Optimisation of big bag filling for mineral products
The Austrian company Herzer Bau- u. Transport GmbH is based in Vienna and Groß Enzersdorf. Production of sand, gravel and crushed stone is part of their daily business. As part of the modernization of its internal packaging and transport processes, Herzer‘s objective was to optimize their existing manual processes and increase automation. Manual processes such as manually inserting pallets or lifting and transporting filled big bags individually using forklift trucks, proved to be time-consuming and labor-intensive.
Herzer formulated clear goals in order to meet the increasing demand and optimize internal processes: The new solution should enable a throughput of 45 big bags per hour, operate largely automatically and allow the handling of different types of big bags and materials. Additionally, improvements in personnel-related costs are expected to emerge. The products being filled have different flow properties, which presented a challenge for the changeover.
The decision to commission Statec Binder as a partner for this project was based on the convincing combination of technical advice, individual solution expertise, and the comprehensive service package. In particular, the possibility of obtaining a solution that was precisely tailored to the requirements played a central role.
Automation with flexibility
A comprehensive solution for Herzer was designed, consisting of a big bag filling station with integrated automatic pallet separation and two additional automatic empty pallet storage areas, which can hold up to 45 empty pallets. The gross filling system packs big bags weighing between 800 and 1,200 kg and has a capacity of 45 big bags per hour. Another element of Statec Binder‘s solution was a corner transfer, that enables the filled big bags to be lifted and transported away simultaneously using a double fork. These adjustments result in significantly faster internal material handling and reduction of various costs.
Another challenge of the project was the differences in loop length and volume of the big bags. Statec Binder was able to solve this with special programming of the machine control panel (HMI). This user-friendly operation allows the selection of different presets depending on the product and bag type. This flexibility is crucial for the company’s daily requirements.
Prior to delivery, a detailed factory acceptance test was carried out at Statec Binder in Gleisdorf, attended by a team from the general contractor BAG Klöch and representatives of Herzer Bau- u. Transport GmbH. The acceptance was successful and all requirements were met to the customer’s complete satisfaction.
Since commissioning in 2024, the system has been running smoothly in daily operation. Herzer benefits from a largely automated filling process, which has not only increased production capacity but also reduced personnel costs. Orders can now be processed faster and more efficiently – while at the same time making more resourceful use of personnel. Herzer also relies on STATEC BINDER for service: The company uses our 1-6-11 service program, which has already been used for two scheduled service appointments.
”It’s not the price that counts, but flexibility. When selecting our suppliers, we don’t go for the cheapest provider, but the one who thinks, acts, and grows with us. Our services are customized because they are developed directly with our customers. Every requirement and every challenge has helped us move forward. In Statec Binder and BAG Klöch, we have found two partners who share our philosophy. The customized and flexible solution we have developed together enables us to respond precisely to our customers’ needs – efficiently, modernly, and with an eye to the future. We are particularly proud that our collaboration has enabled us to automate several manual work steps. This not only makes us faster and ready for action at short notice, but also brings us up to date with the latest technology,” reports Martin Herzer from Herzer Bau- u. Transport GmbH about the project.
