SYSTEM FLOW 

SYSTEM FLOW — Evolution in Industrial Filling Control

SYSTEM FLOW was developed to achieve higher quality standards in bag filling systems, both in production performance and maintenance efficiency. It is a solution created from real industrial experience, designed to overcome the known limitations of conventional filling systems used for cement, mortars and other powdered or granular products.

Today, most bag filling systems used in the cement and mortar industries are based on mechanical solutions operated by pneumatic components. These systems typically use two-position pneumatic cylinders to control the coarse filling and fine filling stages. After the weighing controller has been parameterized for each specific product, the system carries out the filling cycle according to the values defined by the operator or technician.

These systems are commonly referred to as conventional systems because they follow a traditional weighing control logic, based on standard weighing controllers available on the market. These controllers are designed to work with different types of products, different flow rates and different applications. However, despite being widely used, these solutions present common limitations, regardless of the equipment origin or manufacturer.

One of the main limitations of conventional systems is directly related to the use of pneumatic cylinders and their mechanical components. In production, the wear of these elements can result in weight variation, causing bags to be filled with either overweight or underweight. In maintenance, specific two-position pneumatic cylinders are usually expensive components and, due to continuous operation and mechanical wear, require frequent intervention.

In practice, these cylinders have an initial operating period during which they maintain a more stable and accurate response. However, after a few months of operation — in many cases around three months — changes in their behavior begin to appear. Internal wear, the condition of the compressed air supply lines, humidity, impurities or dust accumulated inside the components can cause the final closing positions to lose accuracy. As a result, bag weights become unstable and almost daily intervention in the filling parameters may become necessary.

This is a common issue across the industry. Overweight bags represent a significant amount of raw material that, every year, is no longer invoiced and is delivered to the customer without any financial return for the producer. On the other hand, operating with underweight bags is not an acceptable option, as it leads to non-conforming products, rejects, rework, stoppages, higher energy consumption and increased labor requirements during production.

For this reason, both underweight and overweight directly affect the profitability of the operation. Underweight increases rejection rates and reduces line efficiency. Overweight represents a direct loss of product, increases transport costs, raises energy consumption and reduces industrial margins. In a context where raw materials, energy and operating costs have an increasing impact on industrial competitiveness, weight stability becomes a critical factor.

It was precisely based on these challenges, and on more than 10 years of daily experience with industrial filling systems, that SYSTEM FLOW was developed.

SYSTEM FLOW was created as an alternative to conventional systems, with the purpose of improving the process in several critical areas: weight stability, reduced operator intervention, lower dependence on constant parameter adjustments, reduced mechanical wear, lower maintenance costs and improved energy efficiency.

By replacing the traditional logic based on pneumatic cylinders with an electric and progressive solution, SYSTEM FLOW enables a more precise, repeatable and adaptive control of the material behavior during filling. The objective is not simply to fill bags, but to ensure a more stable, efficient and controlled process over time.

With SYSTEM FLOW, production is no longer so dependent on the mechanical condition of pneumatic cylinders, the quality of compressed air or continuous parameter readjustments. The system was developed to operate in a smarter way, following the real flow rate of the product and maintaining a more consistent filling pattern, regardless of the natural variations of the material or the working conditions of the machine.

In summary, SYSTEM FLOW represents an evolution in industrial bag filling technology, offering a modern, fully electric solution with lower maintenance requirements, greater weight stability and improved control of the production process.