Packaging & Storage Line — Equipment Specification
1. Process Objective
Package finished flaxseed oil, whole seed, meal, and gum powder into consumer-ready and bulk formats at a sustained line rate of 600 bph (bags/hr, VFFS) while maintaining product quality through controlled-atmosphere packaging and in-line contaminant detection. All packages achieve O₂ headspace ≤ 2 % (N₂ flushed), weight accuracy ± 2 g (consumer packs), and are 100 % screened for metal and physical contaminants. This station is designated CCP-5 (Critical Control Point — Metal Contaminants & Package Integrity).
2. Equipment Configuration & Flow Diagram
Dry Product (seed, meal, gum powder) Oil Product
│ │
▼ ▼
[ Bulk Filler ] → (FIBC / 1 MT) [ Pump / Holding Tank ]
│ │
▼ ▼
[ Bag Filler ] → (10–25 kg bags) [ Drum Filler ] → (20–200 L drums)
│ (N₂ headspace purge)
▼
[ VFFS Machine ] ← (roll-stock film, 600 bph)
│
▼
[ N₂ Flush Tunnel ] → Bag sealing (O₂ ≤ 2 %)
│
▼
[ Checkweigher ] → Reject (± 2 g tolerance)
│
▼
[ Metal Detector ] → Reject (Fe 0.5 / NF 0.7 / SS 1.0 mm)
│
▼
[ X-Ray Inspection ] → Reject (glass, stone, dense plastic)
│
▼
[ Date Coding / Labelling ]
│
▼
[ Case Packer / Palletiser ]
│
▼
[ Finished Goods Warehouse (ambient, 15–25 °C, RH ≤ 60 %) ]
3. Equipment Specifications
| Parameter |
Value |
| Type |
Intermittent-motion VFFS (bag-in-box / stand-up pouch) |
| Line speed |
600 bph (10 bags/min, max 70 bpm) |
| Bag size (L × W) |
150 – 400 mm × 100 – 300 mm |
| Film width |
250 – 650 mm |
| Film material |
Laminate (PET/Al/PE, PET/met-PE) |
| Fill volume |
100 g – 5 kg |
| Fill accuracy |
± 2 g (via servo-driven auger / volumetric cup + checkweigh feedback) |
| Sealing |
Dual jaw, serrated + flat, temp. control ± 2 °C |
| Sealing temperature |
140 – 200 °C (depending on film) |
| Gas flushing |
Integral N₂ purge lance (post-fill, pre-seal) |
| Control |
10" HMI + PLC (Ethernet/IP) |
| Material (contact) |
SS316 (auger, cup, funnel); SS304 (frame) |
| Air consumption |
200 L/min @ 6 bar(g) |
| Ex-proof |
Zone 22 rated for combustible dust (powder filling) |
3.2 Bag Filler (10–25 kg)
| Parameter |
Value |
| Type |
Open-mouth bag filler, gravity + auger trim |
| Capacity |
6 – 8 bags/min (25 kg) |
| Weight range |
5 – 50 kg |
| Accuracy |
± 50 g (gross weigh) |
| Bag type |
Woven PP, paper, or PE liner |
| Stitching |
Sewn closure with tape (DS-9C head) |
| Material |
SS304 contact |
3.3 Bulk Filler (FIBC / Big Bags)
| Parameter |
Value |
| Type |
Ganries / weigh-frame, vibratory densification |
| Capacity |
10 – 15 bags/hr (1 000 kg FIBC) |
| Weight range |
500 – 1 500 kg |
| Accuracy |
± 0.5 kg |
| Filling spout |
Inflatable seal + dust extraction |
| Loop handling |
Auto loop hang / release |
| Pallet base |
Integrated fork-pockets for conveyor |
| Material |
SS304 (contact), carbon steel (frame) |
3.4 Drum Filler (Oil)
| Parameter |
Value |
| Type |
Automatic net-weight drum filler |
| Capacity |
15 – 20 drums/hr (200 L / 180 kg oil) |
| Drum sizes |
20 L pail – 200 L drum |
| Fill accuracy |
± 0.1 kg |
| Fill lance |
Sub-surface, rising level (minimise aeration) |
| N₂ purge |
Headspace purge to O₂ ≤ 2 % pre-seal |
| Tare/bulk/trim cycles |
3-stage: 95 % bulk → 99 % dribble → 100 % trim |
| Material |
SS316 (all wetted surfaces) |
| Drum handling |
Conveyorised — auto-index, centring, lid placement |
| Ex-proof |
Zone 1 rated (drum filler area, oil mist) |
3.5 N₂ Flush Tunnel
| Parameter |
Value |
| Type |
Conveyorised tunnel, pre-heated N₂ (blanket + jet) |
| Conveyor width |
400 mm |
| Tunnel length |
3 000 mm |
| N₂ flow |
50 – 100 Nm³/hr (VFD controlled) |
| N₂ purity |
99.9 % (from PSA generator) |
| Residual O₂ target |
≤ 2 % (CCP-5 limit) |
| O₂ monitoring |
In-line paramagnetic sensor (1 per zone) |
