CASE STUDY: How to solve spice packaging

Why the company started addressing packaging technology

Once again, it was confirmed that good things are worth waiting for. We first met the representative of the Austrian family-owned organic spice company at an engineering trade fair in 2019. After some time, they contacted us again. They needed to automate packaging because their original machine was no longer sufficient in terms of capacity.

Typical production situation:

• increasing production volumes
• insufficient performance of existing technology
• high demands on product variability

Problems that needed to be solved

On-site analysis revealed that the project would not be just about a packaging machine, but about designing a complete functional system:

• extreme product variability with different structures
  • ground spices
  • dried herbs
  • blends
• high dust levels (e.g. cinnamon) – risk of leaking seals
• specific pouch formats:
  • small dimensions
  • gusseted bottoms
  • mechanically “ironed” edges
  • side longitudinal seal
• very limited space in the production hall
   

Final solution: combination of technologies

The core of the system is the vertical packaging machine TOBOGAN 250S, designed for efficient and hygienic food packaging into various types of pouches.

It was an ideal fit for this project thanks to:

• high flexibility
• ability to be integrated into a production line
• stable operation with minimal downtime
• readiness for connection to a central dust extraction system (key for high-quality film sealing)

It was also important for the customer that the machine can work with various packaging materials and produce different pouch types. This made it ideal for their wide product range.

Two dosing systems on one machine

The TOBOGAN 250S is equipped with two types of dosing systems that can be quickly exchanged depending on requirements.

RACKET S – highly precise and reliable auger filler.

Advantages:

• precise dosing
• suitable for dusty products such as flour, spices, matcha, or protein powders
• consistent dosing with minimal deviation thanks to a stirrer and optimized auger design
   

RACKET LW4 – precise high-accuracy linear weighers

Advantages:

• efficient and reliable weighing and dosing of loose or particulate materials
• minimal deviation
• reduced material waste
• increased production efficiency
• high performance thanks to four weighing channels
• easy adaptation to specific product requirements
   

The ability to quickly switch dosing systems ensures maximum flexibility without the need for two separate production lines.

The line also includes:

• label applicator combined with thermal transfer printing directly onto the film
• CAB-Z feeding conveyor for product supply to the machine hopper
• CAB-OD discharge conveyor for removing filled bags from the machine
• highly sensitive metal detector directly on the discharge conveyor

Packaging dusty products has its specifics

Dusty products present a specific challenge. Dust can enter the seal area of the package and affect its tightness and quality.

In practice, this issue is solved through a combination of:

• properly selected dosing system type
• structural machine modifications
• connection to a central dust extraction system
• use of antistatic equipment
• regular maintenance and cleaning

Result of the cooperation

We delivered a compact packaging line that:

• handles a wide product range
• ensures stable packaging quality
• fits even into very limited space
• can be extended with additional equipment

What did the new line bring to the organic spice producer?

• Peace of mind – stable packaging quality even with highly dusty products (ground cinnamon)
• Maximum flexibility – switching between ground spices and whole herbs takes only a short time by replacing the dosing system
• Simpler operation – more intuitive and faster cleaning and control

But the greatest reward was a seemingly small detail. During a reference visit, the owner spontaneously showed us an empty space in the hall where he is already planning to install another line from us. And that is the best possible feedback.

Are you solving a similar issue with dusty products?

We are happy to look at your production directly and design a solution tailored to your products, space, and requirements.
Leave us your contact details – we will get in touch and arrange the next steps.
 

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