Behn + Bates makes food packing mechanically clever

The Behn + Bates Integra IV series for valve bags increases hygiene and energy efficiency to a new level within the food packing sector.

The newly designed Integra IV series features a complete Plug ’n Pack system that integrates the packing machine, bag applicator and discharge system to maximise hygienic operation while minimising commissioning and installation efforts.

“The Integra IV series meets the unique requirements of a variety of food products and makes life easier for producers. Each machine is customised to spec through the configuration system,” said Christoph Ransiek, sales manager at Behn + Bates. “For customers seeking a cleaner and quieter packing solution, the Integra IV gives a compelling alternative to wannabe-housed or unhoused packing machines in industries where hygiene, safety and flexibility are top priorities.”

Preassembled, the Integra IV series includes a bagging unit and bagging applicator integrated into the external housing. In the nomenclature of the INTEGRA “IV”, the letter “I” stands for “integrated” and the letter “V” for “valve bag.”

The housed machine supports up to four filling spouts with a range of bag lengths and widths. It can be equipped with either an impeller- or air-based filling and dosing unit. The German word for impeller is “turbine” and for air is “luft.” As a result, the Integra IV becomes an IVT if it has an impeller or an IVL if features pneumatic technology.

Fully equipped with the MEC 4.0 weighing system, the Behn + Bates’ Integra IV allows full line communication. The new human-machine interface (HMI) system with an integrated industrial personal computer (IPC) allows the machine to be tailored to a specific industry to ensure optimal performance without unnecessary complexity. It features a redesigned 15.6-inch touch operator panel for improved usability.

The enclosed housing has been completely redesigned. All critical components are hung rather than floor mounted which keeps dust contained during the filling process, maintaining a cleaner environment.

For ease of cleaning, the cabin features large openings and doors with a new, flexible design to reduce interior cleaning times by up to 50%. The bag magazine and chair also fold open to achieve accessibility for ease of cleaning and access for the operator. The application arm is now capable of diagonal motion in addition to as horizontal and vertical movements, which increases performance speeds by up to 10%. These features all culminate in a design that supports a completely new level of hygienic and allergen-controlling standard, demanded by food plants.

Swivel-mounted switch cabinets increase accessibility for maintenance and repairs. The pneumatics and cladding elements are centralised in one easy-to-access space with cables and hoses attached to assemblies via the machine roof, which is designed to protect electrical components.

The newest Integra generation can be equipped with specialised AI technology, called the QUAT²RO product suite:

1) QUAT²RO BAGcheck ends the problem of packing the right products into the wrong bag — 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 VALVEcheck offers the ability to increase production by an average of 10% by detecting if the valve of the bag is sufficiently opened to ensure a precise application of the bag. Bags with improper opening will simply be dropped and a new bag retrieved.

3) QUAT²RO MATEXcheck minimises 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 in down in mere seconds.

4) QUAT²RO SEALcheck detects improper and incorrect bag closures to effectively address the second most common customer complaint. Though the ultrasonic sealing technology of current bags offers high reliability and industry acceptance, several factors such as bag architecture, application time of the ultrasonic welding and product volume in the valve during closure, can affect the quality of the seal. By monitoring every bag as it is transported from the packer to the palletiser, SEALcheck can ensure that bags which are not properly sealed will not leave the facility.