At Barcelona Packaging Hub, we share specialized technical knowledge to help the industry make strategic decisions about their packaging processes. On this occasion, we highlight the expertise of our member TMI , a specialist in end-of-line solutions, who offers a detailed guide on how to configure an optimal bagging machine for feed ingredients, taking into account the multiple factors that affect efficiency, hygiene, and profitability.
Producing and processing premixes, correctors, and ingredients for the agri-food industry is no simple task. To meet the nutritional and mineral needs of different animal species and the market’s growing demand, a wide range of products with varied characteristics and behaviors are developed.
Managing such diversity within a single plant is complex. It impacts not only the manufacturing or mixing process but also the type of packaging and the bagging operations. This article outlines the key aspects to consider when defining the most suitable bagging solution for ingredients intended for animal feed.
1. Number of products and batches
From vitamins and macro-correctors to enzymes, antioxidants, and aromas, the range of products that a feed ingredient manufacturer can handle is extensive. This variety often leads to a high number of small batches, which directly impacts line optimization — every change of batch consumes time and labor for cleaning and setup, ultimately reducing overall production efficiency.
For companies managing multiple batches, the dreaded downtime becomes a frequent challenge. Therefore, the bagging machine must allow quick and easy batch changes without cross-contamination. This can be achieved with equipment specifically designed for that purpose, featuring hygienic design finishes and, ideally, tool-less cleaning, enabling operators to access and clean all parts of the system without tools.
2. Product properties
Bagging pellets for animal feed is not the same as dosing a powdered vitamin corrector. The dosing process and the technical complexity differ substantially.
In a pellet production plant, dosing typically relies on belt feeders and paper bags with stitched closures, a straightforward process with limited technical demands.
However, when handling powdered products such as vitamins, premixes, additives, colorants, or medicated ingredients, where particle size is measured in microns, the scenario changes entirely. The bagging line must be capable of:
- Ensuring airtightness during the bagging process and in the final package.
- Containing or preventing the release of dust during filling and handling.
- Featuring smooth, easily cleanable surfaces to prevent dust buildup and contamination risks.
- Adapting to aluminum or similar bags with air extraction or product de-aeration systems to ensure bag and pallet stability.
All these elements directly influence the configuration of the bagging machine and the technology required to ensure an optimal bagging process for each specific product.
3. Hygiene and accessibility
Every facility dedicated to food production must maintain specific hygiene conditions to ensure product quality, whether for human or animal consumption (although, in the case of products intended for human consumption, the requirements are generally stricter).
To achieve this, it is essential to keep the environment and surroundings free of dust, prevent residues from remaining in the ducts through which the product flows, and establish a cleaning protocol that eliminates any trace of product during each batch change.
This brings us once again to the issue of downtime: the more time devoted to cleaning, the less production time the bagging line has, and the lower the profitability. For this reason, it is essential that the bagging machine be as accessible as possible and designed so that operators can clean it quickly, in other words, that it complies with the principles of hygienic design
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4. Logistics
When defining technical end-of-line solutions, logistics requirements must always be taken into account. To do this, it is important to ask yourself a series of questions:
Does your product require a hermetic bag to preserve its properties for a longer period of time? Will you be transporting your goods in containers?
Are you exporting your product to countries with strict packaging regulations? Do you need to ensure that your product arrives intact at its destination?
If the answer to most of these questions is yes, you should consider investing in high-quality packaging and protecting your pallets with more than just plastic, to prevent unexpected costs in the long run.
It is essential to choose a bag that helps maintain the product’s properties and is compatible with a bagging machine capable of efficiently extracting air from the bag. When vacuuming is done correctly, palletized loads become more stable. Moreover, if the pallets are laterally protected with film and cardboard, breakages throughout the handling chain are minimized and product returns are reduced.
5. Available space
Regardless of the type of product or bag, there is one question that cannot be overlooked before configuring the bagging solution: how much space is available for the end-of-line area?
Whether it is a new facility or an existing one that needs to be upgraded, it is essential to consider the space that can be allocated to packaging, including the bagging machine, palletizing, wrapping, handling, and storage of filled pallets. And not only in terms of square meters, but also height: a building with limited ceiling height may restrict the installation of systems such as a de-aeration probe or a Cartesian palletizer.
Moreover, contrary to what many might think, a fully automated installation can sometimes be more compact than a semi-automatic one. It’s important to remember that post-bagging operations such as bag sealing, labeling, or sack flattening also require space, while an automatic bagging machine can integrate all these processes within as little as 15 m², depending on the model.
A practical case
Each of these factors must be analyzed individually to define the most suitable technical solution in every case. At TMI, a member company of Barcelona Packaging Hub, they offer specialized consulting to ensure that the implementation of a bagging machine, whether automatic or semi-automatic, is a complete success.
A clear example is that of a manufacturer of additives and feed blends. The
Initially, these mixtures and additives were bagged manually into aluminum and PE bags. Air was partially removed by hand, and a Goglio degassing valve was used to evacuate the remaining air. Although this method was hygienically acceptable, it presented several disadvantages: high labor demand, the need for special bags, reduced product shelf life, and difficulties in forming tall pallets.
The need to automate the process was evident. TMI conducted laboratory testing of the different products, analyzing their density and behavior. This made it possible to determine the optimal dosing parameters to cover the wide range of products and to define the appropriate bag sizes for each identified range.
From this study, a compact bagging and palletizing line was designed, consisting of:
- ILERSAC HCBSD automatic bagging machine for open-mouth, heat-sealable bags
- ILERPAL H hybrid layer palletizer
- ILERGIR automatic stretch wrapper
- ILERBOX corrugated cardboard side protection module
This installation is highly compact, performing all processes, bagging, air extraction, heat sealing, weight control, rejection of non-compliant bags, palletizing, wrapping, top film application, and side protection, within approximately 75 m².
In addition, the conventional ILERSAC H bagging machine was redesigned with a hygienic design, becoming the new ILERSAC HC, aimed at making it more accessible, easier to clean, and completely dust-free. The redesign included several key improvements:
- Preventing any dust emission during the bagging process, thanks to a new flexible, airtight, and mobile bagging spout.
- Applying hygienic finishes throughout the product path and on all surrounding machine surfaces.
- Increasing the distance between stations inside the bagging machine for greater accessibility.
- Preventing dust accumulation and contamination points through integrated hygienic cabling within the chassis.
These upgrades enable the customer to perform batch changes much more efficiently, optimizing both time and resources.
Another major improvement was achieved in logistics: with the new ILERPAL H automatic bag palletizer, the company can now produce pallets up to 2.7 meters high. This represents a clear logistical advantage, maximizing the capacity of HQ containers used for maritime export. The addition of the ILERBOX module also allowed automation of side protection with cardboard, ensuring that bags reach their destination intact.
At Barcelona Packaging Hub, we value technical solutions like this innovations that place the bagging machine at the core of process optimization for the packaging of agri-food ingredients.
Are you looking to optimize your bagging system for feed ingredients? Barcelona Packaging Hub connects you with the most suitable technical solutions for your specific needs.