| Temperature control |
Ambient – 40 °C (optional heated N₂ for oil) |
| Exhaust hood |
Integrated, to atmosphere |
| Air curtain |
Inlet / outlet air curtain to minimise N₂ loss |
| Material |
SS304 tunnel + PTFE belt |
3.6 Checkweigher
| Parameter |
Value |
| Type |
Dynamic in-motion, load cell (EMFR) |
| Conveyor speed |
Up to 80 m/min |
| Weight range |
50 g – 5 kg (VFFS packs) |
| Accuracy |
± 0.5 g (3σ at 600 bph) |
| Reject |
Pneumatic pusher / air-blast (lateral) |
| Displays |
Running average, trend, histograms |
| Feedback |
Auto-tare compensation to VFFS filler |
| Washdown |
IP65 (hygienic design) |
| Parameter |
Value |
| Type |
Balanced-coil, multi-frequency |
| Aperture size |
300 mm × 150 mm (W × H) |
| Detection limits |
Fe: 0.5 mm / NF: 0.7 mm / SS 316: 1.0 mm |
| Frequency |
Auto-tune (50 – 800 kHz) |
| Product effect |
Auto-learn / auto-balance |
| Reject |
Pneumatic pusher (same as checkweigher reject line) |
| Conveyor speed |
Matched to line (up to 80 m/min) |
| Data logging |
Event log with product image + time stamp |
| Standards |
HACCP / BRC / IFS compliance ready |
| Washdown |
IP65 (hygienic) |
3.8 X-Ray Inspection System
| Parameter |
Value |
| Type |
Dual-energy X-ray (DX-ray) |
| Generator |
160 kV / 1.5 mA, air-cooled |
| Detector |
Linear diode array (0.4 mm pitch) |
| Conveyor width |
500 mm |
| Throughput |
Up to 80 m/min |
| Detection capability |
Metals: Fe ≥ 0.3 mm, SS ≥ 0.4 mm — Glass: ≥ 0.5 mm — Stone: ≥ 1.0 mm — Dense plastic: ≥ 2.0 mm |
| Reject |
Pneumatic pusher + confirmation sensor |
| Software |
Real-time image processing; zone-based algorithm |
| Safety |
Lead shielding — < 1 µSv/hr at surface |
| Data logging |
Full image archive (30 days) |
| Standards |
GFSI, BRC, IFS |
3.9 Date Coder / Labeller
| Parameter |
Value |
| Date coder type |
Thermal inkjet (TIJ) / laser |
| Print area |
Up to 50 mm × 25 mm |
| Print speed |
Up to 100 m/min |
| Labeller type |
Roll-fed wraparound + top label (optional) |
| Labeller speed |
Up to 80 labels/min |
3.10 Case Packer / Palletiser
| Parameter |
Value |
| Case packer type |
Pick-and-place (3-axis servo) |
| Cases per min |
8 – 12 |
| Palletiser type |
Low-level robotic gantry (4-axis) |
| Pallet load |
Up to 1 200 kg |
| Stretch wrapper |
Rotary arm, pre-stretch 250 % |
| Format |
Unit Size |
Packaging Material |
Throughput |
| Retail pouch |
250 g – 1 kg |
PET/Al/PE laminate |
600 bph (VFFS) |
| Stand-up pouch |
500 g – 2 kg |
Stand-up gusseted, zipper |
400 bph |
| Bag-in-box |
5 – 20 kg |
PE liner + corrugated |
12 bpm |
| Consumer drum |
20 L (18 kg oil) |
HDPE / steel |
15 – 20 drums/hr |
| Industrial drum |
200 L (180 kg) |
Steel (epoxy-lined) |
15 – 20 drums/hr |
| Bag (woven) |
10 – 25 kg |
PP woven + PE liner |
6 – 8 bags/min |
| FIBC |
500 – 1 500 kg |
PP bulk bag |
10 – 15 bags/hr |
| Metric |
Target |
Monitoring Method |
| Line speed (VFFS) |
600 ± 20 bph |
PLC cycle counter |
| Fill weight accuracy (VFFS) |
± 2 g (≤ 1 kg pack) |
Checkweigher (100 %) |
| Fill weight accuracy (drum) |
± 0.1 kg |
Filler load cell |
| Headspace O₂ (CCP-5 limit) |
≤ 2 % |
In-line paramagnetic O₂ sensor |
| Metal detector sensitivity (Fe) |
0.5 mm (CCP-5) |
Daily test with test sticks |
| X-ray: glass / stone detection |
≥ 99.9 % rejection at 0.5 mm |
Weekly challenge test |
| Package seal integrity |
≤ 0.1 % leakers |
Vacuum decay / burst test (hourly) |
| N₂ consumption |
≤ 100 Nm³/hr |
Flowmeter |
| Overall equipment effectiveness |
≥ 85 % |
OEE dashboard (downtime + speed + quality) |
6. HACCP — CCP-5 Integration
| CCP |
Hazard |
Critical Limit |
Monitoring |
Corrective Action |
| 5a |
Metal contamination → physical hazard |
Fe ≥ 0.5 mm, NF ≥ 0.7 mm, SS ≥ 1.0 mm |
Continuous MD; test sticks hourly |
