Folding ton bags are compressed and shaped by bundling | Cylinder pressurization+automatic bundling · Conventional three passes · 2.5 seconds/pass

1、 Industry background and pain points

After folding the ton bags (container bags) neatly, they are bundled into a fixed number of bundles.
 It is common in the industry to bundle 500 ton bags into one bundle. Whether this bundle is tightly tied or not directly determines
whether it can be stacked higher later, loaded into the container, and whether it will be loose during transportation.

The folded ton bag is made of soft material, which is fluffy and has a large rebound.
The common practice in factories at present is to separate the pressing and bundling into two parts: first,
use a hydraulic press to press the ton bag tightly - the pressure of the hydraulic press is sufficient, and it is pressed very firmly;
After pressing, manually tie two or three ropes together. The problem lies in the second half: the tightness of manual bundling depends entirely on the hand feel,
and the tightness of two or three ropes in the same bundle may be different. After bundling and releasing, entering storage and transportation,
the ropes are subjected to uneven force, causing the bag to slowly rebound and the bundling shape to become loose; In addition, the two processes are done separately, and the hydraulic press pressure is slow,
and manual bundling cannot be done quickly. It takes several minutes to tinker with each bundle, and the peak shipment is stuck in this link.

The real determinant of whether a bundle can stand upright is the bundling process: the tightness of the straps is consistent and can be maintained consistently,
 making the bundle neat, dense, and stackable. The tightness of artificial rope bundling is uncertain, and it is easy to rebound and loosen after stacking or long-distance transportation.
The same amount of volume will increase - if the warehouse is not stacked high or the container is not fully loaded, it is equivalent to buying a bundle of air with storage area and shipping cost.

2、 Product Features and Workflow

The ton bag pressurization and bundling machine combines "pressurization" and "bundling" into one device and one process: a pressurization cylinder (cylinder diameter 160mm, stroke 800mm) is installed above the table, which drives the pressure plate to descend and compact the folded ton bags; After the compaction is in place, there is no need for manual intervention. The machine automatically completes the feeding, tightening, hot melt bonding, and cutting of the tape, pressing the fluffy soft products into a neat and compact bundle, and then lifting and discharging the pressure plate.

The workflow is as follows: manually place the folded ton bags (usually 500 per bundle) on the non powered drum table → push them into the pressure station → the cylinder drives the pressure plate to press downwards (with a stroke of 800mm) → start the binding with a foot pedal, regular three passes → automatic pressure binding → pressure plate lifting → manually push them out and enter the next bundle.

The tabletop is a non powered drum structure, and loading and unloading are completed by pushing and pulling, without the need to lift heavy bundles up and down; The bundling strength can be adjusted from 1 to 9 levels, the hot stamping temperature is constant, and it has a packing counting function. In addition to ton bags, folding and pressure bundling of soft sheet products such as tarpaulins and canvas are also applicable (customized according to product size). At present, loading and unloading are done manually, and automatic loading and unloading can be modified as needed.

3、 Product parameters (ton bag pressure strapping machine)

4、 Homework method

The standard configuration is manual loading and unloading: the folded ton bags are manually loaded onto the roller table, pushed into the pressurization station, and after pressurization and bundling are completed, pushed out. One person can operate it, suitable for mixed production of multiple specifications and medium to low batches.

5、 Data comparison 

6、 Advantages of the plan

1. Binding speed: Automatic binding after pressure is applied, 2.5 seconds per pass - the hydraulic press applies pressure slowly, and manual binding is even slower, saving the entire shipping cycle time.

2. The tightness of the bundling is controllable: the strength can be adjusted from 1 to 9 levels, the temperature of the hot stamping head is constant, and the tightness of each strip is consistent, without relying on hand feel; The problem of uneven tension and rebound in the later stage of rope tying is no longer present.

3. One machine with two processes: pressurization and bundling are completed on the same equipment, saving one hydraulic press, one bundling station, and one operator.

4. Unified number and position: The regular three passes are completed at once, with each bundle being consistent, stacked neatly, and counted clearly.

5. Effortless operation: The unpowered drum table can be pushed in and out, and heavy bundles do not need to be lifted up or down. It can be operated by a single person.

6. Reliable control and drive: Fanyi PLC control board+human-machine interface, 3 sets of servo motors for the whole machine (M1 hot melt shear compression, M2 conveyor belt pulling, M3 pre conveyor belt storage bin), automatic belt feeding+secondary loading, stable operation.

7. Counting and leaving traces: equipped with packaging counting function, the number of shipped points does not need to be manually counted; The bundling parameters can be stored and checked on the touch screen.

8. Wide adaptability and customizable non-standard: In addition to ton bags, folding and pressure bundling of soft sheet products such as tarpaulins and canvases are also applicable; The height of the countertop can be adjusted from 700-850mm, and the bundling size, pressure stroke, and pressure plate size can be customized according to the product specifications. The loading and unloading can also be changed to automatic as needed.

7、 Applicable objects

Factory bundling station for container bag (ton bag) making factory and packaging material factory; The packaging process of soft products that require bundling according to a fixed number of strips (usually 500 strips per bundle); Folding and pressure bundling of soft sheet products such as tarpaulins and canvas (customized according to the folded size); And standardized packaging before warehousing turnover and logistics shipment. The loading and unloading process is currently manual, suitable for mixed production of multiple specifications and medium to low batches.