Bulk filling

Filling a bulk bag: accuracy, rate and dust pull against each other

A bulk bag is not a large small bag. At a tonne the tolerances that felt generous at 25 kg become a conversation with the customer, and the air the product carries becomes the dominant problem.

Published · 2 min read

The numbers stop being forgiving

At 25 kg, half a percent is 125 g — usually inside the declared tolerance. The same half percent on a 1,000 kg bag is 5 kg. Whether that matters depends entirely on what the customer does with the bag, which is why the first question is never about accuracy at all.

Three quantities that move together

Accuracy wants a slow, gentle finish. Rate wants a large main flow. Dust control wants the bag closed and under negative pressure. Each of those pulls against the other two.

The usual compromise is two-stage filling: a large main flow up to the last few kilos, then a stopped or dribble feed for the remainder. The dribble time is what the cycle time is actually made of, so it is the number worth arguing about — not the headline rate.

The air is the hidden variable

Product entering the bag displaces air, and that air has to leave through the fabric. If it cannot, the bag balloons, the load on the suspension frame changes, and the weight reading wanders while the bag is still settling.

This is why a station that weighs accurately on a dry day can miss on a humid one: the fabric clogs, the air stays, the reading moves.

Weigh the bag, or weigh the product

Suspension weighing weighs the whole bag on its loops. It is simple, and it sees exactly what the customer will see — but it also sees every swing of the bag.

Product weighing keeps the scale away from the bag and the frame, at the cost of trusting the discharge to be complete. The choice is usually made by how much the bag moves on your frame, not by nominal accuracy.

Where to look next

How much of the cycle the dribble stage really takes is visible in the ton-bag clip: the last few kilos are not the last few seconds.

The stations themselves are under bulk bag filling, and if the bag or the product is unusual, that is the conversation to have first.