InterProcess Sp. z o.o. | Rozwiązania dla przemysłu
Big bag systems · Bag filling
BSA big bag filling stations
Dust-free filling of FIBCs weighing up to 2000 kg. Two levels of automation, BSA-V1 and BSA-V2, configured individually: a sealed bag spout, a dust collection system, weighing with OIML R61 legal-for-trade approval, and full integration with the line’s control system.
Dust-free FIBC filling
Contained filling with minimal operator involvement
BSA series big bag (FIBC) filling stations deliver efficient, dust-free filling of large-format bags. Every station is configured individually, around the properties of the product, the throughput required, the type of bag and the ambient conditions. Dust-free operation comes from an inflatable spout seal or a mechanical clamp, while an integrated dust collection system protects the operator and the surrounding area.
The stations work alongside screw, vibratory and belt feeders, pneumatic conveying, weighing systems and process control and visualisation systems. They are built from powder-coated carbon steel or from 1.4301 (AISI 304) and 1.4404 (AISI 316L) stainless steel, optionally to food-grade standards (FDA, EHEDG), pharmaceutical requirements (GMP) and in an ATEX version. The range is completed by our big bag emptying stations.
2000 kgmaximum load capacity of the bag being filled
up to 2500 mmmaximum bag height, width to suit, chosen freely
OIML R61optional legal-for-trade approval of the weighing system as an automatic weighing instrument
The BSA station family
BSA-V1 · BSA-V2
BSA stations in service — click to enlarge
The BSA family comprises two models with identical equipment options, differing in how far bag handling is automated. The empty bag is hung on four loop hangers on the frame, and its spout is pulled over the station’s filling spout and sealed tight, the material passes straight into the bag, with no contact with the surroundings.
Material can be delivered by any conveyor, screw, belt or vibratory. A platform scale with automatic control shuts off the supply of material once the target mass is reached, and a vibrating compactor spreads the material evenly and makes full use of the bag’s volume.
Key BSA specifications
- Load capacity
- up to 2000 kg
- Bag dimensions
- height up to 2500 mm, any width, the frame is matched to the bag
- Station height
- 2000–3000 mm (footprint 1210 × 1445 mm)
- Spout sealing
- inflatable spout seal or mechanical clamp
- Weighing system
- platform scale with automatic shut-off, optional OIML R61 legal-for-trade approval
- Materials
- powder-coated carbon steel, 1.4301 (AISI 304) or 1.4404 (AISI 316L) stainless steel
- Dust collection
- dust collection system with a filter, bag pre-inflation with compressed air
- Options
- vibrating compactor, metal detector, sampling, ATEX 21/22, FDA and EHEDG builds
Downloads
BSA-V1 vs BSA-V2
Which model should you choose?
The choice of model depends on how far the process is automated, the throughput required and the way filled bags are taken away. Both models have identical equipment options, they differ only in how far bag handling is automated.
| Parameter | BSA-V1 standard | BSA-V2 automation |
|---|---|---|
| Design type | standard, stationary | advanced, with automation |
| Bag suspension | 4 loop hangers on the frame, manual | 4 loop hangers and automatic quick-release hooks |
| Bag lifting | — | ✓ recommended option, tensions the bag and optimises filling |
| Roller conveyor system | — bag taken away by forklift | ✓ works with an automatic roller conveyor |
| Spout sealing | inflatable seal or clamp | inflatable seal or clamp |
| Weighing system | optional (platform scale, OIML R61) | optional (platform scale, OIML R61) |
| Vibrating compactor and pre-inflation | optional | optional |
| Max. load capacity | 2000 kg | 2000 kg |
| Material and ATEX | carbon steel / AISI 304 / AISI 316L · ATEX optional | carbon steel / AISI 304 / AISI 316L · ATEX optional |
| Typical application | lower-throughput lines, manual operation | automated lines, high throughput |
BSA-V1: standard filling station
A proven, stationary design for manual bag filling. The operator hangs the empty bag on four loop hangers on the frame, pulls the spout over the filling spout and starts the fill. A tight connection between bag and spout, by inflatable seal or mechanical clamp, keeps the operation dust-free.
The station can be fitted with a platform scale whose automatic control shuts off the supply of material once the target mass is reached (with optional OIML R61 legal-for-trade approval). Once filled, the bag is lifted off the frame and taken away by forklift or pallet truck.
Specification: height 2000–3000 mm · footprint 1210 × 1445 mm · bag height up to 2500 mm · load capacity 2000 kg.
