C O L B Y

B U L K F I L L I N G

S Y S T E M S F O R P A C K I N G

P O W D E R E D P R O D U C T S

P O W D E R P A C K A G I N G T E C H N O L O G Y

w w w. c o l b y p o w d e r. c o m
C O L B Y .

A W I D E R A N G E O F B U L K F I L L I N G S O L U T I O N S

Colby is dedicated to The service we provide is unique. In fact, as our clients in the Americas, Europe, Africa,
the Arabian Gulf and the Australasian region will attest, there is nothing like it in the
the design and
world.
manufacture of
Colby is the only supplier capable of meeting the full spectrum of powder filling and
packaging systems packaging requirements saving you the need to search the world for specialised
specifically for machinery.

powdered products. Whether purchasing an individual machine or a fully integrated filling line, all clients
benefit from Colby’s superior understanding of the exacting requirements of powder
handling and packaging.

We also know these industries can demand very high quality and sanitary standards, so
we do everything with these standards in mind.
H I G H A C C U R A C Y

O N - H E A D W E I G H I N G

The key to our success The Colby on-head weighing system is like no other. Colby’s advanced filling head
combines feed chute, bag clamp and high accuracy load cell into one complete
in bulk filling is our
functional unit.
unique net weighing
This combination means we can reliably undertake net weighing and ensure we
filling head system. achieve the highest accuracy possible.

When combined with our proprietary digitiser and weigh control system, we
achieve unbeatable performance.

Colby takes advanced designs

from concept through to
successful implementation
 S I N G L E H E A D
F I L L E R S
Colby filling machines
use precisely
engineered components
in conjunction with
high technology
control systems to
provide reliability and
accuracy.
Single Head Filler with Ultrasealer
SINGLE HEAD FILLERS
Colby can supply a wide range of single head filling systems for their clients, ranging
from simple single head fillers through to fully automatic units; incorporating dual
augers and bag loading.
Our entry level fillers provide ultimate simplicity for basic product recovery operations
where speed and/or accuracy are not required.
25-1
The 25-1 filler uses dual augers which combine to
give the benefit of speed while achieving standard
deviations of 15 g (0.53 oz) on powdered products.
The filling cycle consists of 5 fully adjustable stages,
as follows:
• Bulk fill - fast and slow feed
• Fine fill - fast and slow feed
• Product `in flight’ compensation
The weigh controller is self-tuning with user friendly
on-screen help and has a number of product files
for quick changeover/multiple weight settings. 25-1 Filler
25-1/ST
The 25-1/ST inline filler is designed to meet a wide range of
packing needs, including manual and automated solutions.
The optional probe assembly and base compaction unit can be
used to produce a very stable pack, making this a versatile filler
for a wide range of powders.
Horizontal augers feed the product to the fill heads,
simultaneously, which enables optimum filling rates to be
achieved.
The initial, or bulk, fill is a timed volumetric fill, which
discharges approximately 90% of the final product
weight and then the integral conveyor lowers the bag and
out-feeds to the secondary top-up station.
 R O T A R Y

F I L L E R S

Our rotary fillers Most modern production plants require higher speed packing systems.

provide higher Colby have developed a range of fillers that use multiple
auger stations and rotating filling heads to maximise filling
production rates and
rates whilst retaining high accuracy.
reliability.
The Colby rotary fillers combine multiple bag preparation,
filling and treatment stations in one compact footprint. The
filler incorporates bulk filling and top-up filling stations
with vibration and de-aeration to produce an
accurate and stable final product.

Each machine uses our advanced weigh

controller unit which is self tuning. Features
include a user-friendly `on screen’ help
system, statistical collection and product files
for quick changeover/multiple weight settings.

25-2 & 25-4

These fillers use dual filling augers and multiple heads to obtain a filling
cycle consisting of 5 fully adjustable stages, including bulk fill, fine fill and
product `in flight’ compensation.

25-6

The 25-6 filler uses three filling augers,

which combine to give the
benefit of speed, while achieving
standard deviations of 15 g
(0.53 oz) on powdered
products. The filling
cycle consists of
bulk, intermediate
and fine fill, with
product `in flight’
compensation.

Line integration is a core competence for Colby.

B O T T O M U P

F I L L I N G

Filling systems for some products require extra product compaction and more attention
to dust control.

The Colby bottom up filler uses a moving filling head that slides vertically over the
product feed tube to achieve effective compaction and dust control. This system
operation means that product has minimal height to fall into the bag. As the filling
head lowers during filling, there is minimal air turbulence, fluidising and dust
generation. The result is low dust emissions and a well compacted product fill.
M O D I F I E D

A T M O S P H E R E P A C K I N G

Pre-gasser

Food powders in bulk packaging often need

atmosphere enhancement to maximise shelf life.

Colby can assist.

We have a range of Modified Atmosphere Packing

(M.A.P.) systems that can remove oxygen from food
powders and replace it with inert gasses - typically N2
and CO2.

Colby M.A.P. systems use two main methods to achieve

this: `Pre-gassing’, where the product is M.A.P. treated
prior to filling, or `Post-gassing’, where the
product is M.A.P. treated after it is filled into it’s
final packaging.

Both methods can use vacuum or pressure

(flushing) to remove oxygen.

Colby has successfully commissioned many

systems using these technologies.

Our vacuum pre-gas systems are widely used for

bulk filling applications, as
is our integrated
`Modugas’ system which
combines our bottom up
filler with vacuum pre-
gassing to achieve a
superior result.
Modugas
Our latest innovation is
the `Post Gas 25’ which is
specifically designed for
M.A.P. treatment of 25 kg
(50 lb) bags in slow speed
and medium speed
applications.

