Solutions & Stories

1. Industry Context & Pain Points

The health supplements, protein powder, and nutraceutical industry is growing rapidly, yet manufacturers face significant and common challenges:

• Stringent Hygiene & Safety Requirements: Products are for human consumption, demanding production environments, equipment materials, and cleaning protocols that meet strict food-grade or even pharmaceutical-grade standards.

• Complex, Multi-Step Packaging Processes: Operations involve filling, inserting spoons/scoops, adding desiccants, sealing, and labeling. Manual handling is inefficient, error-prone, and drives up labor costs.

• Need for Flexible Production: Market trends require agility—short runs, multiple product variants, and custom packaging. Production lines must switch quickly between different can sizes, fills, and labels.

• Demand for Traceability: Consumers and regulators require clear visibility into batch numbers, production dates, and ingredient sourcing.

• Pressure to Control Costs: Rising labor expenses, material waste reduction, and energy efficiency are constant concerns for operational management.

2. Boan Machinery Integrated Smart Packaging Line Solution

To address these challenges, Bao'an Machinery offers a complete, start-to-finish smart packaging line solution integrating 16 automated units. Our "Clean-Fill-Seal-Label-Pack-Palletize" system enables fully unmanned, closed-loop production from empty container feeding to finished pallet output, helping you build a highly efficient, clean, and intelligent packaging operation.

Detailed Process Flow

1. Front-End Pre-Processing: Ensuring Container Cleanliness

• Intelligent Unscrambler: Automatically orients and aligns empty containers from a bulk supply, feeding them singularly and orderly onto the conveyor. Features a buffer system to prevent jamming (Capacity: up to 120 BPM).

• Pneumatic Cleaning Machine: Containers are inverted, and multiple high-pressure air jets perform non-contact blow-off cleaning to remove dust and particles, ensuring internal cleanliness before filling (Speed: 20-30 BPM).

2. Precision Filling & Component Insertion: Accurate Product Handling

• Servo-driven Screw Filler: Utilizes a precision auger system with dynamic weighing for accurate filling of powders like protein. Fill range: 10-5000g with high accuracy (±0.5%). All product contact parts are 304 stainless steel.

• Dual Vibratory Bowl Feeder System:

  • Feeder 1: Orients and inserts spoons/scoops.

  • Feeder 2: Orients and inserts desiccant packets.

  • Both systems synchronize seamlessly with the filling rhythm via sensors and guide rails.

3. Sealing & Identification: Secure Closure and Branding

• High-Speed Capping Machine: Integrates cap sorting, feeding, and screw-capping. Servo-controlled for adjustable torque, suitable for various round, square, or flat containers (Speed: 50-60 BPM).

• Electromagnetic Induction Sealer: Creates an airtight foil seal by generating instantaneous heat. Includes an automatic detection and rejection system for containers missing foil or with poor seals (Line Speed: up to 30 BPM).

• High-Precision Container Labeler: Applies pressure-sensitive labels to round containers (Φ35mm–Φ95mm) with accuracy within ±1mm. Capable of high speeds (up to 200 BPM) and full line synchronization.

4. Secondary Packaging & Logistics: Ready for Distribution

• Automatic Case Erector/Packer/Sealer System: Forms corrugated cases, arranges and loads containers, and applies adhesive in "I" or "H" patterns.

• Case Labeler: Automatically prints and applies shipping labels, product info, or traceability codes to the outer case.

• Automatic Strapping Machine: Applies plastic or steel straps around sealed cases for transport stability.

• Robotic Palletizer: Stacks finished cases onto pallets in pre-programmed, stable patterns. Can be integrated with AGVs or conveyors for direct transfer to warehousing.

5. Complete Line Integration & Control

• Modular Conveyor System: Custom-designed (straight or L-shaped) to ensure smooth container transfer between all stations.

• Centralized Control System: The entire line is managed by a PLC with an industrial HMI (Touchscreen). Enables single-point control, parameter setting, production counting, fault diagnosis, and offers connectivity for data collection and MES integration.

3. Key Advantages & Value Proposition

• Superior Production Flexibility: Adjustable mechanisms and parameterized controls allow quick changeovers between various container heights (30-180mm), diameters (20-80mm), and cap types, ideal for high-mix, low-volume production.

• End-to-End Food-Grade Safety: Constructed with 304 (or optional 316L) stainless steel on all product contact surfaces. Smooth, crevice-free designs facilitate easy cleaning and comply with GMP/HACCP guidelines.

• High Intelligence & Reliability: Core stations feature servo drives, PLC control, and premium components (Delta, Schneider, Autonics, etc.), ensuring precision, stability, and extended uptime.

• Tangible Cost Savings & Efficiency Gains: Full automation can reduce direct labor by over 70%, increase overall packaging efficiency by 40-60%, and minimize product giveaway from human error.

• Modular & Scalable Design: Solutions can be implemented in phases to match budget and facility constraints. Future-ready for adding modules like vision inspection, checkweighing, or robotic pick-and-place.

4. Typical Configuration (Protein Powder Example)

5. Boan Machinery Support Ecosystem

1. Pre-Sales Consulting & Planning: Engineers provide site assessment, capacity analysis, and line layout design.

2. Custom Design & Manufacturing: Equipment is adapted to your specific container, product, and label specifications.

3. Installation, Commissioning & Integration: We provide turnkey installation, synchronization, and performance optimization.

4. Comprehensive Training: We train your operational and maintenance staff and provide full technical documentation.

5. After-Sales & Ongoing Support: We offer remote technical support, preventative maintenance plans, spare parts supply, and upgrade services.

6. The Outcome: Enhanced Competitiveness

By implementing a Boan Machinery Smart Packaging Line, your business will achieve:

• Superior Product Quality: Automated processes ensure consistent fills, reliable seals, and professional presentation.

• Transparent, Traceable Production: Automated data collection provides a foundation for quality traceability and lean manufacturing initiatives.

• Strengthened Market Position: You gain the ability to respond faster to market opportunities with lower unit costs and higher quality standards.