Client application
Automatic bagging machines for powdered food colourings
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Context & customer needs
A major player in the manufacture of additives for the agri-food industry, specialising in the production of food colourings, was looking for a high-performance solution for packaging high value-added powders, in particular carmine (a natural colouring derived from cochineal, widely used in the food industry).
A dual requirement
- A semi-automated solution for more flexible production runs, with a throughput of 2 bags/minute, while allowing for rapid format and recipe changes.
- A fully automated line reaching 260 bags/hour, also capable of bag-in-box packaging with quick transitions between different colours, without heavy operator intervention.
Main constraints
- Variability of bag formats (10 to 25 kg).
- Thorough cleaning between each batch to avoid any cross-contamination between dyes.
- Need for reduced cleaning time, as the factory cannot produce if it cannot bag.
Customer product
Food colourings
The facilities process various powdered food colourings, including carmine, which is used in many food products. These powders, which are highly colourful, require perfect containment and quick, effective cleaning between each batch to prevent cross-contamination.
Technical challenges
The project had to overcome several major challenges to ensure performance, hygiene and production flexibility:
- Prevent cross-contamination between very powerful and sensitive food colourings.
- Reduce downtime associated with cleaning, which had previously been too long.
- Maintain a dosing accuracy of ±40g on bags weighing between 10 and 25 kg.
- Ensure an appropriate production rate: 2 bags/minute for small batches and 260 bags/hour for the automated line.
- Integrate a bag-in-box function with simplified recipe changeover and without significant human intervention.
Comply with CIP/NEP (Cleaning-In-Place) standards and guarantee rapid drying without residual moisture (Dry-In-Place).
Halpaq solution proposed
Halpaq developed and integrated two complementary systems at the customer’s site in the United States to meet the high requirements for flexibility, hygiene and performance.
The solution implemented includes:
- Semi-automated bagging machine equipped with the Easy-Clean system, allowing for quick disassembly of parts in contact with the product.
This design facilitates the transfer of parts to the washing room and significantly reduces downtime. - Fully automated bagging line with bottom-up filling, incorporating a complete CIP/CIP + Dry-In-Place system.
This installation allows colour changes in less than 4 hours, ensuring perfect hygiene and eliminating any risk of cross-contamination. - Multi-format flexibility: both machines accept bags weighing 10 to 25 kg, while maintaining a high level of dosing accuracy and speed.
Line operation
- Automatic bag loading (or manual on the semi-automated version).
- Bottom-up filling, ensuring consistent packaging and limiting dust.
- Controlled deaeration to ensure good density in the bag.
- Closing and labelling with integrated traceability.
- Bag-in-box option on the automated line, with elevator conveyor for controlled bag deposit.
- Easy-Clean (semi-automatic) or CIP + Dry-In-Place (automated) cleaning, allowing production to restart within 4 hours.
Benefits for the customer
- Increased production rates thanks to two performance levels tailored to requirements.
- Production flexibility for small batches, enabling greater commercial responsiveness.
- Significant reduction in downtime associated with cleaning.
- Increased dosing accuracy, limiting losses of high value-added products.
- Elimination of cross-contamination between dyes.
- No contamination of the room thanks to the confined and dust-free system.
- Total flexibility in terms of bag formats and product recipes.
- Reduced operator presence, improving safety and reducing labour costs.
| Parameter | Semi-automated | Automated |
|---|---|---|
| Cadence | 2 bags/min | 400 bags/hour |
| Bag formats | 10 to 25 kg | 10 to 25 kg |
| Dosing accuracy | ±40 g | ±40 g |
| Cleaning | Easy-Clean removable | NEP/CIP + Dry-In-Place |
| Restart time | 4 h | 4 h |
| Option bag-in-box | Non | Yes, automated recipe change |
The equipment used for this project
Equipment
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