A flour mill wanted to increase its packaging capacity to 250 paper open-mouth bags per hour. Maxpac supplied a new big-bag filling machine that had to fit seamlessly into the existing production environment, where space was limited.
For a flour mill that grinds wheat into different types of flour, produces blends for bread and pastry, and also packages flour and mixes in various formats, additional capacity was needed. The products are supplied to bakeries, food manufacturers, and distributors in Belgium.
The existing bag-filling machine was outdated and worn. As a result, it became less reliable, no longer met current safety standards, and maintenance and technical support became increasingly difficult. The new system needed to process approximately 250 paper open-mouth bags per hour. At the same time, available space, proper dust extraction, budget, and reliable service were important constraints.
At first glance, the requirement seemed straightforward: replace the existing bagging system with a higher-capacity machine. In practice, the main challenge was integration.
The new equipment had to fit within the available space and connect to the existing production environment. Several sizes of paper open-mouth bags needed to be processed on the same machine. The existing palletizer also had to continue operating with the newly filled bags.
That meant selecting the right machine was only one part of the project. The entire line still had to function as one integrated system.
The customer already had a bag-filling machine supplied through Maxpac in operation at the site. Their experience with that system and with Maxpac’s technical support had been positive. As a result, the customer again preferred a solution supplied and supported by Maxpac. They also preferred, where possible, to work with a single supplier for this type of equipment.
Operations Manager: “Very satisfied with the packaging line. It meets the required capacity and downtime is minimal.”
The new line also delivered a clear improvement in reliability. While the old system experienced several breakdowns per week, the new line now sees very few breakdowns per month.
Maxpac developed the solution as an upgrade to the existing packaging process, rather than as a standalone machine.
The system included a new hopper and weighing system, followed by an open-mouth bag-filling machine for paper bags. A ticket dispenser, sewing line, and roller press were also included. The roller press flattens the filled bags before they continue through the line. Conveyor belts then transport the bags to the existing robotic palletizer. A new electrical cabinet was also part of the solution.
This integration was important because the available space was extremely limited. The machine configuration was therefore adapted to the existing production environment. This made it possible to achieve the required increase in capacity without replacing the entire existing infrastructure.
Flexibility was another important factor. The customer uses several sizes of paper open-mouth bags. These formats had to be programmed into the machine so the same system could support different packaging requirements.
Finally, the existing palletizer had to be adapted to the newly filled bags. This meant the integration extended beyond the filling machine itself: the transition to the existing end-of-line equipment also had to work correctly from a technical standpoint.
A well-considered system integration
After the initial request, Maxpac consolidated the technical requirements and translated them into an RFQ for the machine builder.
This was followed by the 3D design and the first complete quotation.
After the machine was tested during a FAT, it was delivered and installed at the customer’s site, after which the packaging line was commissioned. The limited installation space was the main factor that made this project non-standard. The equipment had to be adapted to the physical constraints of the environment. At the same time, the different bag sizes had to be configured correctly, and the existing palletizer had to be adjusted to the new setup.
This combination of new and existing components made proper system integration essential: hopper, weighing, filling, closing, flattening, conveying, and palletizing all had to function once again as one continuous packaging process.
Ultimately, the integration served one clear objective: to increase packaging capacity within the existing production environment. The customer was targeting approximately 250 paper open-mouth bags per hour.
But capacity alone does not tell the full story. In daily operation, the new system also represents a significant improvement. The machine is fully compliant in terms of safety and food-grade requirements. It also provides greater accuracy and flexibility for the different bag sizes processed by the customer. Finally, selecting the same machine builder again creates greater consistency in both equipment and operation.
At the same time, the packaging line replaces an aging system for which service and spare-parts availability were becoming increasing concerns. With the new installation, the customer once again has a system that is supported locally by Maxpac. This fits the need for a packaging process that not only delivers sufficient capacity, but also remains practical to manage over the long term.
For the customer, the project therefore involved more than simply replacing an outdated bag-filling machine. Within the physical constraints of the existing production environment, the packaging line gained capacity and flexibility through a compliant installation that integrates with the existing infrastructure and is once again supported by a trusted technical partner.
Adapting a packaging line to your existing production environment? Increasing capacity does not automatically require an entirely new production environment. The right solution starts with the available space, the product, the required capacity, and the machines the new system needs to work with.
This reflects Maxpac’s approach to packaging projects: increasing capacity does not automatically require an entirely new production environment.
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