Packing facilities in the cement, building materials, food and chemical industries have benefited from Haver & Boecker’s Quat²Ro technology for more than two decades. First introduced in 2005, Quat²Ro machines use Form-Fill-Seal (FFS) technology and offer significant advantages in product protection, cleanliness and energy consumption with up to 50% less per bag compared to traditional systems.
Equipped with Quat²Ro technology, the Roto-Packer RS is the industry’s first and only rotary packing machine to offer a fully enclosed FFS packing process, resulting in minimized product loss, increased weight accuracy, optimized transport and a highly palletizable final product.
“We knew some industries — cement, building materials and pigment packing plants especially — needed a new packing option to keep their product safe and uncontaminated throughout the shipping and storage process. The development of Quat²Ro technology didn’t just give packing operations a highly efficient machine, it also increased the protection of their product once packing is completed. FFS bags help ensure our customers’ product is protected and uncontaminated throughout the packing and shipping process,” said Mark Wehling, head of sales group minerals at Haver & Boecker. “We’re excited to introduce the Roto-Packer RST featuring Quat²Ro technology in light of the 20th anniversary of this advanced product.”
Many operations ship their products worldwide or go through lengthy logistics processes leading to the risk of product spills or contamination due to improperly sealed bags. The Roto-Packer® RS solves these challenges by cutting and welding each bag shut, which results in a fully sealed, weatherproof bag. This process reduces film consumption, further minimizing material use, and leads to the ability to ship bags further and store them longer while minimizing product loss and maximizing profits and customer satisfaction.
The fully enclosed, compact Roto-Packer RS rotary packing machine produces between 400 to 1,200 bags per hour (7-20 bags per minute) with up to 10 filling spouts. The compact footprint allows for easier positioning of the machine and less wasted space on the packing line. The enclosed housing of the packing machine maintains cleanliness during the filling process in powder-packing applications. For ease of interior cleaning, the cabin features large openings and doors. Easier accessibility simplifies maintenance and reduces wear, resulting in increased weight accuracy and a longer machine life. Specialized dosing units and a vibration plate to provide proper deaeration and compaction create a highly efficient packing process with more product filled into a smaller bag.
For fine powder applications, the Roto-Packer comes in the RST version, which is equipped with the T-Module (Turbine), a vertical impeller-based system. This system is optimized with vibrating bottles or vacuum rods to increase efficiency and provide proper deaeration throughout the packing process.
The Roto-Packer also comes in the RSL, which is an air filling module that conveys product into the packaging via air pressure. The L-module is available with a fully ventilated base plate in the pressure chamber. Overall, both filling module options from Haver & Boecker result in over 50% less energy use than traditional filling modules.
Thanks to the redesigned, preinstalled platform, the RS features faster commissioning and shorter assembly times, leading to faster delivery. On the delivery day, Haver & Boecker’s service team visits the packing facility to install the Roto-Packer RS and provide operator training. Adjustments can be made to meet each facility’s individual needs through the HMI, which is controlled by MEC 4.0.
Multiple customization options are available to upgrade technology on the system. New motors enhance data-driven reporting and ensure issues can be identified more precisely before they can lead to stoppages. Updated technological options include compaction detection, patented fill-level detection during bag filling, smart ventilation and even glue edge detection for bags. Boasting a global service footprint, Haver & Boecker’s team serves as an ongoing consultant to the operation to ensure that filling goals are met.
The RS series integrates QUAT²RO AI products, which use a high-definition camera and a self-programmed algorithm to create added user benefits.
1) QUAT²RO Bag Check — ends the problem of packing the right products into the wrong bag, which is a common mistake that leads to millions of dollars in credits. The system scans the empty bag to ensure it matches the product specifications defined by the operator. If the bag that is placed onto the spout is not correct, the packer will not begin the filling process.
2) QUAT²RO MatEx Check — minimizes the risks involved with bursting bags thereby increasing operator safety and eliminating countless hours of cleaning. The MATEX system uses a high-definition camera to monitor the bag as it is being filled, triggering an immediate stop if a bag bursts. Unlike the standard monitoring system based on weight increase which can take several minutes to stop, this trigger shuts down in mere seconds.
Through Bespoke, Haver & Boecker consults on bag selection to find the most compatible option for the operation. Their team considers the equipment and the product to create a harmonized filling process. They can also design custom packaging for their customers. By helping to choose and design the FFS bags with specialized features — like a deaeration channel with a UFP-Perforation to help air escape the bag without losing additional product — Haver & Boecker helps customers present their bag as their business card, protecting the product from the elements and creating more visually appealing bags and pallets.
