Our Cone Table Elite (CTE) Bulk Bag Filler is one of the most versatile and capable bulk bag fillers in the industry. Unlike other fillers, the CTE bulk bag filler features the company’s patented cone table densification system which densifies material in the bag, increases bag stability, and bulk bag filling throughput.
Consider the CTE Bulk Bag Filler when you require maximum bulk bag densification, bag stability, bag stacking capabilities, weighing accuracy and the highest bagging rates.
Features
- Best Densification & Bag Stability
- Unmatched Bag Stacking
- Weighing Accuracy
- Industry Benchmark High-speed Bagging – 35+ bags/hour!
- Multiple Bag Types
- Nitrogen purging (optional)
- HOW IT WORKS & BENEFITS
- YOUR REQUIREMENTS
- CONFIGURATIONS
- MODELS & SPECIFICATIONS
- COMPONENTS & OPTIONS
- CONTROLS
- APPLICATIONS
HOW IT WORKS & BENEFITS
How The CTE Bulk Bag Filler Works
Our patented coned densification table provides tamping & densification to ensure proper ingredient fill. The table assembly consists of a truncated pyramid welded on a frame with two integral electro-mechanical vibrators.
The CTE moveable carriage assembly raises & lowers placing the bottom of the bag into contact with the cone table. This forces ingredient into the bottom corners of the bulk bag during filling, providing maximum densification & a flat-topped, stable package.
Cone Table Densification Explained
Geometry creates stable base
1. Build a stable base
The cone table’s shape directs product to the bottom corners of the bag to create a stable foundation.
Efficient energy transfer
2. Transfer maximum energy
The cone table makes direct contact with the bag resulting in maximum vibration energy transfer.
Bag stretches up to 5%
3. Stretch the bulk bag
A bulk bag typically spends 50% of the filling cycle hanging from its loops and not in contact with the cone table. During this time the bulk bag stretches, increasing volumetric efficiency and assisting with bag stabilization. A stretched and densified bulk bag will not slump and will hold more product.
Flat top removes angle of repose
4. Removes the angle of repose
Almost any dry bulk solid has an angle of repose which is the angle formed by the peak of material produced when pouring a dry bulk solid. To produce a flat-topped bag, the horizontal top of the cone table pushes up a column of product every time it comes in contact with the bag. When the cone table is removed from contact with the bag, the angle of repose is flattened.
CTE Bulk Bag Filler Benefits
Best Densification and Bag Stability
The CTE Bulk Bag Filler features patented cone table densification ideal for powders, granules or pellets that are easily aerated and/or difficult to compact. When the bulk bag is properly stretched and the material is deaerated with a flattened angle of repose, the result is a very safe and stable bag.
Unmatched Bulk Bag Stacking
The CTE is the only bulk bag filler available that produces filled bulk bags that are so stable they can safely be double stacked within the filler itself as well as in storage areas. This allows end users to maximize operator productivity and minimize storage and warehousing costs.
Weighing Accuracy
The CTE Bulk Bag Filler utilizes hang weighing and delivers repeatable best-in-class weighing accuracy of +/- 1-2 lb.
Industry Benchmark High-Speed Bagging
The CTE Bulk Bag Filler delivers unmatched bulk bagging rates of 30-35 bags/hr. with weighing and more than 40 bags/hr. with pre-weighing! These bag fillers are often configured with automated filled bag removal to maximize bagging rates and operator productivity.
Multiple Bulk Bag Types
The CTE Bulk Bag Filler can fill lined or unlined bags, with or without an outlet spout. Air or nitrogen can be used in the filling process. Bulk bags can also be filled with or without pallets.
YOUR REQUIREMENTS
Before selecting a particular bulk bag filler, some key factors need to be considered. This not only helps to assess a customer’s own particular needs but also assists our design engineers in determining the optimum system for those needs.
Q. How do we handle the bulk bag?
A. By pallet or by the bag loops.
Q. What bag style and size do we use?
A. At this stage, you should consult both the bag manufacturer and Spiroflow. The bag needs to optimize all its volume for safe storage and transport.
Q. How do we contain dust?
A. An inflatable neck seal effectively contains the dust during filling. All our filling heads have an inner product flow and an outer annulus for dust evacuation. A dust extraction port is also included.
