DIAMOND V, USA / Animal Feed Additives

CHALLENGE

Diamond V needed an automated packaging system for highly hygroscopic and powdery materials that hardened upon exposure to air. The solution also required extreme precision to avoid material waste and ensure reliable seals for long shelf life.

SOLUTION

Concetti, in close collaboration with its U.S. partner Bratney, provided customized bagging lines with advanced features like conditioned environments, precise dosing, reliable sealing, and fast recipe changes.

DIAMOND V, USA

Diamond V’s Dusty Challenge: How Concetti and Bratney Delivered Reliable and Precise Packaging Solutions

Case Study

In 2015, Diamond V sought a packaging solution for a hygroscopic powder that hardened upon air exposure. The challenge required minimal air contact, robust moisture protection, and precision. Through close collaboration with Bratney Companies, Concetti designed a system featuring a gross weigher with screw feeder, FFS bagging machine, hybrid palletizer, and specialized bag reels for extended shelf life. These machines were installed in a conditioned room to control humidity. The precise weighing, innovative bag flattening, and air-venting systems ensured high accuracy and consistent results.

In 2018, Diamond V returned for two new lines to address bagging inefficiencies with different feed materials. Together with Bratney, Concetti implemented a system with dual-screw feeders, mechanical bag alignment, and versatile sealing capabilities, resolving issues with accuracy and sealing from previous suppliers. The result was a reliable, efficient system with seamless material transitions and reduced downtime.

Technical Solution

Concetti, in collaboration with Bratney, provided:

Conditioned Room Design
The equipment was installed in a controlled environment to prevent the hygroscopic material from absorbing moisture and hardening, ensuring optimal performance and material integrity.
Dual Screw Feeders for Accurate Weighing
Two inclined screw feeders, one for bulk filling and another for fine adjustments, ensure precise weighment and prevent material flow issues, achieving weight accuracy within ±0.2%.
Form-Fill-Seal (FFS) Bagging Machine
Designed to handle the hygroscopic material with minimal air contact, the FFS machine included a thermal transfer printer for permanent printing on bags during the unwinding process.
Hybrid Robotic Palletizer
A robotic system that ensures stable pallet stacking by flattening the bags and venting excess air, preserving the material's quality and reducing moisture risks.
Integrated Deaeration Probes
To remove trapped air within the bags, deaeration probes were included, preventing aeration of the material and ensuring a consistent bag fill.
Automatic Recipe Changeovers
Advanced automation allowing the entire packaging line to adapt to different materials and production requirements within 90 seconds, enhancing operational flexibility and efficiency.

Strengths

Exceptional precision (±0.2%) prevents material waste.
Hygroscopic material handled safely in conditioned environments.
Reliable sealing systems for long-term moisture protection.
Faster production line transitions (90 seconds).
Durable, efficient, and cost-effective mechanical solutions.
Close collaboration with Bratney ensured seamless support and implementation in the U.S.

Conclusion

Concetti’s tailored solutions, developed in close partnership with Bratney Companies, transformed Diamond V’s packaging processes. By addressing technical challenges with precision, reliability, and innovation, Concetti and Bratney delivered systems that improved productivity and ensured long-term success.

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