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But how does such a packaging machine basically work? Depending on the type of packaging machine, in our case open-mouth bags or FFS (form-fill-seal) for free-flowing to powdery products, the packaging process runs differently. The basic principle is the same:

1. A single bag, made of woven PP, PE or paper, is placed on the filling clamp
2. The product is precisely filled into the bag after the product is previously weighed by a scale
3. It is conveyed to a closing machine.

Sounds like a simple process. The complex thing about packaging machines is not the basic process, but the adjustments and precision of the components. Fully automatic packaging machines only function reliably when specific process steps are coordinated with each other.
The interaction is of utmost importance here, because otherwise it could happen that a filled bag is released too early or the product flows without a bag having been attached to the filling clamp. Such scenarios must of course be prevented and this requires precise programming, commissioning and operation.
If cleaning and maintenance measures are then carried out regularly, a packaging machine will provide several decades of good service.

Most common types of packaging

• Open-mouth packaging machines, using a pre-made bag made of paper, PE or woven PP
• FFS (Form-fill-seal) packaging systems
• Big Bag Filling stations

Open-Mouth versus FFS bagging:

The modes of operation of the two machines clearly show the differences between the two types of packaging machines. Whereas open-mouth bagging machines use a prefabricated bag and either sew, seal or heat-seal it after filling, the FFS packaging machine makes the bag before filling and always seals it. Depending on the product to be packed and the required output, either an open-mouth or FFS machine is the better choice.

Open mouth bagging machines

The processes up to the filled and sewn bag are designed to be simple but effective. Prefabricated bags made of woven PP, PE or paper are separated from a stack in the magazine with the aid of vacuum suction cups and transported to the deposit table.
Here, the bag is opened by means of a squeegee, placed on the filling clamp, clamped and filled. The filled bag is then picked up and placed on the conveyor belt and from there transported to the bag closing machine, which sews, welds or heat-seals the bag depending on the material.

FFS (form-fill-seal) bagging machines:

The work stations of the machine are divided into forming, filling and sealing the bags. Due to this principle, three bags can always be processed at the same time.
The advantage of this is that the cycle time of each work step is optimized and, even at high production speeds, it is ensured that the bags are always formed, filled and sealed at exactly the right time.

1. The tubular film is pulled to the first sealing bar with the help of a dancer roller/balancing rocker, where the bottom of the bag is sealed and a knife cuts the individual bag from the roll.
2. The bag is then passed to the filling station and placed on the filling clamp.
3. Once the bag is filled, it is passed to the next welding station where the top weld is made.
4. As soon as this is finished, the bag is transported by conveyor belt, e.g. to a palletizer.

Vertical FFS bagging machine

1. The flat film is pulled over a forming shoulder, which has a low-friction coating, and formed into a tube.
2. A permanently heated sealing bar performs the vertical overlap sealing.
3. The weighed product enters the bag via the filling tube.
4. Two electronically controlled sealing bars seal the finished pack at the top and simultaneously form the bottom seal for the next pack.
5. Intensive air cooling enables the shortest possible cycle times.
6. A built-in knife separates an already filled bag from the tube.
7. The bag is then transported via a conveyor belt to a palletizer.

Differences in product handling

The basic structure above the machine is similar for both FFS and open-mouth. An infeed hopper is installed above the packaging machine. On a steel frame placed above the machine is a scale, depending on the product with gravity, belt or screw dosing, which in turn is placed below a product silo or the product infeed.
Depending on the characteristics of the product, machines can be equipped with, for example, a dust-tight filling clamp or, in the case of abrasive products, with a special casing.

How does a palletizer work?

In palletizers, whether high-level or robotic palletizers, bags or cartons are stacked on a pallet and then secured for storage or shipping, for example. A simple description of how a palletizer works:

1. A bag or carton arrives at the palletizer via a conveyor belt.
2. It is brought into the correct position and positioned on the pallet.
3. As soon as the layer is finished, the next layer is started and thus bags or cartons are stacked more and more on top of each other.
4. When the defined number of layers has been reached, the entire pallet is conveyed to the pallet securing unit.

Degrees of automation in packaging systems

1. Manual: In the case of manual bagging systems, personnel are always required during operation of the machine to place the bag to be filled on the filling clamp, fasten it and, after filling, guide it to be sewn or welded. All these steps must of course be carried out in compliance with various safety precautions.
2. Semi automatic: If a semi-automatic packaging machine is used, only personnel are required to place the bag to be filled on the filling clamp. The machine fills the bag and places it back on the conveyor belt, which transports the bag to a closing machine, without the intervention of personnel.
3. Fully automatic: Fully automatic packaging systems clearly have the advantage that the machine works independently and carries out processes automatically. For this reason, personnel are only required to monitor the safe operation and settings of the machine. This means that personnel resources can be used more efficiently. In addition, fully automatic bagging systems can increase performance and thus output. A variety of safety precautions ensure reliable and, above all, safe operation.