Integrated Granules & Powder Mixture Weighing and Packaging System | Multi-Material Flexible VFFS Packaging Line
This fully integrated, intelligent weighing and packaging system is professionally engineered for mixed packaging of granules and powder materials, with a customizable freely-switchable control program to meet diversified production needs. It is widely applicable to instant oatmeal + milk powder, mixed nuts + seasoning powder, grain + nutritional fortifier, feed pellets + vitamin additives, spice granules + powder, pet food + nutritional supplements, pharmaceutical granules + powder and other multi-material packaging scenarios. This turnkey solution realizes one-stop automated production from separate material conveying, independent precision weighing, flexible mode switching to automatic bag forming, filling and sealing, perfectly matching the production needs of food, feed, pharmaceutical, daily chemical and chemical industries.
Industry Pain Points
·Severe formula ratio deviation and product inconsistency: Traditional pre-mixing process for granules and powder causes serious material layering, leading to unstable ingredient ratio in each package, which violates strict formula regulations of food, feed and pharmaceutical industries, and brings huge product recall risks and brand reputation loss.
·Poor equipment flexibility and high investment cost: Ordinary packaging equipment can only handle single powder or single granule packaging, unable to support individual packaging and mixed packaging at the same time. Enterprises need to invest in multiple production lines, resulting in high equipment cost, large workshop space occupation and long product changeover cycle.
·Coexisting production difficulties of dual materials: Powder is prone to dust diffusion, wall sticking, static electricity and blockage, while granules are easy to break and jam. Traditional equipment cannot solve these two problems at the same time, resulting in serious workshop pollution, raw material waste, high product damage rate and unqualified finished product appearance.
·Unstable weighing accuracy and raw material loss: Powder and granules have huge differences in fluidity, bulk density and material properties. A single weighing system cannot guarantee the metering accuracy of both materials at the same time, resulting in frequent overweight/underweight problems, massive raw material cost loss and non-compliance risks in international trade.
·High manual dependency and cross-contamination risk: Traditional mixed packaging requires a lot of manual participation in pre-mixing, feeding and transferring, leading to low production efficiency, soaring labor costs, and high cross-contamination risks especially for food and pharmaceutical grade products.
·Frequent production downtime and high maintenance cost: Powder wall sticking and granule jamming lead to frequent shutdown for cleaning, serious equipment wear, high failure rate, and huge later maintenance cost, unable to support 24/7 continuous mass production.
·Difficulty in meeting international certification standards: Equipment with sanitary dead corners is hard to disassemble and clean, failing to meet strict international industry standards such as FDA, BRC, HACCP for food and GMP for pharmaceutical, which restricts enterprises from entering the global market.
Core Customer Demands
·All-in-one flexible production capacity: One set of system supports free switching of three packaging modes - individual powder packaging, individual granule packaging, and granules & powder synchronous mixed packaging, to meet multi-SKU production needs and reduce equipment investment cost.
·Dual independent precision weighing system: Separate metering units customized for the material properties of powder and granules, to ensure accurate and controllable formula ratio of each package, completely solve the pre-mixing layering problem, and fully comply with international industry formula standards.
·Fully sealed dust-proof and anti-breakage design: Full-process closed material conveying and metering structure, to eliminate powder dust pollution, wall sticking and blockage, while avoiding granule breakage, ensuring finished product quality and workshop environment safety.
·Fully automated continuous production: Unmanned production from material feeding, metering, packaging to finished product output, to reduce manual contact, cut labor costs, avoid cross-contamination, and improve overall production efficiency.
·Fast formula and specification changeover: One-click switching of product formula, packaging specification and packaging mode, with short debugging time, to adapt to the flexible production needs of small-batch and multi-category products.
·Food-grade compliant structure: No sanitary dead corner design, easy to disassemble and clean, to meet the requirements of FDA, BRC, HACCP, GMP and other international mainstream industry safety certifications.
·Stable and durable performance: Wear-resistant and anti-sticking structure adapted to powder and granules, with low failure rate, easy operation and maintenance, supporting 24/7 long-term continuous stable operation, and reducing later operation and maintenance costs.
·Compact integrated structure: Greatly reduce workshop floor space compared with multiple independent production lines, and adapt to different workshop layouts of various scales.
Our Tailored Complete Solution
We provide a turnkey, fully integrated granules and powder mixture packaging solution, with modular design and intelligent control system, which can be flexibly adjusted according to your material properties, production capacity and packaging specifications. The standard configuration fully covers the whole process of multi-material packaging, and can be seamlessly docked with your front-end production line and back-end boxing/palletizing equipment.
Core Solution Units
·Screw Conveyor: Professional fully sealed powder conveying unit with anti-sticking, anti-static and anti-blocking design, specially customized for powder materials. It smoothly and stably transports powder to the upper hopper of the auger filler, with no dust leakage, no material residue and no blockage during the whole process.
·Auger Filler: High-precision powder metering unit, optimized for ultrafine powder, easy-caking and poor-fluidity powder materials. Equipped with high-precision load cell, it realizes stable and accurate quantitative filling of powder, with fully sealed structure to avoid dust diffusion and ensure long-term weighing accuracy.
