HUBER ENGINEERED MATERIALS, USA / Synthetic Amorphous Silica

CHALLENGE

Huber Engineered Materials faced difficulties in packing synthetic amorphous silica (SAS), a lightweight, air-entrained powder, aiming for a 35% densification to improve shipping efficiency.

SOLUTION

Concetti's FFS system with advanced air evacuation and densification technology ensured compact, dust-free, and stackable polyethylene bags for SAS.

HUBER ENGINEERED MATERIALS

Efficient Packaging for Lightweight Powders: Huber's Success with Concetti’s FFS System*

Case Study

Challenge:
Huber Engineered Materials needed to densify their SAS powder by 35% to optimize shipping, reduce trapped air in the bags, and ensure stable pallets during transportation. The ultra-fine nature of SAS caused significant air entrapment, complicating densification and efficient bagging.

Solution:
Concetti installed two fully automated Form Fill Seal (FFS) machines featuring:

Gross weighers for precise filling.
Densification screw feeders to mechanically compact the powder.
Double air evacuation systems: Mechanical and vacuum-driven processes removed entrained air.
Polyethylene bags with labyrinth venting systems ensured better sealing, moisture resistance, and recyclability.

Result:
The system achieved 150 bags/hour with a final SAS density of 7.49 lb/ft³, yielding compact, durable, and recyclable bags. Transportation and production costs were significantly reduced, while nuisance dust and facility downtime were minimized.

Technical Solution

Concetti provided:

Form Fill Seal machines with gross weighers for precision.
Densification screw feeders for initial compaction.
Double air evacuation system with sintered probes and vacuum extraction.
Polyethylene bags with labyrinth venting for gradual air release.
Robot palletizing system for stable and secure stacking.

Features & Benefits:

Precise weighing and filling accuracy.
Robust polyethylene bags, moisture-resistant and recyclable.
Reduced air entrapment for compact stacking.
High throughput: 150 bags/hour.
Fully automated system requiring minimal operator intervention.

Strengths

35% densification achieved for SAS powder.
Lowered transportation and production costs.
Improved bag strength and moisture resistance.
Reduced dust for a cleaner work environment.
Automated operations ensure consistent output.
Enhanced sustainability with recyclable packaging.

Conclusion

Concetti's tailored FFS solution helped Huber Engineered Materials overcome significant challenges in packaging SAS. The innovative system delivers operational efficiency, cost savings, and sustainability, underscoring Concetti’s expertise in bulk powder packaging.Discover how our innovative packaging solutions can elevate your operations. Contact us to learn more about this case study and explore how we can address your unique challenges!

*This case study was completed in 2015. Since then, the facility has been acquired by another brandl. We are sharing this case study due to its technical significance and the success of the solution implemented.