Smart Expansion and Modernization of Fertilizer Packaging Lines

The Challenge

More capacity, stricter standards and maximum flexibility

Katoen Natie Tessenderlo, a specialist in high-tech logistics for fertilizers, turned to Maxpac to maximize the efficiency of its packaging operations.

The requirements were clear: with rising production volumes and stricter quality standards, renewing the existing packaging lines had become inevitable. But the new solution needed to do more than just boost capacity. It had to fit seamlessly within the limited available space, meet the strict safety requirements of the Katoen Natie group, and ensure that at least 50% of the production capacity remained operational during the demolition and installation phases.

The project involved the installation of new packaging lines for potassium sulphate in 20 and 25 kg bags, as well as a big bag filling line for various weights.

The Packaging Line

Maximum efficiency, minimal downtime

A solution that handles higher volumes without interrupting production.

Together with partner Concetti, Maxpac designed, delivered, and implemented a completely new packaging line consisting of four advanced packaging systems. These are equipped with gravity net weighers that accurately dose the fertilizer into Concetti’s FFS-machines. These machines can process up to 1,200 bags per hour, ensuring a significant capacity increase.

Once filled, the bags are weighed and labeled with a unique tracking ID before being transported via conveyor belts to high-level palletizers. The bags are stacked in an optimized pattern to form stable pallets. Dynamic shuttles then move the pallets to hydraulic presses, where they are compacted to allow stacking up to four levels high, without requiring additional racking or support.

Finally, the pallets are secured with a stretch hood for maximum stability and protection during transport and storage. Thanks to the smart layout, forklifts can pick up two pallets at once, optimizing internal logistics.

Maxpac also developed a fully customized solution for big bags: the Flex-Auto big bag filling station. This station is fully integrated into the existing production line and provides an efficient, flexible way to fill a range of big bag formats.

Tubular Film Bagging Machine (FFS)

Concetti

Machines for forming, filling, and sealing packaging with volumes from 5 to 50 kilograms. Suitable for both free-flowing and challenging-to-flow products.

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Flex-Auto Big Bag Filling Machine

Maxpac

The Flex-Auto is the ultimate solution for companies seeking maximum efficiency and automation in their big bag filling processes.

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The result

Uninterrupted production, future-ready

An optimized and future-proof packaging line that meets the highest demands.

To ensure business continuity, the project was carefully phased so that at least 50% of production capacity remained online during the transition.

Following the successful installation, Maxpac provided in-depth training to Katoen Natie’s technical teams and operators, enabling them to maintain and even expand the line independently. Maxpac, of course, remains on call for complex issues and emergencies.

Thanks to the smart integration in the existing production space and a well-thought-out software approach, bottlenecks were eliminated. Moreover, the solution not only guarantees a more efficient process, but also a safe working environment that meets Katoen Natie’s strict safety regulations.

With this advanced packaging solution, Maxpac is proud to support Katoen Natie in their ambition to innovate and grow.

Consult with our experts

Our packaging specialists are ready to assist you with the design, installation, startup, maintenance, and optimization of your packaging line.

Consult with our experts today, free of obligation. And see how you can achieve more reliability, efficiency, and return from your packaging line as soon as tomorrow.

Contact us

COO / Managing Partner

Abdellah Chiua

+32 (0)3 710 51 70

abdellah.chiua@maxpac.be

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