A global kaolin producer needed to strengthen its position in a highly competitive market. Kaolin, also known as China clay, is a versatile mineral used worldwide but is notoriously difficult to handle because of its aerated and dusty characteristics. The company relied on an in-house designed dual bulk bag filling system that operated at just 7.2 bags per hour and required two operators. Slow filling rates and heavy manual involvement limited overall production and operator efficiency.

The Bulk Bag Filling Challenge

The producer aimed to overcome significant operational challenges to better serve their global customer base. Their main objectives included:

• Increasing fill rates to 12 bags per hour at 14,500 pounds or 6,500 kilograms per hour using 2,500 pound or 1,000 kilogram bulk bags.
• Densifying the aerated kaolin to ensure each bag was upright, evenly filled, safe and stable for container shipping.
• Reducing manual handling and minimizing operator requirements to improve safety and productivity.
• Integrating the system with the existing plant-wide Distributed Control System using a single control panel.

Bulk Bag Filling Solution

Our engineers delivered a comprehensive solution centred on the Cone Table Elite Bulk Bag Filler designed for maximum product densification. The system included:

• Dual Cone Table Elite bulk bag fillers to achieve continuous and efficient high-speed filling.
• An integrated operator platform with a slip sheet dispenser to improve workflow.
• Automatic bag removal shuttles for seamless handling and transport of filled bags.
• Powered and gravity roller conveyors with sensors to move bags safely and efficiently.
• A single PLC control panel with automatic and manual functions, designed to communicate directly with the plant’s Distributed Control System via Ethernet.
• The system leverages Akona’s semi-automated filling solutions to maintain high throughput while reducing operator intervention. This approach balances automation with hands-on control, ensuring precise filling, improved safety and efficient changeovers.

The advanced Cone Table design ensured thorough product densification, resulting in stable and consistently filled bags ready for international shipment.

The Bulk Bag Filling Result

After implementing the Akona bulk bag filling system, the kaolin producer achieved outstanding results:

• Fill rates increased from 7.2 to 12 bags per hour, effectively doubling throughput.
• Operator involvement was reduced, enhancing safety and improving overall productivity.
• Encouraged by these improvements, the company installed a second identical dual system within the same facility to support continued growth and demand.

Bulk Bag Handling Partnering Performance

At Akona Process Solutions, we work alongside our customers to design integrated systems that drive performance, improve safety and increase operational efficiency. Our focus on reliability, quality and precision engineering helps customers stay competitive and meet evolving market needs.

Want to learn more?

If you’re interested in our bulk bag filling systems and want to learn more, speak with our team. We’ll work closely with you to find the best solution for your material processing and operational goals.