- InterProcess Sp. z o.o.
Bulk Bag Filling Stations — Dust-Free FIBC Filling
Bulk bag filling stations (FIBC fillers) of the BSA series deliver efficient, dust-free filling of flexible intermediate bulk containers with minimal operator involvement. Each station is custom-configured to suit the client’s requirements — product characteristics, target throughput, bag type and site conditions. The design ensures dust-free operation through an inflatable spout seal or a mechanical clamp, while an integrated dust collection system protects operators and the surrounding environment.
We offer two station models: BSA-V1 (standard design) and BSA-V2 (advanced, featuring automatic bag lifting and quick-release hook system). Both models can be integrated with screw,vibratory and belt feeders, pneumatic conveying systems, weighing systems and process control and visualisation systems. Constructed from AISI 304 or 316L stainless steel, optionally compliant with food-grade standards (FDA, EHEDG), pharmaceutical requirements (GMP) and suitable for explosive atmospheres (ATEX).
BSA Model Comparison
The choice of model depends on the degree of process automation, the required throughput and the method of removing filled bags. Both models share the same optional equipment — the difference lies in the level of bag-handling automation:
| Parameter | BSA-V1 | BSA-V2 |
|---|---|---|
| Design type | Standard, stationary | Advanced, with automation |
| Bag suspension | 4 loop hangers on frame — manual | 4 loop hangers + automatic quick-release hooks |
| Bag lifting | — | Recommended option — tensions the bag and optimises filling |
| Roller conveyor system | — | Compatible with automatic roller conveyor |
| Spout sealing | Inflatable spout seal or mechanical clamp | Inflatable spout seal or mechanical clamp |
| Weighing system | Optional (platform scale, OIML R61 legal-for-trade certification) | Optional (platform scale, OIML R61 legal-for-trade certification) |
| Vibration densification | Optional | Optional |
| Bag pre-inflation | Optional — air inflation | Optional — air inflation |
| Max. load capacity | 2000 kg | 2000 kg |
| Material of construction | Carbon steel / AISI 304 / 316L | Carbon steel / AISI 304 / 316L |
| ATEX version | Optional | Optional |
| Typical application | Lower-throughput lines, manual operation | Automated lines, high throughput |
BSA-V1 — Standard Bulk Bag Filling Station
The BSA-V1 is a proven, stationary design for manual bulk bag filling. The operator hangs an empty bag on four loop hangers within the frame, pulls the bag spout over the fill spout and starts the filling process. A tight connection between the bag and the fill spout — provided by an inflatable spout seal or a mechanical clamp — ensures dust-free operation.
Material is conveyed into the bag via any suitable feeder — screw, belt or vibratory. The station can be equipped with a platform scale with automatic material cut-off once the target weight is reached (with optional OIML R61 legal-for-trade certification as an automatic weighing instrument). After filling, the bag is removed from the frame and collected by forklift truck.
BSA-V1 Specifications: height 2000–3000 mm, width × length 1210 × 1445 mm, max. bag width 1000 mm, max. bag height 2000 mm, max. load capacity 2000 kg.
BSA-V2 — Advanced Filling Station With Automatic Bag Lifting
The BSA-V2 is an advanced design intended for more automated bulk bag filling lines. Unlike the BSA-V1, the V2 model is designed to work with an automatic roller conveyor system for removing filled bags — once filling is complete, the bag is automatically transported on a pallet to the palletising zone or warehouse. The station is equipped with automatic quick-release hooks that speed up the detachment of filled bags and reduce cycle times.
As a recommended option, we offer a bag lifting system that tensions the bag during the initial filling phase — this helps to fill the bag more efficiently, ensuring even material distribution. This solution minimises operator involvement to hanging the empty bag and pulling the spout over the fill head, while the remainder of the process is handled automatically.
