rotary packers
DESCRIPTION
Packing machines that rotate and packTRANSCRIPT
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rotary packersGE PLUS III
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Example of Ventomatic packing plant • 14 spout rotary packer GEV PLUS III• automatic bag applicator INFILROT • automatic palletiser POLIMAT C50
Output rate:5000 bags/hour (25 kg bags)
The latest and most successful step in the continuous path of innovation
is represented by the new GE PLUS III rotary packer generation
that distinguishes itself in the market for the very compact and modular
design with very high flexibility and expandability thanks to the modular
integration between mechanical parts and electronic control.
Ventomatic was the first manufacturer to develop a
microprocessor-based controller for filling and weighing
units on packers and the first to introduce the electronic
rotary packer in an industry that up until than had
only known packers with mechanical weighing system.
Ventomatic Head Quarter
GIROMAT GE PLUS III
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Rotary mechanical packer GM 10 (10 filling units)
The GE rotary packer familyVentomatic is located nearby the historical town of
Bergamo (North-East of Milan, Italy), where are
concentrated all of its activities, from R&D to production
and assembly.Here our company started the production
of packing equipment in 1957. Since the Ventomatic
has been recognised for its innovative design and
for the originality of the solutions it has proposed to
the industry.
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Rotary electronic packer GEV 16 PLUS III (16 filling units)
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GE PLUS III - Configuration
Ventomatic rotary packers GE Plus III are specially designed and
developed for handling many types of building materials, with a
wide range of configurations such as:
• Vertical or horizontal shaft impeller depending on the particle
size distribution of the product
• Various impeller designs
• Bag clamping device for glued and stitched bags and suitable for
various bag construction material
• Quick discharge system
• Bag sealing system on board (knurling technology)
Ventomatic supply and control complete packing lines including:• Cement feeding such as bucket elevator, vibrating screen and vane feeder;
• Filled bag transport system comprising bag cleaning, electronic check weigher, bag trap, belt conveyor, curves, bag diverters;
• Bag loading comprising manual truck loader, automatic truck loaders and palletisers;
• Dust recovery system comprising screw conveyors, bag filters, hoppers;
GE PLUS III - Main features
Example of Ventomatic complete installation
Rotary packer GEV 14 PLUS III (14 filling units)
Magic boxInfrared data transmission device
for connecting the bag filling units
(mounted on the rotating part)
with the operator panel and the
control system;
Ventodigit IIIMulti-microprocessors electronic
weighing unit designed for bag
filling application. OIML and PTB
certified;
Bag supportsaddleAvailable for wide-range
of bag types and sizes
and for manual or
automatic levelling (two
or multi-positions);ImpellerVertical or horizontal shaft
impeller configuration for
optimal filling according
to the par ticle size
distribution of the product
being packed;
Filling unitImpeller, fluidisation system,
guillotine valve, nozzle and
supporting frame, all designed for
high weight accuracy, high output
and low dust emission;
EncoderFor tracking the angular position
of each bag filling unit and to
control the bag filling cycle;
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The encoder tracking system significantly simplifies
the packer and offers shorter and easier erection and
tuning and eliminates sources of possible malfunctioning.
The positions for each of the filling operations is quickly
and accurately set on the operator panel, eliminating the
need to physically position externally mounted mechanical
devices on the packer. Specific sequences of the filling
cycle (and their positions) can be set in relation to type
of product, empty bag size, etc.
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GEV PLUS III - Vertical shaft impeller
PROCESS: Ventomatic introduced a new philosophy in packing technology with the vertical shaft impeller. The product feed flow
is in the same direction as the impeller shaft, and due to the blade design, the internal turbulence is minimised and the product
is completely centrifuged. The result is an optimal deaeration of the product itself and a minimum kinetic energy dispersion
means high filling performance.
Optical connection MAGIC BOX
Legend0) Control Status (ALARM)
1) Bag application
2) Tare
3) Not filled bag
removing position
4) Bag Evacuation
5) Saddle Return
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2
3
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GE PLUS III - Encoder
The sequence of the bag filling operations is defined by the peripheral
location of the bag on the packer during the filling cycle: empty bag
application location, tare location, bag disharge location, etc. During
the rotation and according to its location, the filling unit receives
the relevant commands.These points, on bag location, are normally
determinated by a complicated system of microswitches, solenoid
valves, pneumatic cylinders etc., all mounted on the external
perimeter of the packer.
Ventomatic packers, however, fulfil the same operations with an
encoder mounted on the top of the rotating shaft of the packer. It
continuously tracks the angular position of the packer and, via a field-
bus connection, the information is sent to the filling units that react
accordingly.