Isolate and re-inspect rejected product; investigate source; recalibrate MD |
| 5b |
Headspace O₂ > 2 % → oxidative rancidity |
O₂ ≤ 2 % in finished pack |
In-line O₂ sensor (every pack or every 30 sec) |
Reject affected packs; check N₂ supply / tunnel seals; adjust N₂ flow |
| 5c |
Glass / dense contam. > 0.5 mm |
No detectable glass, stone, or dense plastic ≥ 0.5 mm |
X-ray (100 % of packs) |
Reject; quarantine preceding 30 min; root cause investigation |
| 5d |
Weight underfill |
Net weight ≥ label declared (T1/T2 per weights & measures) |
Checkweigher (100 %) |
Auto-reject underweight; trim feedback to VFFS filler |
7. Maintenance Schedule
| Component |
Frequency |
Activity |
| VFFS sealing jaws |
Daily |
Clean residue; check Temp. accuracy; inspect serration |
| VFFS film unwind |
Weekly |
Check dancer arm, unwind brake |
| VFFS auger / cup |
Per product change |
Dismantle and clean; verify fill weight |
| N₂ tunnel O₂ sensor |
Daily |
Zero & span calibration |
| Checkweigher load cell |
Weekly |
Calibrate with certified weight set |
| Metal detector |
Every 30 min |
Test with Fe/NF/SS test sticks (per BRC/BRCGS protocol) |
| X-ray detector |
Weekly |
Clean diode array; run daily self-test + weekly challenge |
| X-ray generator |
Semi-annual |
Replace cooling oil; anode inspection |
| Drum filler lance seals |
500 cycles |
Replace PTFE seals |
| Drum filler N₂ valve |
Monthly |
Clean and function test |
| Case packer grippers |
Monthly |
Inspect suction cups / mechanical fingers |
| Palletiser |
Quarterly |
Check chain tension; lubricate linear guides |
| Stretch wrapper |
Semi-annual |
Replace pre-stretch belts; calibrate tension |
8. Spare Parts Inventory (Minimum Stock)
| Part |
Qty |
Supplier Reference |
| VFFS sealing jaw (serrated) |
2 |
VFFS-SJ-400 (OEM) |
| VFFS film cutter blade |
5 |
VFFS-FCB-650 |
| N₂ O₂ sensor cell (paramagnetic) |
1 |
O2-PM-CELL |
| Checkweigher load cell |
1 |
CW-LC-30KG |
| Metal detector test sticks |
1 set |
MD-TEST-FE/NF/SS |
| MD reject pusher solenoid |
2 |
MD-SOL-PN |
| X-ray diode array segment |
1 |
XR-DIODE-0.4MM |
| Drum filler PTFE seal kit |
2 |
DF-SEAL-KIT |
| Drum filler fill lance |
1 |
DF-LANCE-316 |
| Case packer suction cup |
20 |
CP-SCUP-30 |
| N₂ tunnel air curtain fan |
1 |
NT-FAN-400 |
9. Utility Requirements
| Utility |
Connection |
Peak Demand |
| Electrical |
400 V, 3-phase, 50 Hz |
45 kVA |
| N₂ |
4 bar(g), 99.9 % |
100 Nm³/hr |
| Compressed air |
6 bar(g), oil-free |
500 L/min (VFFS, rejectors, case packer) |
| Dust extraction |
2 000 m³/hr @ −1.5 kPa |
Bulk fill + bag filler points |
10. Safety & Compliance
- ATEX Zone 22: VFFS area (gum/meal powder); bag filler station; bulk filler dust extraction.
- ATEX Zone 1: Drum filler station (oil mist zone).
- X-ray safety: Annual survey per UK HSE IRR17 / US FDA 21 CFR 1020.40 — public limit < 1 µSv/hr at 10 cm.
- Metal detector: Self-test log maintained for BRC / GFSI audits; MD belt interlocked to reject gate.
- LOTO: Checkweigher belt drive, VFFS seal jaw servo, drum filler indexing, X-ray conveyor.
- PPE: Cut-resistant gloves for film handling; ear plugs (> 85 dB(A) in case packer area); dosimeter badges for X-ray area.
- Weights & Measures: All checkweighers verified to Class X(1) accuracy with traceable standards (monthly).
11. Warehouse Storage Conditions
| Parameter |
Target |
Monitoring |
| Ambient temperature |
15 – 25 °C |
Data-logger (hourly) |
| Relative humidity |
≤ 60 % |
Hygrometer (continuous) |
| FIFO / FEFO |
By production date |
WMS (barcode scan) |
| Pest control |
IPM programme (monthly) |
External contractor |
| Inventory system |
Real-time WMS |
SAP / ERP integration |
Document Owner: Process Engineering Manager
Revision: 1.0
Date: 2026-07-20
CCP-5 Validated: Production Manager / HACCP Team