Case Study Minerals & fuels

Challenge accepted!

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Challenge accepted!

How a project for a salt producer results in a new version of STATEC BINDER’s CERTOPAC

One of the leading manufacturers of salt & salt tablets in Belarus was looking for a strong partner for the packaging of salt pellets. The reason for this was the step towards automation combined with a significant increase in capacity. Another important factor for the customer was the consistently high quality of the packaging.

The requirements


Packaging of salt pellets in 25 kg bags (both prefabricated open-mouth bags and bags from PE tube) and subsequent palletizing

  • packing of salt pellets in 25 kg bags
  • in prefabricated open-mouth bags and bags from PE tube
  • output of 700 bags per hour for packing & palletizing
  • installation of the new packaging line in the existing building

The solution


For packaging: Extension of the CERTOPAC with an FFS module For palletizing: PRINCIPAL-R due to the low space requirement

  • CERTOPAC-Combi for packing the salt pellets
  • Additional FFS module for packaging in PE bags from the tube
  • Guaranteed capacity of 700 bags per hour for packing & palletizing

Exciting and challenging projects are part of STATEC BINDER’s everyday business. “Our goal is to offer our customers the perfect solution for bagging and palletizing their products. For this reason, challenging projects are always an opportunity for our company to grow and to prove to the customer that he has made the right choice with us,” says Josef Lorger, Managing Director of STATEC BINDER GmbH. The salt producer’s project was one of these challenging projects, which even resulted in a new version of an existing machine.

The customer was looking for a bagging machine to pack the salt pellets in 25kg bags, which could process open-mouth bags as well as bags from PE tube. A palletizer was also required. Due to the required performance and the limited space available, STATEC BINDER decided to use the CERTOPAC for packaging the salt pellets and the PRINICPAL-R robotic palletizer.

“The project was challenging in more than one aspect. For a long time, we had the idea to equip the CERTOPAC with an FFS module. The salt producer placed its trust in us and we started with the developments”, explains Edmund Gruber, Senior Sales Manager STATEC BINDER GmbH. He adds that the handling of the salt pellets was not easy either. These should of course end up in the bag as a whole, but would also break easily. For product feeding and weighing, the weighing machine with belt feeding was therefore chosen. In addition, the product feed of the salt pellets caused a high noise level. For this reason, insulation was applied from the buffer hopper to the filling spout. The desired output of 700 bags per hour was achieved with the new CERTOPAC-Combi machine. The robot palletizer, with a capacity of 750 bags per hour, palletizes the finished bags. The two machines had to be installed together with a stretch hooder in a limited space, which was also a major planning task. But the well experienced STATEC BINDER team also mastered this task.

During the development of the CERTOPAC-Combi, particular attention was paid to ensuring that the changeover from bag separation from the bag magazine to the production of bags from tubular film was simple and uncomplicated. The filling process is identical for both variants. The sacks are either separated from the sack magazine or produced from the tubular film and conveyed to the deposit table. There the bag is put on the filling spout, filled and placed on the conveyor belt. From there it goes to the bag closing machine, which sews, seals or hot-glues the bag depending on the material.

After successful commissioning and another two years, the salt producer needed another packaging line. Since the first packaging line was running to the customer’s complete satisfaction, he turned to STATEC BINDER for the next packaging line. This time the CERTOPAC was offered and ordered only for open-mouth bags together with the PRINCIPAL high-level palletizer. The biggest challenge in this project was the planning of the machines in the given space. With the bagging machine, a fixed point of feed needed to be met. “Planning into existing buildings is usually not an easy task. Fully automatic machines need enough space and of course we also want to save our customers from having to make major alterations. In the meantime, we have also become professionals when it comes to planning into existing and especially small or narrow buildings and ask the customer not to carry out any or only a few modifications”, says Jürgen Schoder, Project Manager STATEC BINDER GmbH.

Since the required output for the second project was higher (880 bags/hour for the bagging machine, 1000 bags/hour for the palletizer), the CERTOPAC was equipped with a double weigher with belt feeding. The PRINCIPAL was excellently suited for the high performance required for palletizing. A spiral conveyor was installed so that the filled and sealed bags could reach the palletizer due to the limited space.

„For challenging projects like these, good cooperation with the customer is of the greatest importance. The cooperation with the customer and our representative Ruben Tevikyan was and is very good and cooperative, which is always very important for us.“

Edmund Gruber, Senior Sales Manager
STATEC BINDER GmbH
„“


STATEC BINDER

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