National Bulk Equipment, Inc.


Bulk Bag Fillers

Bulk Bag Fillers: In-Use Advantages

View NBE Bulk Bag Fillers in Action
Bulk Bag Filler System Video
Bulk Bag Filler System Video
Bulk Bag Filler System Video
Bulk Bag Filler System Video
Bulk Bag Filler System Video
Bulk Bag Filler System Specifications

View NBE Sanitary Bulk Bag Filler in Action
Sanitary Bulk Bag Filler System Video
FDA, 3-A, USDA Compliant

Bulk bag fillers are also commonly known as big bag filling stations, bulk bag loaders, and big bag fillers. NBE offers dry bulk material processing operations a bulk bag filler product line designed to fully integrate with upstream and downstream material processing systems. NBE big bag fillers can fill up to 20 bulk bags per hour, using only one operator. Automatic and dust-free bag filling, weighing, and densification further combine to increase line throughput and reduce process costs. Constructed of heavy gauge carbon steel or type 304 stainless, the components and framework of every NBE big bag filling station are built for trouble-free operation; even in rugged bulk bag filling process conditions and where demanding material handling requirements exist.

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Bulk Bag Fillers: Features & Integration Guide

Bulk Bag Filler Support Frameworks:
All NBE bulk bag filler frames are constructed to withstand the harshest of processing and packaging plant environments and demanding duty cycles, including those requiring FDA, 3-A, USDA or international regulatory compliance. NBE cantilevered bulk bag filling stations enable bulk material processing operations to run production at designed speeds without concern for constant material waste, re-work, and excess labor costs common with under-performing big bag filling systems. NBE bulk bag filler systems provide a 4,500 lb. hang weight capacity, and an 18,000 lb. deck capacity.

> Cantilevered Bulk Bag Support Framework
cantileveredframework

Cantilevered Bulk Bag Support Framework

Provides unobstructed access from three sides of the filler for attaching and detaching bags. Cantilevered frames are generally used in medium to high capacity bag per hour filling capacities due to the ease of integrating indexing and accumulating roller conveyors. Additionally, cantilevered filling system can be automated to a degree that the only operator intervention required is to hang and spout empty bulk bags.

Bulk Bag Support Framework
cantileveredframework
> Powered Cantilevered Mast Height Adjustment
mastheightadjustment

Powered Cantilevered Mast Height Adjustment

Cantilevered models come standard with a hydraulic system to quickly raise and lower the cantilevered mast. This feature provides flexibility to accommodate a range of bag sizes, provide ergonomic access for varying operator heights, as well as help square up filled bags. The increased operating speed and power of the hydraulic system versus traditional ball screws greatly increases the bag-per-hour capacity of the fill station while allowing the fill head frame to safely hang a 4000 lb. load when required.

Height Adjustment Controls:
A linear transducer provides infinite adjustability for the cantilevered mast within the 36" range of travel. Height setpoints are easily entered into the HMI eliminating the need to manually adjust position switches on the machine.

Mast Height Adjustment
mastheightadjustment
> Four-post Bulk Bag Support Framework
fourpostframework

Four-post Bulk Bag Support Framework

An economical base frame from which many available options can be added to improve filling speed, accuracy, and bag stability. The main framework features 32" of manual height adjustment in 4" increments to allow proper positioning for various sized bulk bags 4-post frames are generally used for low-to-medium bag per-hour filling capacities.

Four-post Bulk Bag Support Framework
fourpostframework
> Fill Head Only (for customer-supplied filling equipment)
fillheadonly

Fill Head Only (for customer-supplied filling equipment)

Unsupported fill head frames are used to mount the fill head assembly directly from existing equipment. These are generally used for low-to-medium bag per-hour filling capacities.

Fill Head Only
fillheadonly
> Sanitary/Hygienic Construction
sanitaryhygienic

Sanitary/Hygienic Construction

This sanitary bulk bag filler is specifically designed for hygienic processing and packaging applications where compliance with FDA, USDA, 3-A, BISSC, or international standards is required. This NBE sanitary bulk bag filler can comply with process protocols where 3-A Accepted Practices or other cGMPs are necessary. The NBE sanitary bulk bag filler design includes CIP features, such as: 304-2b construction, continuous-weld seams ground to a No. 4 finish, and tool-less, quick-clean component designs to simplify sanitizing and inspection.

