Efficient big bag filling for
bulk mineral materials (gravel, crushed stone, sand)

Project implementation and technical features:

Herzer Bau- u. Transport GmbH, based in Vienna and Groß-Enzersdorf, Austria, is an established company in the sand, gravel and crushed stone production sector. As part of the modernization of its internal packaging and transport process, Herzer wanted to optimize the existing manual processes and automate them to a greater extent.

Previously, big bags were filled using a simple semi-automatic system: although the material was filled automatically, the empty pallets had to be inserted manually. After each filling, the filled big bag had to be lifted off individually using a forklift truck and transported away. This method of working was not only labor-intensive, but also caused delays. As the company produces various products with different flow properties, filling also posed a challenge.

Herzer formulated clear goals in order to meet the increasing demand and optimize internal processes: The new solution should enable an output of 45 big bags per hour, work largely automatically, enable the handling of different big bag types as well as materials and at the same time bring advantages in terms of the use and costs of personnel resources.

The STATEC BINDER solution: automation with flexibility

We designed and supplied a comprehensive solution for Herzer, consisting of a big bag filling station including integrated automatic pallet separation and two additional automatic empty pallet storage units. These enable the storage of up to 45 empty pallets. The station processes big bags weighing between 800 and 1,200 kg and is designed as a gross filling system. The customized solution enables a filling capacity of 45 big bags per hour, with a low overall height of the system. The output also depends on the flowability of the respective product - an even higher output would be possible with particularly flowable materials. Another key element of the solution is the corner transfer at the end of the full pallet transport: the filled big bags are positioned in such a way that they can be lifted off the forklift truck and transported away at the same time using a double fork, which significantly speeds up internal material handling.

The HMI system not only allows the overall control and selection of specific products and big bag types, but is also connected to the customer's office software. This automatically generates a daily filling protocol that documents how many big bags of which material have been filled - a valuable tool for internal planning and customer communication.

Before delivery, a detailed factory acceptance test was carried out at STATEC BINDER in Gleisdorf, in the presence of a team from the general contractor BAG Klöch and representatives from Herzer Bau- u. Transport GmbH. The acceptance was successful and all requirements were met to the full satisfaction of the customer.

"It's not the price that counts - it's the flexibility. When selecting our suppliers, we don't go for the cheapest provider, but for the one who thinks, acts and grows together with us. Our services are individual - because they are developed directly with our customers. Every requirement, every challenge has brought us further.

In STATEC BINDER and BAG Klöch, we have found two partners who share our philosophy. The customized and flexible solution that we have developed together allows us to respond precisely to the needs of our customers - efficiently, modern and future-oriented.

We are particularly proud of the fact that we have been able to automate several manual work steps through our collaboration. This not only makes us faster and ready for action at short notice, but also brings us up to date technologically." - Reports Martin Herzer from the Herzer Bau- u. Transport GmbH about the project.