Q. Can the filling system be automated?
A. If filling by volume, options such as pallet dispensers, automatic bag loop release, bag take-off and accumulation conveyors should be considered. These can be added at a future date to standard Spiroflow bulk bag filling equipment.
Q. Will the equipment need to be grounded?
A. If the area poses an explosion risk, static dissipative or groundable bags may be recommended together with a suitable static monitoring device.
Q: Can we use nitrogen purging?
A: Nitrogen purging is an option. Traditionally when bag filling, the bag would be inflated with air before filling commences, but nitrogen can be used instead to increase product shelf life.
Q. Do we need a bag liner?
A. If the product is very fine, you probably will, to prevent leakage or moisture ingress. However, various alternatives can be used such as coated bags or special bag seams. The liner must be inflated correctly to avoid creasing and subsequent discharge problems.
Q. Is your product highly aerated? Do you have problems producing upright, stable bags?
A. Usually, yes. Vibration at the base of the unit deaerates and compacts the product to optimize the bag volume and form a safe and stable load. The CTE bulk bag filler uses our patented Cone Table densification for highly aerated powders.
Q. Is automatic loop release and height adjustment available?
A. Automatic loop release is available but height adjustment is not offered on the CS Base Filler the C-Series & CTE bulk bag fillers offer height adjustment. Yes, automatic loop release of filled bags is a useful labor-saving option for pallet loaded bags. Powered height adjustment is also recommended if different sized bulk bags are being filled in order to speed up the filling process.
Q. Can the equipment be adapted to fill other containers?
A. Yes. Spiroflow supplies a range of options for filling rigid bins, drums, and boxes/octabins.
CONFIGURATIONS
Our CTE bulk bag fillers can operate as stand-alone units or part of a semi-automated filling system.
MODELS & SPECIFICATIONS
The CTE Bulk Bag Filler can be configured with a variety of components. Based on your application a Spiroflow engineer will recommend one of three CTE designs.
| Model | Vibration |
|---|---|
| CTE-SC | Equipped with (2) 1.0 hp (.75 kW) vibrators at 1,200 rpm |
| CTE-MC | Equipped with (2) 1.5 hp (1.1 kW) vibrators at 1,200 rpm |
| Specifications | |
|---|---|
| Description | The Spirofil CTE Bulk Bag Filler is used for filling by weight and provides high volume filling as well as a patented design for maximum material deaeration. The Spirofil CTE Bulk Bag Filler consists of a main support structure, a dual-purpose twin tube filling head & bag loop hanger arms. It includes hang weighing, a cone table densification system & a flexible connection. Hang weighing of the bag is performed by a weigh frame that floats on precision load cells mounted to the upper frame structure. The bag hanger arms & fill head assembly are bolted to the weigh frame. |
| Fill Rate & Bag Capacity | • Up to 35 bulk bags/hour • More than 40 bulk bags/hour (pre-weigh) • Bag capacity – 4,400 lb/2,000kg |
| Standard Materials of Construction | Carbon/mild steel materials of construction |
| Frame Style & Standard Components | • Single Post Design - Main support structure & weigh frame • Dual-purpose twin tube filling head/nozzle • Pneumatic neck seal • Manually retracting drive off bag loop hanger arms • Load cells • Fixed cone table densification system • Flexible connection • Carriage brake motor • Clean valve |
| Load Cells | When filling by weight three (3) load cells are mounted on the upper frame structure for HANG WEIGHING (200% overload capacity with 100% section capacity) |
| Typical Dimensions | • Height: 120”+/3,000mm+ depending on bag size • Width: 54”/1,400mm • Depth: 78”/2,000mm |
| Pneumatic Requirements | 80 psi/5.5 bar @ 25 CFM (750 l/cycle) |
| Electrical Requirements | 5 hp (3.7 kW), 230/460/575 V, 3 Phase, 60 Hz |
| Energy Consumption | Plant Voltage: 230/460/480/575 Control Voltage: 24 V DC/120 AC |
| Dust Control/Air Displacement | • The filling nozzle design includes an inner open-ended cylinder, with a second concentric cylinder (one end closed by an annulus) attached to it. • The product passes through the center cylinder into the bulk bag while displaced air & dust is routed through the outer chamber & through a dust sock to a dust collection (by customer) connection. • Bags are secured to the nozzle with an outer spring clamp. |
COMPONENTS & OPTIONS
Nitrogen Purging
| Standard Components | |
|---|---|
| Base Unit | The Spirofil CTE Bulk Bag Filler consists of a main support structure, a dual-purpose twin tube filling head & bag loop hanger arms. It includes hang weighing, a cone table densification system & a flexible connection. The bag hanger arms & fill head assembly are bolted to the weigh frame. |
