal or foreign bodies. In addition, every bag is photographed for reference, and anything detected will result in the bag being automatically rejected, with a full investigation taking place.
The bag enters a fully automated bailing machine that will first index the bags to the partner’s requirement, for example, 2 x 2. Once indexing is complete, the bundle will move forward and become vertically wrapped in stretch film before going through the same process to be horizontally wrapped. This is so the bundle is fully encased, secure and protected.
As the completed bundle exits the bailing machine, it passes an automatic bail label applicator that places the partner label onto the outside of the bundle. The data on the label is automatically generated by the main control computer, eliminating any potential human error. The bags are then fed into the automated palletiser machine. This huge machine will do a variety of functions resulting in a completed pallet at the end of the process. Finally, we automatically apply a label to the pallet. Whilst this is done, the roller conveyor the pallet stands on records the weight of the pallet. The pallet is now taken to our storage facility, ready for the partner to order.