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Successful development of new dosing system to speed up filling processes.

The project was supported by the German Central Innovation Program (ZIM) for promoting research and development for small and medium-sized enterprises. Thanks to the findings, Teepack has managed to increase the performance of its vertical, form, fill and seal machine Zenobia. The machine is available in all African countries from PMD Packaging Systems .

For more than 60 years our name has stood for quality and for making good things even better, says Dr Ing. Stefan Lambertz, one of the project managers and a member of Teepacks executive board. Our cooperation with TUD was based on this philosophy too. Together, we were able to increase the production speed of the Zenobia even further. In the long run, this is a real benefit for our customers.

Alongside Lambertz, graduate engineer Thorsten Lehmann from Teepack, Prof. Dr Ing. Jens-Peter Majschak, Johann Holzweiig and Matthias Frank were involved in the project. It was managed by TUD s Institute for Processing Machines and Mobile Working Machinery.

New dosing system, faster flow

With the aim to increase the flow velocity of loose products like rice, peas, linseeds, couscous and coffee beans, the team designed a highly dynamic cup dosing system and modified the downstream filling line.

The team intensely studied the flow behaviour of rice, along with the products relevant motion directions. Their findings were that when a telescoping filling hopper is used as opposed to the conventional height-adjustable version bridging and subsequent blocking of the hopper can be avoided.

This adjustment in the hopper area also noticeably reduces product inclusions in the area of the cross seam. The specification of a 100 to 110 milliseconds sealing range per kilogram of rice was also met by the team. They also optimised the cup fillers motion profiles and fully sealed the production area. The adjustments led to a significant decrease in dust and loss of product in the filling process.

Some of these findings have already been implemented by one of our customers. We will now implement them as a standard for new machines, says Lambertz. Existing machines can easily be upgraded accordingly.

The project serves as a perfect example that simulation-supported development and optimisation carries a lot of potential, particularly in medium-sized businesses for construction of packaging machines, adds Majschak. Some skills and tools are incredibly difficult to establish in-house. Granting companies access to them via research funding is an excellent way to secure the leadership position of the German packaging machine industry in the world market.

In cooperation with Dresden University of Technology (TUD), the packaging specialist Teepack developed a highly dynamic cup dosing system over the past three years. The innovative solution dramatically increases the filling speed of products like rice, couscous, linseeds or coffee beans.

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Publication:South African Food Review
Date:May 27, 2016
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