Fill Head Only
sanitaryhygienic

Bulk Bag Filler Loop Hangers:
Safe, secure, and designed for minimum operator interaction, NBE bulk bag filler loop hangers eliminate bag slip during the bulk bag filling sequence and speed bulk bag changeout cycles.  Automatic hook release releases bulk bag loop when fill cycle completes. Traversing rear hooks automatically place rear hooks at the front of the bag filler to safely hang and spout the bulk bag.

> Automatic Bulk Bag Loop Hangers
automaticloophangers

Automatic Bulk Bag Loop Hangers

Pneumatic-actuated bag hooks allow automatic hook release upon completion of the filling cycle eliminating the need for the operator to manually detach bags.

Automatic Bulk Bag Loop Hangers
automaticloophangers
> Manual Bulk Bag Loop Hangers
manualloophangers

Manual Bulk Bag Loop Hangers

Manually adjustable front and rear bulk bag support hooks are spring-loaded to ensure bag loops are securely held during operation. Unique to the NBE patent-pending hook design is the improved operator safety that results from the spring-loaded safety clasp tightening as weight is applied. This design eliminates the potential for the bag loops to inadvertently slip out of the hook during the filling sequence. The bulk bag support hook position is adjustable to accommodate various size bags.

The NBE exclusive radial hook design securely hangs bags of various sizes and weights up to 4000 lbs.

Automatic Bulk Bag Loop Hangers
manualloophangers
> Traversing Rear Bulk Bag Loop Hangers
traversingloophangers

Traversing Rear Bulk Bag Loop Hangers

Pneumatic-actuated, linear bearing-guided rear bag hooks automatically position the rear bag hooks at the front of the filler allowing an operator to hang and spout an empty bag without the need to lean into or walk around the machine.

Traversing Rear Bulk Bag Loop Hangers
traversingloophangers

Bulk Bag Filler Base Styles:
NBE big bag filling station base designs ensure safe, efficient bulk bag filling regardless of bag style, material characteristics, or fill rate. The NBE platform-top bag filler base keeps bulk bags stable during fill cycles, and also supports slipsheets or pallets. NBE big bag fill stations can integrate roller conveyors for automated applications where bulk bag indexing and accumulation is required. Vibratory densification systems can be included with the platform or conveyor base design.

> Platform Top: Bulk Bag Filler Base Style
platformtopbbf

Platform Top: Bulk Bag Filler Base Style

The fill station base typically consists of a platform top or roller conveyor, depending on the application requirements. Densification options are available for integration to either base style.

Provides a stable flat surface for the bag, slip sheet, or pallet to sit on during the filling sequence.

Traversing Rear Bulk Bag Loop Hangers
platformtopbbf
> Roller Conveyor Top: Bulk Bag Filler Base Style
rollerconveyorbasestyle

Roller Conveyor Top: Bulk Bag Filler Base Style

The fill station base typically consists of a platform top or roller conveyor, depending on the application requirements. Densification options are available for integration to either base style.

Allows the indexing of bulk bags into, and out of, the fill station. Can be automated for more efficient filling cycles.

Roller Conveyor Top Bulk Bag Filler Base Style
rollerconveyorbasestyle
> Densification Table: Bulk Bag Filler Base Style
densificationtablebasestyle

Densification Table: Bulk Bag Filler Base Style

A base-mounted adjustable vibratory densification system is designed to settle the product in the bag during the filling cycle to produce a more dense and square package. The high-amplitude, medium-frequency vibration is isolated from the main framework by airbags during operation.

Densification Table Bulk Bag Filler Base Style
densificationtablebasestyle

NTEP-certified Bulk Bag Filler Bag Weigh Systems:
NBE big bag filling stations enable integrated scale systems in one of three bulk bag weighing options. Base-weigh scales mount load cells to the lower framework; bulk bags are completely supported and weighed during the final bulk bag fill stage. Hang-weigh scales mount load cells to the bulk bag loader fill head mast using an integrated weigh bridge. The bulk bag hangs centered and stable while begin weighed. Pre-weigh systems position a weigh hopper directly above the bag filler; weigh hoppers are re-charged while a new bulk bag is spouted.

> Base-Weigh Bag Weighing System
basebagweigh

NTEP-certified Base-Weigh Bag Weighing System

A range of completely integrated scale systems are available in hang-weigh, base-weigh, or pre-weigh configurations. Most designs incorporate adjustable load cell mounts that can be easily trimmed for the best overall scale performance. Additionally, the load cells are mounted in a manner that does not weigh the entire machine. This results in increased scale accuracy as the load cells transmit weight gain information to the digital scale controller mounted to the main control enclosure.