| Load Cells | Hang weighing of the bag is performed by a weigh frame that floats on three (3) precision load cells mounted to the upper frame structure. |
| Fixed Cone Table | Our patented coned densification table provides tamping & densification to ensure proper ingredient fill. The table assembly consists of a truncated pyramid welded on a frame with two integral electro-mechanical vibrators. The CTE moveable carriage assembly raises & lowers placing the bottom of the bag into contact with the cone table. This forces ingredient into the bottom corners of the bag, providing maximum densification & a flat-topped, stable package. |
| Manual Retracting Drive Off Hanger Arms | Manually adjustable trombone style arms are used to retract the outer loop attachment points closer to the operator during bag rigging. The drive-off hanger arm ends are angled up to prevent loop slippage. For use with forklift bag removal CTEs only. |
| Filling Nozzle | The filling nozzle design includes an inner open-ended cylinder, with a second concentric cylinder (one end closed by an annulus) attached to it. Product passes through the center cylinder into the bulk bag while displaced air & dust is routed through the outer chamber & through a dust sock to the end user’s dust collection connection. Bulk bags are secured to the nozzle with an outer spring clamp. An optional inflatable neck seal is also available. |
| Pneumatic Neck Seal | Used in conjunction with the standard filling nozzle the Pneumatic Neck Seal Assembly provides a positive & reliable method of sealing the bag spout to the filling nozzle. The neck seal system also works with lined bags. The inflation assembly consists of a stainless steel filling nozzle, food grade rubber sleeve, pneumatic valve, regulator, filter, gauge & interface components mounted to the machine in the most convenient location to the operator. Includes a hand operated switch mounted on the filler frame for inflating the neck seal. |
| Clean Valve | 2-Position Knife Gate Valve Pneumatically Operated Stainless Steel Contact Metal Construction Mounted on the carriage frame directly above the filling nozzle the two positions allow for closing off the fill head, eliminating any dribble from the flex during carriage travel while there is no bag in place. |
| OPTIONAL COMPONENTS | |
|---|---|
| Load Cells & Junction Box for Automatic Bag Removal (ABR) | The CTE bulk bag filler is easily incorporated into a semi-automated filling system which typically includes an automatic bag removal (ABR) shuttle. Four (4) shear beam load cells are located under the ABR conveyor leg supports & wired to a summation box. The summation box is wired back to the control panel for weighing drums, totes and/or boxes or as a secondary check weigh system. |
| Super Cone Table | The Super Cone Table is used for very difficult to densify products, typically finely divided powders, and similar ingredients. It Includes two (2) ¾ HP electromechanical, adjustable amplitude vibrators. The Super Cone Table’s vibrator is a 6-pole type meaning they rotate at 1,200 RPM. From decades of experience applying cone table densification technology, this has been determined as the most effective vibration frequency for difficult to densify ingredients. The transfer of vibration energy into the powder as the bag is filling is increased by as much as 4X. The Super Cone Table is mounted to the CTE base frame using specialized shock mounts that virtually eliminate transference of vibration to the frame. |
| Mega Cone Table | The Mega Cone Table is used for very difficult to densify products, typically finely divided powders, and similar ingredients. It Includes two (2) 1 HP electromechanical, adjustable amplitude vibrators. The Mega Cone Table’s vibrator is a 6-pole type meaning they rotate at 1,200 RPM. From decades of experience applying cone table densification technology, this has been determined as the most effective vibration frequency for difficult to densify ingredients. The transfer of vibration energy into the powder as the bag is filling is increased by as much as 4X. The Mega Cone Table is mounted to the CTE base frame using specialized shock mounts that virtually eliminate transference of vibration to the frame. |
| Nitrogen Purging | This is the process of first filling a foil or plastic bag with nitrogen (instead of air). The bag can be left inflated or vacuumed, then heat-sealed to ultimately extend product storage life. |
| Retracting Bag Support Hooks | The remote pair of bag loop support hooks pneumatically retract to facilitate the hanging of the empty bag from the operator’s location. |