·320 VFFS (Vertical Form Fill Seal) Machine: High-performance compact vertical packaging machine, specially matched for this integrated system. It automatically completes bag forming, material filling, date coding, airtight sealing and bag cutting in one go, compatible with pillow bags, quad-seal bags and other common bag types, with stable and consistent sealing performance, perfectly adapting to small and medium batch packaging demands.
·Z-type Bucket Elevator: Professional closed vertical lifting unit for granule materials, with anti-drop, anti-breakage and anti-scattering bucket design. It smoothly lifts granule materials to the upper hopper of the linear weigher without damaging the granule shape, with fully sealed structure to avoid material leakage and workshop pollution.
·Supporting Platform: Heavy-duty 304 stainless steel supporting platform with anti-slip design and safety guardrails. It provides stable and safe installation space for the upper weighing units, effectively reduces the impact of equipment vibration on weighing accuracy, and facilitates daily maintenance, cleaning and debugging of the equipment.
·Finished Product Conveyor: Food/industrial-grade finished product conveying equipment, which stably transports the sealed finished packages to the subsequent inspection, boxing or palletizing link, perfectly matching the production beat of the front-end equipment to ensure non-stop continuous production of the whole line.
·4-head 0.5L Linear Weigher: High-precision granule metering unit, specially optimized for small and medium granule materials. With 4 independent 0.5L hoppers, it realizes fast and accurate quantitative weighing of granule materials, with anti-carding design to avoid material blockage, and stable weighing performance even for irregular granules.
Standard Workflow & Freely Switchable Packaging Modes
·Pour powder materials into the hopper of the screw conveyor, and granule materials into the hopper of the Z-type bucket elevator respectively.
·The screw conveyor transports powder materials to the upper hopper of the auger filler, and the Z-type bucket elevator lifts granule materials to the upper hopper of the 4-head linear weigher, with fully sealed conveying for both materials.
·Set the target weight for the auger filler (powder) and the 4-head linear weigher (granules) respectively through the intelligent control system, according to the product formula requirements.
·Freely switchable customized program supports 3 packaging modes to meet all your production needs:
A) Individual powder packaging: Only the auger filler operates to complete quantitative filling and packaging of powder materials alone.
B) Individual granule packaging: Only the 4-head linear weigher operates to complete quantitative filling and packaging of granule materials alone.
C) Granules & powder mixture packaging: Both the auger filler and the linear weigher operate synchronously, discharge materials in sequence according to the preset formula, and complete the mixed packaging of two materials in one bag, ensuring accurate formula ratio for each package.
·The 320 VFFS machine automatically completes bag forming, synchronous material filling, airtight sealing, date coding and finished bag cutting in one continuous process for each package.
·The sealed finished packages are transported to the subsequent process through the finished product conveyor, realizing fully automated continuous production of the whole line.
Final Achievable Production Effects
·Industry-leading flexible production capacity: One set of equipment realizes 3 packaging modes with one-click free switching, replacing 2-3 independent production lines, reducing equipment investment cost by more than 60%, and saving workshop floor space by more than 50%.
·Ultra-high formula accuracy and weighing stability: Dual independent metering units for powder and granules, with weighing accuracy controlled within ±0.2% for powder and ±0.3% for granules, completely solving the problem of material layering and ratio deviation in the pre-mixing process, 100% ensuring the formula consistency of each package, fully complying with international food, feed and pharmaceutical industry formula standards, and eliminating product recall risks.
·Fully sealed dust-free and anti-breakage production: Full-process closed structure, with powder dust control rate up to 99.9%, completely solving workshop dust pollution, raw material waste and potential safety hazards; granule breakage rate ≤0.5%, perfectly maintaining the complete shape and premium quality of granule products.
·Fully automated unmanned production: Reducing manual labor demand by more than 90%, greatly cutting labor costs, avoiding human-induced cross-contamination, and increasing overall production efficiency by 3-4 times compared with semi-manual production, supporting 24/7 long-term continuous stable operation.
·Fast product and formula changeover: One-click switching of product formula, packaging specification and packaging mode, with debugging time controlled within 5 minutes, perfectly adapting to small-batch multi-SKU production demands, greatly reducing production downtime.
·Full international certification compliance: Full 304 stainless steel main structure, no sanitary dead corners, tool-free quick disassembly design, easy to clean and disinfect, fully meeting FDA, BRC, HACCP, GMP and other international mainstream food, pharmaceutical and feed industry safety certification requirements.
·Stable and durable operation with low maintenance cost: Anti-sticking, anti-blocking, anti-abrasion component design, adapting to various powder and granule materials, reducing equipment failure rate by more than 80%, greatly cutting unplanned downtime and later maintenance costs.
·Strong scalability and compatibility: Can be flexibly configured with auxiliary units such as online metal detector, check weigher, nitrogen flushing system, date printer and automatic boxing system according to your production needs, and seamlessly docked with your front-end production line and back-end logistics system.
Contact Us
Customized solutions are available for different production capacity demands, packaging specifications, material types and industry certification requirements. Contact our professional technical team now to get an exclusive quotation and customized turnkey solution for your multi-material packaging production.