Base-Weigh:
The load cells are mounted to the lower framework, and are isolated to lengthen load cell life. The bag is completely supported by the weigh deck during the final filling phase. This design also provides the flexibility to accurately fill drums and other rigid containers with the fill station.

Base Weigh Bag Weighing System
basebagweigh
> Hang-Weigh Bag Weighing System
hangweighsystem

NTEP-certified Hang-Weigh Bag Weighing System

A range of completely integrated scale systems are available in hang-weigh, base-weigh, or pre-weigh configurations. Most designs incorporate adjustable load cell mounts that can be easily trimmed for the best overall scale performance. Additionally, the load cells are mounted in a manner that does not weigh the entire machine. This results in increased scale accuracy as the load cells transmit weight gain information to the digital scale controller mounted to the main control enclosure.

Hang-Weigh:
The load cells are mounted to the fill head mast and integrated with a weigh-bridge assembly. The bag hangs from the weigh-bridge bag hangers by taut straps and remains on center during the filing process. This design is the perfect solution for filling potentially unstable, tall bags.

Hang-Weigh Bag Weighing System
hangweighsystem
> Pre-Weigh Bag Weighing System
preweighsystem

Pre-weigh Bag Weighing System

A range of completely integrated scale systems are available in hang-weigh, base-weigh, or pre-weigh configurations. Most designs incorporate adjustable load cell mounts that can be easily trimmed for the best overall scale performance. Additionally, the load cells are mounted in a manner that does not weigh the entire machine. This results in increased scale accuracy as the load cells transmit weight gain information to the digital scale controller mounted to the main control enclosure.

Pre-Weigh:
Weigh hoppers can be positioned directly above the bag filler which provides the ability to achieve high filling rates by simultaneously recharging the hopper while the operator spouts a new bulk bag.

Pre-weigh Bag Weighing System
preweighsystem

Bulk Bag Filler Fill Head Details & Options:
NBE bulk bag filling stations can be configured with custom fill head designs to ensure seamless integration to any dry bulk material processing operation. Even standard NBE big bag fill head designs deliver in-use advantages. A concentric tube fill head design has an 8 inch diameter feed tube, centered within a 12 inch diameter outer fill spout. This standard bulk bag loader spout design includes an inflatable bladder seal, a 3 inch inlet for a bag inflation device, and a separate, 3 inch exhaust vent port.

> Bag Inflation Blower
baginflationblower

Bag Inflation Blower

Provides bag inflation prior to filling material in order to properly shape the bag for maximum stability.

Blower:
A 1 HP electric blower package provides rapid bag inflation prior to material introduction in order to properly shape the bag for maximum stability and filling capacity.

Fill Head Details:
The fill head assembly system includes a concentric tube design that has an 8" diameter product feed tube located within a 12" diameter outer fill spout. The feed tube is connected to the outer tube with quick release knobs for easy cleaning between batches. The standard fill head also comes complete with an inflatable bladder seal, 3" inlet for optional bag inflation devices, and a 3" exhaust vent port.

Bag Inflation Blower
baginflationblower
> Dust Collection
dustcollection

Dust Collection

An air displacement outlet allows for connection to an integrated dust collector system, vent sock, or filter cartridge.

Fill Head Details:
The fill head assembly system includes a concentric tube design that has an 8" diameter product feed tube located within a 12" diameter outer fill spout. The feed tube is connected to the outer tube with quick release knobs for easy cleaning between batches. The standard fill head also comes complete with an inflatable bladder seal, 3" inlet for optional bag inflation devices, and a 3" exhaust vent port.

Dust Collector
dustcollection
> Traversing Fill Head
traversingfillhead

Traversing Fill Head

The fill spout traverses forward from the machine center toward the operator. This brings all bag and operator interface points well within arms length for ease of spouting the bag inlet.

Hanging and spouting the bag with the fill head mast in a horizontal orientation, as opposed to vertically, provides the quickest and easiest method for spouting new bags. New bags are stiff and typically folded length-wise which makes them difficult to handle in a vertical spouting orientation.

Once the bag is attached to the cantilevered mast the operator presses the start-fill button to automatically position the bag in the ideal bag-fill location while inflating it to remove any creases. The end result is the most ergonomic, efficient, and accurate bag fill station.

Fill Head Details:
The fill head assembly system includes a concentric tube design that has an 8" diameter product feed tube located within a 12" diameter outer fill spout. The feed tube is connected to the outer tube with quick release knobs for easy cleaning between batches. The standard fill head also comes complete with an inflatable bladder seal, 3" inlet for optional bag inflation devices, and a 3" exhaust vent port.