BSA-V2: station with automatic bag lifting
An advanced design for automated filling lines. The BSA-V2 works with an automatic roller conveyor system, the filled bag travels on its pallet to the palletising area or the warehouse, with no forklift involved.
Automatically released slings (quick-release hooks) shorten the cycle time, and the recommended bag-lifting arrangement tensions the bag during the first phase of filling, helping the material spread evenly and making better use of the volume of the container.
Key features: automatic hooks · roller conveyor · bag lifting · integration with the weighing system, the compactor and the line’s control system.
Modular design
Optional equipment and integration
Sealing and dust collection
A twin-channel filling head, the inner channel delivers the product, the outer one draws dust-laden air away to a filter. An inflatable spout seal or mechanical clamp, plus bag pre-inflation with compressed air, including bags with a polyethylene liner.
Weighing and dosing
A platform scale with two-stage dosing, coarse and fine. OIML R61 legal-for-trade approval as an automatic weighing instrument, a vibrating compactor to de-aerate and densify the product, and automatic sampling.
Safety and control
A rare-earth magnetic separator or metal detector, an ATEX build (zone 21/22), materials compliant with FDA and EHEDG, and integration with the line’s control and visualisation system.
Operating cycle
How does the big bag filling process work?
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STEP 01
Bag preparation
The empty bag is hung on the loop hangers on the frame. The spout is pulled over the filling spout and sealed with an inflatable seal or a clamp. Optionally, the bag is pre-inflated with compressed air.
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STEP 02
Filling and weighing
Material is delivered by conveyor in a two-stage cycle: fast coarse dosing, then precise fine dosing as the target mass approaches. The controls shut off the supply of material, and the vibrating compactor de-aerates and densifies the product.
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STEP 03
Bag removal
The spout seal is released and the bag is lifted off the frame, by hand (BSA-V1) or by automatic quick-release hooks (BSA-V2), and taken away by truck or by roller conveyor to the palletising area. A densified, evenly filled bag makes a stable load, safe to store and transport.
FAQ
Frequently asked questions
How is dust-free operation ensured during filling?
The spout of the big bag is pulled over the station’s filling spout and sealed tight, either with a pneumatic inflatable seal or with a mechanical clamp. The material therefore passes straight into the bag, with no contact with the surroundings. The station is also fitted with a dust collection system with a filter, which captures the dust generated during filling.
Which model should I choose: BSA-V1 or BSA-V2?
The BSA-V1 is a stationary, manually operated design, well suited to lower-throughput lines where the bag is taken away by forklift. The BSA-V2 is built for automated lines: it has automatic quick-release hooks, works with a roller conveyor, and we offer a bag-lifting arrangement as a recommended option. Both models have identical equipment options (weighing, compactor, seal, ATEX). Our engineers will help you choose the model once they have looked at the process.
Can the station be adapted to non-standard bag sizes?
Yes, every station is designed individually. The modular construction allows the height, the width of the frame, the type of hangers, the diameter of the filling spout and the sealing system to be adapted to a particular type of bag. We handle bags up to 2500 mm high and 2000 kg in weight, bag width is not restricted, as the frame is matched to its dimensions. For non-standard bags, please fill in the technical questionnaire.
Can the station operate as a legal-for-trade automatic weighing instrument?
Yes, the BSA station can be fitted with a platform scale that shuts off the supply of material automatically once the target mass is reached. On request, the weighing system is approved as an automatic weighing instrument in accordance with OIML R61 recommendation, which is required where material is sold by weight. The accuracy and the parameters of the system are matched to the product.
Can the station operate in an explosive atmosphere?
Yes, both BSA models are available in an ATEX build for work in areas with a dust explosion hazard (zone 21/22). The build covers the appropriate seals, antistatic earthing, certified electrical components and documentation compliant with Directive 2014/34/EU. On request we use materials compliant with FDA requirements and EHEDG recommendations.
Why InterProcess
Why choose our solutions?
Dust-free filling
Inflatable spout seal, dust collection system, bag pre-inflation.
Modular design
Weighing, compactor, sampling, hooks, bag lifting, roller conveyor.
Individual design
Every station is matched to the type of bag and the nature of the process.
Experience across many industries
Food, chemical, pharmaceutical and construction.
Safety and hygiene
ATEX, FDA, EHEDG and GMP builds.
Technical support and service
Rapid response, spare parts availability, 24/7 cover.
Looking for a big bag filling station?
Get in touch, we will design a station to suit your product, your type of bag and the throughput you need. Fill in the technical questionnaire or arrange a call with one of our engineers.