Optimised blade design for
cement centr ifugation and
deareation;
Self- lubricating sealing system
for reducing wear and dust
leakages;
Static micro switch for
detecting of bag presence;
Slimmer and more rigid
weighing frame;
Pneumatically actuated
bag discharge group;
Optimised fluidisation
system;
Bag support saddle levelling
system available in:
1) manual
2) two positions (pneumatic)
3) multi-positions (motorised)
The performance of the vertical
shaft impeller is optimal with cement
and similar products compared to
the more traditional horizontal shaft
solution, which is hawever still
available for special applications;
Bigger inlet section compared
to the traditional configuration;
Slide valve for material
flow controlling;
Motor directly coupled with
impeller shaft. Absence of
pulleys and belts, eliminates
entirely the wearing and
potential breakages of these
components;
Due to the efficiency of the
bag filling process a minimum
of power 3KW motor is
required;
Simplified supporting frame
facili-tates the operator access
and the maintenance;
Encoder
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Example of GE PLUS III4-spouts packer (supplied with the tank of 8
spout rotary packer) which can be expanded
with up to four additional filling units without
modifying main pneumatic, electric plants
and control system.
Standard capacity table
50 kg
40 kg
35 kg
25 kg
50 kg
40 kg
35 kg
25 kg
8
12
50 kg
40 kg
35 kg
25 kg
50 kg
40 kg
35 kg
25 kg
9
14
50 kg
40 kg
35 kg
25 kg
50 kg
40 kg
35 kg
25 kg
10
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This configuration implies a different product flow compared
to the vertical shaft impeller previously explained and is
more adequate for handling special products.
50 kg
40 kg
35 kg
25 kg
50 kg
40 kg
35 kg
25 kg
50 kg
40 kg
35 kg
25 kg
2400
2560
2640
2880
3600
3840
3960
4320
2700
2880
2970
3240
4200
4480
4620
5040
3000
3200
3300
3600
4800
5120
5280
5760
900
960
990
1080
1200
1280
1320
1440
1800
1920
1980
2160
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GEO PLUS III - Horizontal shaft impeller
PROCESS: The filling device configuration with a horizontal shaft impeller represents the traditional solution for packing powder
products. It is a still valid solution for special types of cement and products with a particle size distribution up to 2 mm. Special
execution is available for particle size up to 5 mm with special lined impeller and guillotine.
GE PLUS III - Modularity and flexibility
A Ventomatic packer is composed of a number of pre-assembled modules, which are prepared and tested before delivering.
These modules are quickly and easily mounted on the central tank of the packer during the erection.The numbered pneumatic
connector plugs and electric rapid connectors avoid the possibility of erection mistakes.
If required and in order to minimise the initial investment, it is possible to put the packer in service with a reduced number of
bag fitting units. In case of future growth in production demand, additional filling units can be easily added on.
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Simplified supporting frame
facilitates the operator access
and the maintenance;
Pneumatically actuated
bag discharge group;
Optimised fluidisation
system;
Slimmer and more
rigid weighing frame;
Static micro switch
for detection of bag
presence;
5 KW Motor coupled
with pulleys and belts
to the impeller shaft;
Bag support saddle
levelling system available in:
1) manual
2) two positions (pneumatic)
3) multi-positions (motorised)
Guillotine group: slide valve
and pinch valve are both
available for controlling the
material flow;
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Weighing functions:Automatic taring
Zero setting
Coarse and fine flow
Filling parameters self adjusting
Filling time control
Dynamic filling cycle optimisation
Set-point correction feed back from the check weigher
(in option)
Packing functions:Check correct empty bag application check
Bag breakage detection
Filling unit aeration (start/stop)
Automatic bag support saddle levelling system
Rapid product emptying control
Continuous bag discharge adjustment according to
rotation speed, bag sizes and product conditions
ApplicationThe new electronic unit is used on all Ventomatic weighing
applications: rotary packers; in-line packers; air- packers;
big-bag machines; belt check weigher, etc
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The supervision and reportingsystem Ventolink III (optional)collects and presents productiondata from packers and beltweighers in tables and in graphicform.
Check weigherThe belt weigher Ventocheck IIIcan also be connected to thesame network exchanging datawith the other systems such aspacker,operator panel,Ventolink III.
Operator panel
HW platformThe completely redesigned HW platform
includes the following main new features:
• Powerful microprocessor permits
high-speed response and very accurate
control of the dynamic weighing process
• Separate weighing module, mounted on a
slot of the main board, equipped
with sigma-delta technology A/D converter
with a double post digital filter action
• Possibility of installing optional modules,
i.e. analog I/O, additional digital I/O,etc for
covering special applications
High performance industrial bus
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GEO PLUS III - VENTODIGIT EWU
Ventomatic has been a pioneer in manufacturing electronic packers since 1980, and with our Ventodigit III, Ventomatic has
achieved the objective of introducing a new all-in-one electronic unit.
