INTRODUCTION

The Plastic Granule FFS (Form-Fill-Seal) Bagging System represents the pinnacle of automated packaging technology for polymer processing industries. Designed specifically for 25kg granular petrochemical products like PP/PE pellets, this system integrates film forming, precision weighing (±0.2% accuracy), inert gas flushing, and hermetic sealing in a single continuous operation. With servo-driven mechanisms achieving 400-600 bags/hour, it meets the rigorous demands of modern plastics manufacturing facilities.

TECHNICAL SPECIFICATIONS

• Model: PG-FFS2500X

• Capacity: 550 bags/hour (25kg standard)

• Weighing System: Loss-in-weight feeder with 0.1% precision

• Film Type: Multi-layer co-extruded PE/PP (150-200μm thickness)

• Sealing: Dual hot bar cross-sealing (160-220°C adjustable)

• Special Features:

• Nitrogen purge system (O₂<0.5%)

• ATEX-certified explosion-proof option

• Anti-static film compatibility

• Power Requirements: 380V±10%, 50Hz, 8.5kW

• Dimensions: 5800×1800×4500mm (L×W×H).

APPLICATION SCENARIOS

Polymer Production Lines

PP/PE pellet packaging with anti-static films

Engineering plastics (ABS, PC/ABS blends)

Recycled plastic flake compaction packing

Specialty Chemical Packaging

Flame-retardant masterbatches

Carbon-black filled compounds

Glass-fiber reinforced materials

Bulk Material Handling

Compounding additives

Plasticizer granules

Polymer catalysts.

OPERATIONAL MANUAL

Pre-Operation Setup

Mount 1000mm wide film roll on servo-controlled unwind shaft

Thread film through forming collar with ±2mm alignment tolerance

Calibrate load cells using certified 25kg test weights

Production Parameters

Bag dimensions: Typically 600×900mm (adjustable in 10mm increments)

Sealing temperature: 180°C for standard PE films

Nitrogen flow rate: 15L/min (adjustable based on material sensitivity)

Vibration compaction: 50Hz frequency for dense packing

Production Cycle

Film advance → Vertical tube formation → Bottom heat seal

Gravimetric filling via split-gate discharge (3-stage filling)

Top sealing with batch coding

Finished bag ejection to take-away conveyor.

MAINTENANCE PROTOCOLS 

Daily:

Clean residual pellets from weighing hopper

Inspect sealing jaws for polymer buildup

Verify pneumatic system pressure (0.6MPa)

Monthly:

Replace worn film guide rollers

Lubricate chain drives with high-temp grease

Calibrate load cell sensors

Annual:

Servo motor encoder verification

Electrical system safety inspection

Complete sealing system overhaul.

TROUBLESHOOTING GUIDE

Issue: Inconsistent bag lengths Solution: 

Adjust film tension to 15-20N and verify encoder alignment

Issue: Weak seal strength Solution: 

Increase temperature by 10°C increments or replace PTFE jaw covers

Issue: Weighing drift Solution: 

Recalibrate load cells and check air cushion stability

Issue: Film jamming Solution: 

Realign forming collar and adjust unwind brake torque.

FREQUENTLY ASKED QUESTIONS

Q1: What film specifications prevent pellet penetration?

A: Minimum 150μm co-extruded film with nylon reinforcement layer.

Q2: How does nitrogen flushing preserve material quality? 

A: Maintains<0.5% O₂ concentration during filling via PID-controlled gas system.

Q3: Can it handle recycled materials with inconsistent bulk density?

A: Yes, with optional volumetric vibration compactor (50Hz adjustable).

Q4: What safety features are included? 

A: Emergency stops, light curtains, and explosion-proof components (ATEX Option).

Q5: How is metal contamination prevented?

A: In-line magnetic separator and metal detector with auto-reject.

INDUSTRY COMPLIANCE

Meets ATEX Directive 2014/34/EU for hazardous areas

Complies with ISO 9001:2025 quality standards

CE Marked for European market.