Optional Equipment and Integration
Thanks to their modular design, BSA filling stations can be fitted with a range of ancillary equipment that enhances the efficiency, accuracy and safety of the filling process:
Sealing and Dust Collection
Inflatable spout seal or mechanical clamp, dust collection system with filter, air-inflation bag pre-forming system (shapes the bag with air prior to filling).
Weighing and Dosing
Platform scale with automatic material cut-off, legal-for-trade certification as an automatic weighing instrument (OIML R61), vibration densification table for material distribution, automatic sampling system.
Safety and Control
Rare earth magnetic separator or metal detector, ATEX-compliant design (Zone 21/22), materials conforming to FDA requirements and EHEDG guidelines, process control and visualisation system.
How Does the Bulk Bag Filling Process Work?
1️⃣ Bag Preparation
An empty bulk bag is hung on the loop hangers of the frame. The bag spout is pulled over the fill spout and sealed with an inflatable spout seal or a mechanical clamp. Optionally, the bag is pre-inflated with air to form its shape before filling.
2️⃣ Filling and Weighing
Material is fed into the bag by a conveyor or feeder. The weighing system monitors the mass — once the target weight is reached, the automated controls cut off the material flow. A vibration densification table ensures even product distribution within the bag.
3️⃣ Bag Removal
The spout seal is released, the bag is detached from the frame (BSA-V1: manually / BSA-V2: automatic quick-release hooks) and removed by forklift truck or by an automatic roller conveyor to the palletising zone.
Frequently Asked Questions (FAQ)
The bag spout is pulled over the fill spout and sealed tightly using an inflatable pneumatic spout seal or a mechanical clamp. This ensures that the material is discharged directly into the bag without contact with the surrounding environment. In addition, the station can be fitted with a dust collection system with a filter to capture any dust generated during the filling process.
The BSA-V1 is a stationary design with manual operation — ideal for lower-throughput lines where the filled bag is removed by forklift truck. The BSA-V2 is a more advanced design suited to automated filling lines — it features automatic quick-release hooks, integrates with roller conveyors, and offers a recommended bag lifting system that tensions the bag for optimal filling. Both models share identical optional equipment (platform scale, vibration densification, inflatable spout seal, ATEX). Our engineers will recommend the right model following a thorough process analysis.
Yes — every station is custom-engineered to order. The modular design allows us to adjust the height, frame width, loop hanger type, fill spout diameter and sealing system to match the specific type and dimensions of the bulk bag. We accommodate bags up to 1000 mm wide, 2000 mm tall and weighing up to 2000 kg. For non-standard bag sizes, please complete our technical questionnaire.
Yes — the BSA station can be equipped with a platform scale featuring automatic material cut-off once the target weight is reached. On request, the weighing system can be certified as a legal-for-trade automatic weighing instrument in accordance with OIML R61 — a requirement when material is sold by weight. Weighing accuracy and system parameters are individually tailored to the specific product characteristics.
Yes — both BSA models are available in an ATEX-compliant version designed for use in hazardous dust and gas atmospheres (Zone 21/22). The design includes appropriate seals, antistatic earthing, certified electrical components and certification in accordance with Directive 2014/34/EU. On request, we also manufacture stations from materials compliant with FDA requirements and EHEDG guidelines for the food and pharmaceutical industries.
Looking for a Bulk Bag Filling Station?
Get in touch — we will design a filling station tailored to your product, bag type and required throughput. Complete the technical questionnaire or arrange a consultation with one of our engineers.
Why Choose Our Solutions?
Dust-free filling – inflatable spout seal, dust collection system, bag pre-inflation
Modular design – platform scale, vibration densification, sampling, quick-release hooks, bag lifting, roller conveyor
Custom-engineered – every station is tailored to the bag type and process requirements
Multi-industry experience – food, chemical, pharmaceutical, construction
Safety and hygiene – ATEX, FDA, EHEDG and GMP-compliant designs
Technical support and service – rapid response, spare parts, 24/7 availability