Packaging Machinery Controls and Upgrades

Thompson Scale has provided improvements to company's existing packaging machinery controls for almost 20 years. Whether it is putting product in bags, boxes, tubs, totes, drums, or bulk bags, we can provide highly integrated yet simple to use fill controls to improve the operation and accuracy of your packaging machinery.

Thompson Scale is the only company to offer filler controls specifically designed to operate this type of machinery. Others may say they can control your packaging machinery, but virtually all of these controls are basic weigh meters with some additional PLC or other type of programming, and in the end, are nothing more than weigh meters. Take a look at our section on Universal Filler Controls. Thompson Scale offers the finest scale controls around. Not only do we offer a wide variety of new packaging machinery controls and systems, but we have many years experience in upgrading customer's existing equipment.

In particular, we have gained a wealth of knowledge in bag packaging machinery controls. The Model 4693 Pneumatic Filler Upgrade Literature briefly describes what is involved in upgrading this type of equipment. There are thousands of valve bag filling machines across North America, ranging from Air, Atmospheric, Impeller, and Auger, with many still in their original all-mechanical condition. Others have either been purchased with some form of controls, or have been modified to provide electronic control, but still lack the accuracy and performance many customers require.

Even though you may believe the cost of your product verses the cost of upgrading your machinery doesn't justify the upgrade, you will be quite surprised at just how quickly you can recover the cost and how much of an improvement the filler upgrade makes to overall production and product weight accuracy.

Filler Upgrade Features:

• Microprocessor Controlled
• Exclusive Compact Load Cell Flexure Assembly
• Eliminates all Knife Edges and Counterweights
• Interfaces to Virtually Any Placer, Hangar, or Robot
• Complete Control of all Filler Equipment I/O, no PLC required
• Requires Only the Target Weight to be Set, the controller handles the rest
• Bulk, Dribble, and Preact Settings are Automatically Calculated Internally. Manual mode is also available for more control
• Modular Design Allows for Easy Trouble Shooting and Service
• Single 4693 Controller is Capable of Operating Two Adjacent Spouts Simultaneously, yet completely independently. This provides simple system integration and lower equipment cost
• Use of Thompson Scale’s unique Traffic Control Feature allows up to four spouts on a common production line to be operated by two 4693 controllers. Controls are "networked" via the Traffic Control card, and allow complete control of bag drops, increasing production rates and eliminating bag jams
• Password Protected for Added Security to protect calibration and configuration settings
• Automatic Compensation for Changes in Product Bulk Density
• Auto-Start for All Spouts
• Stop and Stop/Abort Push Buttons can terminate fills in case of blown bags or operator problems
• Full Diagnostics, Automatic Flow Rate Tracking, and Auto-Correction for changes in flow rates or bulk density
• Elimination of all Mechanical Scale Assemblies. All scale beams and pivots are replaced with state-of-the-art load cell flexures
• Elimination of all Pneumatic Control Devices. All air operated devices are driven by a new electrically controlled solenoid valve assembly housed and pre-piped in a NEMA 4X enclosure
• Auto Start and Discharge is Standard (power chairs not provided)
• Minimum Downtime is Required for Filler Modification

Types of Filler Upgrades Available

Thompson Scale Company has installed our filler upgrades to many different types of packaging equipment. Below is a list of just a few:

• Air Packers
• Impeller Packers
• Auger Packers
• Auger Packers with Open-Mouth Attachments
• Simplex and Duplex Net Weigh Scales
• Open-Mouth Gross Fillers
• Bulk Bag (IBC) Fillers
• Box Fillers (Gaylord or other brand)
• Bag-In-Box Fillers
• Liquid Fillers; drum, tote, and pail

Thompson Scale is also well versed in hazardous area applications, and can improve your production quality in areas up to Class I, Division 1, Groups B, C, or D.

Complete our filler upgrade questionnaire, providing us with information about your current system, and Thompson Scale will provide a detailed proposal for improving your production line performance.