The new weighing unit is based on the vast experience gained from our packer installations worldwide. Every filling spout is
controlled by the new electronic weighing unit VENTODIGIT III (EWU/010).
dimensions
display
load cell
keyboard
memory
digital I/O
analog I/0
interface
height 243 mm, length 128 mm, width 80 mm
graphic LCD, 128x64, LED backlight
6000 div.
IP65 touch-pad with LED
32 (expandable)
16+16 24v optoisolated (expandable)
1+1 10mV/20mA (expandable)
Full CANBUS, RS232/422/485
GE PLUS III - Network
All filling units on the rotary packer are connected to a data network CANBUS. Through a the unique Ventomatic Magic Box
device, all the weighing units are also connected to the absolute encoder for tracking their angular position and to the operator
panel. The operator panel, and the remote control system Ventolink III, receive in real time the complete status of each bag
filling unit and also its weighing performance. Furthermore, all filling units can be completely programmed from the operator
panel.
The MAGIC BOX device consists of infra-red optical communication system specially
developed for high speed data communication in heavy industrial environments.
It is 100% dust proof and not sensitive to any kind of vibrations or EMC noise.
Furthermore, there is no mechanical wear.
A real-time monitor and basic production
statistic page of the Ventocheck III is always
available on the operator panel display.
Operator panel
Ventocheck III completes the packing process and improves
the overall control by providing the following main functions:
• Sorting of broken bags, underweight and overweight bags
• Providing overall production data
• Monitoring each bag single filling unit performance on the
packer
• Adjusting automatically the set- point of each filling unit
on the packer (correction “spout-by-spout”)
See “Important Note” below
• Disabling automatically a filling unit in case of malfunction
or mechanical problems
IMPORTANT NOTE:The packer GE-PLUS III is able to achieve the target weight
performance without necessarly using the feedback from
the belt weigher.
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GEO PLUS III - VENTOCHECK FEEDBACK
The belt weigher Ventocheck III can be directly connected, without using external master or other additional device, to the packer
operator panel and then to all the filling units on board.
GE PLUS III - OPERATOR PANEL
The achievement of greater flexibility and higher level of
automation requires an operator panel quite different to
the conventional pushbutton desk. The HMI (Human
Machine Interface) presents is an IP65 industrial graphic
terminal designed for industrial use and dusty environments
which thanks to a dynamic mimic of the packing line,
provides a clear and detailed overview and monitoring
of all the main equipment.
All the main operations such as start/stop of the line, change of product and bag size, emptying and cleaning of the
line, are completely automatic and programmable.
The overall feeding and packing process is monitored
with the possibility to adjust/optimise the performance
through specific pages of the HMI (protected by different
password levels) such as adjusting timers, variables and
abilitations of the PLC program.
Furthermore, all alarms and warnings are recorded,
facilitating troubleshooting and supporting preventive
maintenance planning.
Bagtrap
Bagdischarge
Bagcleaning
Belt weigher
Ventocheck
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The system is composed of three main parts:
• Supervision line module
• Shift setting module
• Statistical and reporting module
SUPERVISORY MODULE:The basic configuration of this module provides a real-time monitor of the status of the packer and the belt weigher including
actual production recipes, current bag weights, alarms and warning signal tracking and recording. Furthermore, the “recipes
management function” allows the remote setting and tuning of all the working parameters of the packer and the belt weigher.
In case other Ventomatic equipment
is installed (such as automatic empty
bag feeder, bag applicators, automatic
truck loaders, palletisers, it is also
possible to add an expansion module
for their monitoring.
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“Production Statistics” menu for queries
about hourly summary tables relevant
to the last year of production data
The production data recorded in the data
base contains all the information about
packing line number, time, dates, number
of the filling units, shift number, etc., in
response to all most the relevant queries
from the production department.
The status and the performance of the packer and the belt weigher can be summarized with tables or with graphics.
Ventolink III - Statistical and supervisory system
VENTOLINK IIIVentolink III is a new supervisory and data acquisition system for Ventomatic plants, able to collect and elaborate production
data from several different packing lines. Based on Windows, all stored data are exportable to Access or Excel or other formats
according to ODBC standard. It can manage data from rotary packers and from Ventocheck weighers;
Ventolink III - Statistical module
“Monthly Production” menu for queries
about monthly summary tables, relevant
to the last few years
"Bags Details" menu for detailed
queries about each bag produced
during the last few days.The system
can visualize packer data, Ventocheck
data or “cross data” (packer data and
Ventocheck data in the same table)
Ventolink III can collect data from several packing lines
Ventomatic S.p.Avia G. Marconi, 2024030 Valbrembo (Bergamo) Italy
+39 035 468 311+39 035 460 838
www.ventomatic.it
tel.
fax
PACKING SYSTEMS
Empty bag de-palletizer
Bag applicators
Rotary packers
Inline packers
Air packers
Bag treating units
DISPATCHING SYSTEMS
Automatic loading
Manual loading
Palletizers
OTHER EQUIPMENT
Mobile units
Big bag
Bag sealing