Companies in the bulk packaging industry experience a range of material challenges during the packaging and filling process. These challenges include material condensing, densifying, de-airing, material settling and material packing.
During the packaging and filling process, materials become aerated. Material that is transported in an aerated state will eventually settle and compact due to gravity or the vibration in transit.
Aerated material can compact up to 20 per cent and this results in dead space in the container. This dead space can cause product breakage and loss, and in some cases contamination. Further, when transporting materials on a cubic-metre basis, the opportunity to fully utilise the capacity of the entire container is lost. These issues are especially common in industries that process and package, such as nuts, spices, pet food, biomass pellets, livestock feed and grains. These issues also occur in fertiliser and cement-sand packaging and processing. The consequences of these challenges are reduced efficiency, increased operation, transport and storage costs.
VSS vibratory compaction tables are designed to compact, settle and consolidate product and dry bulk materials during the packaging and filling process. VSS vibratory compaction tables are available for light-, medium-, and heavy-duty, depending upon the specific material, application and processing facility.
VSS vibratory compaction tables are suitable for a range of applications in the bulk-packaging processing line. They flatten the cone or pile of material made from the filling station discharging into rigid structure packaging. This compacts and settles material, allowing for up to 20 per cent more material to be added to the container, utilising the full container’s capacity and protects the product from breakage, product loss and decreases the risk of contamination. This also allows for more product to be shipped in the same amount of space, saving money for the producer and customers.
The vibratory compaction tables compact and stabilise flexible intermediate bulk containers (FIBCs), including bulk bin bags or super sacks for easier stacking and handling prior to storage or shipment.
In addition, these tables remove air bubbles from moulds, cast products and liquids (like chocolate) to improve structural integrity, surface finish and quality control. They can also be custom designed to accurately weigh material and fill containers to the required mass. This is important when products are sold or shipped by weight.
With the correct application of vibration, the material should move up and down in the centre of the compaction table with little side to side movement. While all VSS vibratory compaction tables utilise vertical linear vibration to achieve this “up and down” movement, each compaction application design requires the consideration of each application’s unique variables.
When designing a vibratory compaction table, variables like weight, material characteristics and structural design must be taken into consideration as it affects table design, applicable accessories and the vibration frequency necessary for the specific application.
Depending on the application, tables may be designed with a flat deck, a grid deck or a belt table.
For areas that have limited space and where height requirements are at a minimum, the compaction tables are available in low profile. For applications that require accurate weighing and filling, VSS vibratory compaction tables can be equipped with digital scale instruments that use set points to control the start and stop of the fill device and the vibration sequence.
When choosing the correct pneumatic vibrator for the application, the required vibration frequency is largely dependent on the material density; high-frequency vibration with smaller resulting strokes is suitable for heavier material. While lower frequency vibration with its larger strokes is more suitable for lightweight materials.
These tables lower labour hours and costs for packaging and processing lines in the bulk packaging industry.