| Automatic Loop Release | The CTE’s control system automatically releases the bulk bag lifting loops after the bag has been lowered onto the pallet. This eliminates the need for the operator to manually release the four loop latches. |
| Automatic Bag Removal (ABR) Shuttle | Automatic Bag Removal (ABR) consisting of a shuttle system with a CDLR conveyor mounted on the shuttle car. The shuttle resides outside of the CTE until it is time to remove a filled bulk bag. At that time, the shuttle indexes into the CTE. The CTE then lowers the filled bag onto the conveyor or pallet & deflates the pneumatic neck seal. The powered conveyor, mounted on top of the shuttle car, moves the filled bag from the CTE to the first accumulation conveyor. |
| Tilting Fill Head | Prior to rigging an empty bulk bag, the fill head will automatically tilt toward the operator for enhanced operator rigging ergonomics. The bag inlet spout is placed over the filling nozzle. The pneumatic neck seal is then inflated to secure the bag inlet. |
| Access Platform | The access platform, with left or right-side access, is fabricated from heavy angle & bar material with tubular handrails & checker or grid footplate. It can be constructed from carbon/mild steel with Steel-It paint or 304 stainless steel and includes a back plate for mounting a control panel. |
| Automatic Height Adjustment | Automatic Height Adjustment of the fill head & support frame is available via an electric screw jack. |
| Slide Gate Fill Control Valve | A stainless steel slide & aluminum frame complete with a pneumatic actuator set up for three-position bulk/dribble/closed feed operation. The valve is attached to the customer's upstream equipment & is connected to the bulk bag filler via a flexible isolation boot. |
| Knife Gate Valve | The 2-position knife gate valve is pneumatically operated with stainless steel contact metal construction. The two positions allow for closing off the fill head, eliminating any dribble from the flex during carriage travel while there is no bag in place. |
| Pneumatic Bag Neck Seal | Used in conjunction with the standard filling nozzle, the Pneumatic Bag Neck Sealing Assembly provides a positive & reliable method of sealing the bag spout to the filling nozzle. The neck seal system also works with lined bags. The inflation assembly consists of a stainless steel filling nozzle, food grade rubber sleeve, a pneumatic valve, a regulator, a filter, a gauge & a pneumatic hand operated switch mounted on the bulk bag filler frame for inflating & deflating the neck seal. |
| Bag Spout Retaining Ring | Used to provide a positive seal with loose liners, over sized inlet spouts or duffle top bulk bags. |
| Sampling Port | Provides a means for pulling a small sample of material as the bulk bag is being loaded. |
| Bag/Liner Venturi Air Filter | The inflator is attached to the vent spigot of the filling nozzle & does not interfere with standard venting or extraction methods. It includes a pneumatic hand operated switch mounted on the bulk bag filler frame for inflating the bulk bag. |
| Bag/Liner Fan Air Filter | The inflator is attached to a two-way valve that interfaces with the vent spigot of the filling nozzle & does not interfere with standard venting or extraction methods. Inflation is facilitated by means of an electric fan to inflate the bag. |
| Gravity Take Away Roller Conveyor | For accumulating bulk bags on pallets. A section of roller is mounted next to the filler. |
| Powered Roller Conveyor (Beside Filler) | A roller conveyor section is mounted on support legs and is used to transfer/collect empty or full pallets. The conveyor is motorized with rollers that move the loaded bags/pallets down the line. |
| Static Monitoring/Earthing | Specifically designed for use with Type ‘C’ conductive bags & a resistance range of 500 to 1x108 Ohms. |
CONTROLS
Our CTE Bulk Bag Filler can be provided with:
- Gain-in-weight Controls
- Weight Display (no set points)
- Batch Controller
Please share your controls needs with your sales engineer for full specifications.
APPLICATIONS
Complete Bulk Bag Filling Systems & Semi-automated Filling Systems
This is where we truly excel. We take care of everything from concept to commissioning.
A semi-automated bag filling system gives large volume users the benefit of continuous operation without having to stop and unload each bag or gaylord/box. Pallets are automatically fed to the filling rig and the bags are looped onto pneumatically operated hooks. Once filling is completed, the loops are automatically released and the bag is then moved along the line by a powered take-off conveyor.
The drawing above illustrates a dual semi-automated CTE bulk bag filling system. It includes 2 CTE bulk bag fillers, slip sheet dispenser, operator access platform, automatic bag removal conveyors and gravity roller conveyors.