Dinnissen Process Technology specializes in Big Bag filling processes for companies such as Danone, Nestlé, Royal FrieslandCampina and PepsiCo. Among such companies in the food sector, there is an increasing demand for filling Big Bags hygienically and efficiently in cleanrooms in order to ensure the quality of the production process and extend product shelf life. These companies apply very strict standards when it comes to keeping cleanrooms clean, complying with strict hygienic conditions during the filling process, and preventing any contamination from entering via pallets. In response to this demand, Dinnissen has developed a very effective and extremely hygienic Big Bag filling concept.
Handling products via Big Bags quickly, flexibly and in line with specific client needs
The use of Big Bags has spread dramatically since they were first introduced, as they make it possible to package products in the food sector economically, hygienically and safely. Big Bags also offer many advantages in terms of logistics, as they can be easily cleaned, compactly stored and reused. Dinnissen Process Technology specializes in processes for emptying, filling, closing and handling Big Bags. To that end, Dinnissen supplies standard products as well as complete tailor-made solutions for packaging products quickly, hygienically, safely and efficiently in terms of logistics. Dinnissen provides solutions which can range from components of a larger process to complete projects in themselves - for one Big Bag per week or for 50 per hour. The range of solutions offered by Dinnissen enables clients to package and process extremely hazardous and hygienically sensitive products via Big Bags. The special expertise and experience acquired by Dinnissen in this sector have served as the basis for developing these solutions for filling big bags in cleanrooms in compliance with the strictest hygienic standards.
Attaching Big Bags hygienically and efficiently in pallet-free cleanrooms
The process for filling Big Bags in cleanrooms needs to be compatible with very strict standards of cleanliness. Accordingly, the Big Bag filling solution developed by Dinnissen ensures that contamination-prone pallets are kept out of the cleanroom. Throughout the entire filling process the Big Bags are suspended from a special guiding system, thereby ensuring minimal contact with possible contaminants. The fact that the Big Bags are suspended also makes it easier to clean the cleanroom quickly and effectively.
In the first step of the filling process, the Big Bag and its clean inner bag are attached to the filling head. Dinnissen also uses a decontamination module for this step, which safely removes contaminants and particles until the moment that the filling or emptying hose/pipe is connected. After that, the special inflatable seal tightly seals off the connecting hose and prevents any particles from escaping, thereby ensuring that the cleanroom remains clean and particle-free. The Big Bag is then subjected to vacuum and forced into shape using nitrogen. This creates a clean and oxygen-free (<1%) environment which extends the shelf life of food products. The fact that the Big Bag is shaped beforehand, when necessary via vibration, has the added advantage that every corner of the bag is optimally filled. The end result is an optimally shaped and safe result.
Options for safely and precisely filling Big Bags with preset quantities
Hygienic filling processes for Big Bags must be quick and accurate, and must prevent any particles from being spilled during or after the filling process. Dinnissen has developed special solutions for realizing this. For example, large quantities can be quickly added either from a weighing bunker or directly. The filling station can be fitted with an integrated (hi-capacity) screening system, metal detectors or samplers. For the product feeder system, Dinnissen uses various types of elements including valves, screws, belts, chains, vibrators, gates etc. Various weighing systems, overload sensors and level sensors are used to ensure reliable volume and weight measurements. For products which are difficult to compact, the use of a vacuum lance is an option, in which case a vacuum is used to remove air from the product. Dinnissen supplies the necessary technology and equipment for situations in which calibration is critical and assists with successful completion of the necessary procedures by working with legal calibration institutes all over the world. Big Bag stations with tracking and tracing systems, such as bar-code scanning, and automatic interfacing of the Big Bag station via Profibus or Ethernet are also some of the options offered. To prevent any product from escaping and contaminating the cleanroom, Dinnissen uses a specially designed filling head, a special valve for collecting material spillage after filling and very effective particle removal via suction. The option of pneumatically sealing off the filling hose before disconnecting it is also an effective method for preventing contamination of the high-care environment.
Airtight sealing and removal of Big Bags
The last step in hygienically filling Big Bags is the automatic airtight sealing of the inner bag, after which the Big Bag can be closed in any number of ways and fitted with a clean baseplate. Finally, the Big Bag is transported out of the cleanroom while suspended from a special guiding system. It leaves via a special quick-closing door equipped with a forced ventilation system. While the door is being opened and closed, a laminar air current of pre-filtered, conditioned air is blown through at a speed of 0.4-0.5 m/s.
In a medium or low-care environment, the Big Bag is placed on a pallet and integrated into the logistics process. For this part of the production process, Dinnissen offers systems that automatically supply Big Bags, pallets and packaging material via special dispensers, as well as solutions for transporting and stacking Big Bags in seagoing containers or trucks. The latter not only reduces labour costs but also ensures proper and stable loading.Efficient, user-friendly and high-quality operation
Efficient and user-friendly operation is critical for making production processes as cost-effective as possible, so Dinnissen also took ergonomics into account when designing its Big Bag filling stations. For example: operating controls and elements are situated at the same level and hooks, pivoting filling heads and twister heads are all easily accessible. In addition, solutions are available for the automatic coding and sampling of Big Bags for tracking and tracing, metal detection and integration of monitoring screens. Of course, our Big Bag systems comply with all the ATEX, HACCP and GMP guidelines. Dinnissen also incorporates many of the features found in the Big Bag systems to the design of octabins, drums and containers.
Dinnissen Process Technology offers you a unique mix of expertise plus contracting and manufacturing facilities: from a stand-alone machine to a complete turnkey system, from pre-engineering to project management, and from design to assembly to start-up. Our one-stop shopping concept enables us to operate independently of third-party suppliers. Our extensive international network ensures that we can deliver anywhere in the world.