Vollautom. Abfüllmaschine

A fully automatic powder filling machine operates without manual intervention after the initial setup. Containers (bags, cans, bottles, pouches) are automatically indexed into the fill station via conveyor, filled to the target weight, and conveyed away to closing, coding and packing stations — all under PLC control. "Fully automatic" describes the entire filling cycle: (1) automatic container in-feed and positioning; (2) automatic fill and weight control; (3) automatic container out-feed. Options like automatic bag hanging, capping, labelling and palletising extend the automation level further. Fully automatic systems are chosen when throughput exceeds what a semi-automatic machine and one operator can achieve, typically >500 kg/day.

Speed depends on fill weight, powder flowability and machine configuration. Single-head inline automatic (100g–5kg): 30–80 fills/min. Dual-head rotary (100g–5kg): 60–150 fills/min. Multi-head rotary (10–16 stations, 50g–2kg): 100–300+ fills/min. For large-weight fills (10–25kg bags), 20–60 bags/min is typical. For small sachets (<100g) on a high-speed multi-lane VFFS line with combination weigher: up to 400–600 fills/min. These rates are for a single machine — a complete line with upstream and downstream automation can sustain production at the machine's maximum rated speed.

Modern fully automatic powder filling machines are designed for rapid changeover: (1) Call up the target recipe from HMI memory (stores 200+ recipes with all weight, speed and vibration settings); (2) Flush the hopper and fill tube (dry flush or CIP cycle depending on product type); (3) Auto-adjust or tool-free manual adjust of fill spout height and container guide width; (4) Run a few validation fills and confirm on checkweigher. Changeover time: 15–45 minutes for product change, 30–90 minutes if filling system components (auger, funnel) must be swapped. For allergen crossover or pharma products, a CIP cleaning validation cycle is required (60–120 min). Some machines have servo-driven auto-adjustment of all format parameters.

HEMUfill fully automatic powder filling machines support industrial integration: OPC-UA server for SCADA and MES connectivity; Modbus TCP/IP and Ethernet/IP for PLC-to-PLC communication; barcode scanner or RFID reader at in-feed for product identity verification; checkweigher with SPC (Statistical Process Control) data output; vision system for container inspection (cap on/off, label placement, fill level check); serialization and traceability interface (GS1, 2D barcode); remote monitoring and diagnostics via VPN or cloud dashboard. Integration with ERP (SAP, Oracle, custom) for batch management and production reporting is available as a project option.

ROI calculation example (protein powder, 500g cans): Semi-auto: 1 operator, 20 fills/min, 8hr shift = 9,600 cans/day. Operator cost: $40/hr = $320/shift. Fully automatic: 0.5 operator (supervision), 80 fills/min, 24hr operation = 115,200 cans/day. Labour saving: $240/shift × 3 shifts = $720/day. Additional output: 105,600 cans × $0.30 margin = $31,680/day additional revenue. Machine investment: $120,000. Labour-saving payback: $720/day → ~167 days (~6 months). Most customers see payback within 12–24 months when including output increase and giveaway reduction. Contact us for a project-specific ROI analysis.

A fully automatic inline auger filler (single head, 50g–2kg, 30–60 fills/min): $25,000–$60,000 USD. Fully automatic rotary auger filler (4–8 heads, 100–200 fills/min): $80,000–$180,000 USD. Complete fully automatic line with combination weigher + VFFS + checkweigher: $100,000–$300,000 USD. Pharmaceutical-grade fully automatic line with GMP documentation: $200,000–$600,000 USD. Prices vary based on fill weight range, powder type, speed, container format and integration level. Contact us with your specifications for a detailed proposal.