Traversing Fill Head
traversingfillhead
> Concentric Fill-and-Exhaust Tubes
concentrictubes

Concentric Fill-and-Exhaust Tubes

An annular gap between the concentric tubes on the fill head allows air from the blower to enter during bag inflation and displaced air and dust to exit during bag filling.

Fill Head Details:
The fill head assembly system includes a concentric tube design that has an 8" diameter product feed tube located within a 12" diameter outer fill spout. The feed tube is connected to the outer tube with quick release knobs for easy cleaning between batches. The standard fill head also comes complete with an inflatable bladder seal, 3" inlet for optional bag inflation devices, and a 3" exhaust vent port.

Concentric Fill-and-Exhaust Tubes
concentrictubes
> Drum & Box Fill Adapters
drumboxfilladapters

Drum & Box Fill Adapters

These adapters allow the conversion from filling bags to filling drums and other rigid containers. Adapters easily mount to the existing fill head for accurate and dust-free filling.

Fill Head Details:
The fill head assembly system includes a concentric tube design that has an 8" diameter product feed tube located within a 12" diameter outer fill spout. The feed tube is connected to the outer tube with quick release knobs for easy cleaning between batches. The standard fill head also comes complete with an inflatable bladder seal, 3" inlet for optional bag inflation devices, and a 3" exhaust vent port.

Fill Adapters
drumboxfilladapters
> Inflatable Bladder
inflatablebladder

Inflatable Bladder

An inflatable bladder holds and seals the bag spout ensuring dust-free operation. A manual Inflate/Deflate selector switch is located on the upper carriage for ease of spouting the bulk bag to the fill head.

Fill Head Details:
The fill head assembly system includes a concentric tube design that has an 8" diameter product feed tube located within a 12" diameter outer fill spout. The feed tube is connected to the outer tube with quick release knobs for easy cleaning between batches. The standard fill head also comes complete with an inflatable bladder seal, 3" inlet for optional bag inflation devices, and a 3" exhaust vent port.

Inflatable Bladder
inflatablebladder
> Spout Control Valve
spoutcontrolvalve

Spout Control Valve

Bulk- and dribble-feed rates can be achieved by utilizing pneumatic-actuated slide gates or other types of valves based on material flow characteristics and application requirements.

Fill Head Details:
The fill head assembly system includes a concentric tube design that has an 8" diameter product feed tube located within a 12" diameter outer fill spout. The feed tube is connected to the outer tube with quick release knobs for easy cleaning between batches. The standard fill head also comes complete with an inflatable bladder seal, 3" inlet for optional bag inflation devices, and a 3" exhaust vent port.

Spout Control Valve
spoutcontrolvalve

Bulk Bag Filler Automation Control Systems:
NBE bulk bag filling stations are engineered and constructed to provide highly accurate and repeatable big bag filling operation. Control systems can be designed to provide manual or fully-automatic functionality. NBE bulk bag filling station applications engineers assess upstream and downstream line influences then design control systems to monitor process activities and requirements and implement operations to minimize operator interaction, optimize process rates, and reduce material waste. Controls can be frame-, or remote-mounted; and can be designed to any NEMA enclosure standard.

> Manual-Automatic Combination Controls
combocontrols

Manual-Automatic Combination Controls

Control Systems:
An assortment of control options, ranging from manual to fully automatic, are available to integrate with any of the selected weighing options, filling system features, and upstream equipment. The controls can be mounted to the filler frame or any remote location. Control systems can be designed using NEMA 12, 4, 4x, 7, 9 and purged enclosures.

Manual and Automatic Systems:
Utilize a combination of manual switches and digital scale controller I/O to complete the bag-fill sequence of operations. All operator settings and controls, including the scale settings, can be accomplished through the HMI.

Manual-Automatic Combination Controls
combocontrols
> Fully-Automatic Controls
fullyautomaticcontrols

Fully-Automatic Controls

Control Systems:
An assortment of control options, ranging from manual to fully automatic, are available to integrate with any of the selected weighing options, filling system features, and upstream equipment. The controls can be mounted to the filler frame or any remote location. Control systems can be designed using NEMA 12, 4, 4x, 7, 9 and purged enclosures.

Automatic Systems:
Utilize a programmable PLC and panelview HMI to automate the filler sequence of operations. Tasks that are typically automated include moving the traversing fill head and hooks forward and back, raising and lowering bag, inflating bag, filling bag, densifying bag, releasing hooks, closing slide gate, starting and stopping upstream conveyors, deflating seal and indexing the filled bag out of the fill station.

Fully-Automatic Controls
fullyautomaticcontrols