filling packaging automatic with Loose fill

The machine uses 3D laser scanners to detect the remaining volume of the incoming shipping boxes and fills them with the precise amount of cushioning material required to offer optimal protection during transport.

Basic model

• Machine frame in a steel structure system and welded construction
• Machine frame lined with sheet metal infills
• Machine is equipped with swing doors for cleaning and maintenance work
• The swing doors are lockable
• The filling station has a maintenance port which is secured by a safety switch and closed using roller shutters
• Pneumatically controlled stoppers for box separation upstream of the identification system and the filling system which are integrated into the machine
• 3D scanner for identifying boxes or shipping containers
• Pneumatic stoppers upstream of the filling station
• Height-adjustable base frame for the dosing and filling station
• Dosing and filling unit which can move in a longitudinal direction powered by a motor
• Dosing is carried out by means of a servo drive and height setting
• Pneumatic stopper for positioning the box under the filling unit in the conveying direction
• Centring unit for correctly positioning the box under the filling unit
• Vibration system for the uniform filling of boxes with packing chips
• Control cabinet with air conditioner integrated into the machine frame
• VIPA and AS-i-Bus or AS-i Master PLC controller by Bihl+Wiedemann
• 15-inch TFT touch panel monitor for machine operation, parameter adjustment and diagnostics
• Industrial PC for data processing
• Triple warning light
• Electrical components in accordance with supplier standards
• Electrical installation in accordance with protection class IP 54

The boxes are transported into the machine on a roller conveyor. The boxes are separated by means of pneumatically controlled stoppers and individually controlled roller conveyors.

After picking, the filling data for the boxes is sent to a ring buffer through the customer’s merchandise management system.

The barcode applied to the outside of the boxes is read by 2 barcode scanners installed opposite one another. The barcode is used to clearly identify the box and, in turn, correctly assign the volume data.

While the picked boxes are being fed into the machine, the volume data is sent to the dosing unit.

The required volume of packing chips is loaded into the filling chute and the dosing and filling unit moves into the filling position above the box to be filled.

The filling process is started as soon as the box is in this position. During filling, the box vibrates to ensure that the packing chips are distributed evenly into all free spaces.

Once the box has been filled at the dosing and filling station, the filled box is conveyed out of the machine. At the same time, the next box in the waiting position is released and fed into the machine. The box is pushed up against a pneumatically controlled stopper, centred laterally and held in position. As soon as the box is in position the filling cycle starts at the filling unit.

Boxes that are not filled correctly or cannot be clearly assigned are automatically discarded at the ejection station and conveyed out of the machine along a separate belt.