GEA process Engineering Inc takes on the filling challenge

The challenge:

• Pack multiple size packs
• Pack into multiple packaging formats
• Rapid change over between formats
• Pack multiple products
• CIP clean between products
• Pack at multiple rates
• Low head count for operators
• New plant which must work first product produced.

GEA process Engineering Inc with its GEA partner GEA Avapac, took an order for twin packing lines from one of the world's largest ingredient manufacturers to pack the products produced at their new ingredient facility in the USA. Along with the packing lines GEA process Engineering Inc also supplied an Evaporator, Filtermat™ dryer, CIP system and Liquid Processing system.

The client required that the products be packed in multi-wall Kraft bags with impervious liners, or cardboard cases with PE liners or fiber drums with PE liners. The products would have many different flow characteristics from sticky to free flowing crystalline powders. The products could be highly abrasive and possibly corrosive. These issues needed to be handled plus the added complexity of CIP cleaning the filling machines without disassembly between products to provide allergen free packing equipment.

Filling of fiber drums with PE liners

Filling of multi-wall Kraft bags

The packing of the products was a challenge and after evaluating other possible suppliers the client chose GEA process Engineering Inc and GEA Avapac to supply the required equipment, engineering and management resources to handle the project. They realized that this project needed the stainless steel fabricated, easy clean GEA Avapac designed equipment to handle the arduous cleaning regime that they were going to impose and that the multiple formats would require extensive engineering and project management to bring together two packing line which would start-up on time with the new process lines.

GEA Avapac supplied an IBF450 (In-line Bag filler size 450) and an IBF 600 fillers along with box and drum in-feed conveyors, automatic bag loaders, automatic bag sealers, and conveyors. GEA process Engineering Inc integrated into these units: in-feed transitions, box and drum liner heat sealers, and case closer/sealers. GEA process Engineering Inc managed the project from time of order through equipment supply and utilized the USA based installation crew and commissioning technicians.

The installation and commissioning while not with out the normal new site challenges was complete on time and met the requirements of a demanding client with the packing plant immediately able to produce product to the client's specifications. The equipment can be CIP hot rinsed, caustic and/or acid washed, with the system and dried within the GEA process Engineering Inc guaranteed time, providing a clean, allergen free packing plant for the next product.

The challenge was accepted and completed successfully. GEA Niro and GEA Avapac have produced a unique packaging plant which has opened up new opportunities for them in the demanding world of food ingredient production. This project opens markets in pharmaceutical carrier production, fine chemical production, and animal pharmaceutical production as well the many food ingredient production operations where allergen free is an essential requirement.

GEA Niro looks forward to the next challenge that industry places in their hands.