The Thompson Model 4693 Filler Upgrade offers a number of advantages:

Mechanical or old electronic packers take at least 4 to 5 bags on each filler to "line-out" the filler and achieve acceptable weights when changing from one product or weight to another. The Thompson Model 4693 hits Target weight on the first bag or second bag! This dramatically reduces product change-over.

No more flipping trim weights around. Many old mechanical packers require the use of washers to fine adjust weight, and the operator has to pay close attention to change in bulk density and final weights, adjusting the packer many times during production. The 4693 upgrade eliminates this since our controls automatically track changes in bulk density and flow rates, and do a final Check weigh on every bag to confirm proper weight. All of this can be done without sacrificing production rates.

All existing mechanical fillers require someone to periodically check the weight of bags to insure they stay within spec. The Model 4693 displays each final fill weight, and automatically tracks changes in bulk density and flow rates. Typically we reduce rejects from the industry average of 5 to 8 percent to less than 2%!

Mechanical fillers require near-constant maintenance and care to remain relatively accurate. The Model 4693 eliminates virtually all moving scale parts and requires little to no maintenance. Calibration is usually required once a month, and that's about it.

Bag packaging machinery upgrades include three distinct equipment modifications:

1. Removal and replacement of existing mechanical counter-weights and levers, replacing them with rigid and accurate flexure load cell frames.

2. Removal and replacement of existing pneumatic controls, replacing them with electrically controlled solenoid valves and new piping.

3. Installation of electronic filler controls.

Thompson Scale sells packer upgrades in two ways:
#1. We install, start-up, and train your personnel on-site at your facility; #2. You ship your machinery to our Factory in Houston, TX and we complete the upgrade, return the equipment, and then assist you in start-up at your facility.

The on-site installation offers very competitive prices, and allows your maintenance personnel to see the installation step-by-step, learning all they need to know to properly maintain and trouble shoot the equipment. If we are honored with your order for a packer upgrade we will:

1. Travel to your facility before the installation date and meet with your maintenance and operations personnel to review the installation procedure. This allows your personnel to ask questions and become familiar with our equipment before you commit to the installation date. It also allows our technician to inspect the fillers and their placement, and gives us the opportunity to point out items that may need to be addressed before our installation crew arrives.

2. Equipment is shipped to your plant site. This equipment includes all necessary parts, supplies, and tools required for installation of the upgrade. The only items we do not provide are welding and cutting tools, which are not typically required. Once the equipment is on-site, Thompson Scale works with your personnel to schedule a convenient start date, which is typically a Tuesday or Wednesday. This allows you to get your Monday morning problems out of the way, and allows our crew to start and complete the installation before the weekend.

3. On installation day, our crew will require the assistance of one electrical and/or mechanical maintenance person from your facility. This person typically helps the job to go smoothly, and allows first-hand training on the equipment. Thompson Scale provides two (2) technicians for the duration of the installation, which typically takes two to three days for a two or three spout filler upgrade.

4. When the equipment has been installed, Thompson Scale’s technicians will test all mechanical, pneumatic, and electrical portions of the upgrade, and will run several bag’s worth of product to confirm proper operation. We will train your production personnel in the use and adjustment of the filler upgrade package. Our technicians will stay for at least one full day to insure there are no questions or problems. During this time we will also meet with your maintenance personnel to discuss proper maintenance and trouble shooting techniques, and review the operations manuals provided with the equipment.

If the Model 4693 filler upgrade is of interest, please take a few moments to complete the questionnaire found in this section of our web site. It will be automatically e-mailed to our sales department. We will review the data and prepare a formal proposal for upgrading your packaging machinery. Keep in mind that although most of this web page is dedicated to valve bag packaging machinery, we do many upgrades to all types of filling systems, liquid and dry.

• 4693 Filler Upgrade Brochure with Specs 

Complete our on-line questionnaire to receive a detailed proposal for your application. If you choose to fill out this form, Thompson Scale will provide a detailed proposal for equipment to meet your specific requirements. Be sure to include your name, company name, telephone number, and fax number so we can get in touch with you if additional information is needed.

• 4693 Filler Upgrade Questionnaire