Post Gas 25
L I N E

E Q U I P M E N T

BAG LOADER Bag Loader

The Bag Loader is designed for the automatic loading of

empty bags to a bag filler.

The Bag Loader is designed to complement the

Modugas or Rotary Filler range or to load bags to an
existing filling machine.

An operator is only required to replenish the bag

magazine.

BAG PRESENTER

The Bag Presenter is designed for the automatic bag

stretching, de-aeration and presentation of filled bags to
a bag sealer eliminating the need for an operator to feed bags to the sealer. The Bag
Presenter removes entrapped air above the powder level, resulting in greater stack
stability and more efficient space utilisation.

SEALER CLOSER

Sealer Closers are designed for the sealing and closing of gusseted and open
mouthed stepped end bags. The typical bag sealed is multi walled, comprising an
inner plastic liner and an outer paper bag. The outer paper bag is manufactured
Bag Presenter
with multiple paper layers and a pre-applied adhesive on the stepped top. The sealer
section seals the inner liner with adjustable heating elements. Pre-applied adhesive is
reactivated and the stepped top flap is closed over the bag to seal the outer bag.

Sealer Closer
 CHECK WEIGHER

The check weigher is a high accuracy weighing

system for validating the filling process. Our
system enables the reliable checking of
Check Weigher
packaged goods to ensure that quality and
legislative requirements can be met. The
weigher uses load cells and a digital weigh
indicator/controller, combined with an indexing
conveyor to load and check weigh bags or
boxes of finished goods. The weigh controller
can be interfaced with a higher level control
system to provide QA data and can also be
used, in conjunction with a rejecting station,
to remove under or over weight bags.

METAL DETECTOR

Metal detection and removal is a priority for modern food processing plants. We
can supply a range of metal detection units complete with
conveyor systems. These use rectangular annulus detection
elements from established suppliers and integrate them with
plastic slatted belt conveyors. The result is a highly sensitive
metal detection system that can detect ferrous and non-ferrous
materials in paper/plastic lined bags.

Metal Detector

R E J E C T S TAT I O N

Rejected product needs to be

removed from the packaging line
quickly and efficiently with no
downtime. The reject station
enables bags to quickly be slid
from the main line onto a gravity
roller conveyor section using a
proven pneumatic sweep arm.
Rejection is activated by a signal
from the main packaging line
Reject Station
control system.
P A L L E T I S I N G

Our automated robotic palletising systems use modern robotic technology to

pick and stack all types of bags and cartons quickly and efficiently.

We can offer a range of palletising solutions including simple, low floor space
systems through to larger, fully integrated automatic systems.

Fully automated systems can dispense pallets, apply a slip sheet, palletise,
stretch wrap and outfeed without the need for an operator. Typically, a fork lift
truck driver can run the whole operation with minimal intervention.

Multiple packing lines can be handled and palletised either onto the same
pallet or individual pallets by the same robot.

The use of `in-motion’ control systems enables adjustments to stack patterns

while in operation.

Modular design means Colby can easily

integrate new palletising systems into existing
production lines, with minimal downtime.
I N T E G R A T E D

C O N T R O L S Y S T E M S

One of the most To offer the most up-to-date control solutions, Colby works closely with established
suppliers of computer control technology. Our close relationship with these
important aspects of
companies gives us a privileged window into the leading-edge advances they are
any modern making. It also provides us with valuable access to reference sites across a variety of

manufacturing business industries.

is the human/machine As a result, Colby can offer control systems with simple operator interfaces
requiring a minimum of operator training. Automatic monitoring and sequence
interface. If the process control ensure our systems run with minimum staff and have high levels of
is to work at maximum reliability. Colby has the experience to find the right balance between economy and
sophistication.
efficiency, the interface
On the basis of this experience, Colby can provide control systems which are
must be optimised.
tailored specifically to our customers’ needs.

Colby also understands the importance of a formal approach to software

engineering.

We have developed an extensive library

of standard software solutions, which is
continually being expanded and
updated as we provide new advanced
control technology systems worldwide.
Disciplined use of this library enables us
to continue to provide customised
solutions without having to re-invent
the wheel for each project.
B U L K

F I L L I N G

BIN AND BOX FILLING

Colby can also provide bulk filling systems for IBC's and FIBC's, with
capacities from 400 to 1,500 kgs (900 lb to 3,300 lb). The systems have
multi stage filling with high accuracies achieved. Vibration can be used to
settle product prior to sealing. Label printing and automatic sampling can be
provided.

LINE EQUIPMENT

Bulk bag or box filling often requires the integration of different equipment
such as pallet dispensers and
wrapping machinery.

Colby can assist here as well.

We can integrate a wide range of

OEM equipment with our own and
provide a high quality system linked
by belt, roller or chain conveyors.
S U P P O R T

Is your system Our customer commitment doesn’t finish when an order is placed with us. We can assist
our clients with a comprehensive support program including:
operating the way it
should be?
MAINTENANCE

The Colby Sapac Correct maintenance is essential. If this is not planned correctly it can result in
unexpected downtime and increased costs. We can help with a variety of programs and
Service Division has
support services.
the experience,
resources and
SPARE PARTS
components required Colby can offer a complete spare parts service with short lead times and prompt delivery.
to service your
equipment and TRAINING

systems. To achieve the best result, plant operators should understand the equipment and systems
they are using. Colby can help by providing thorough, detailed training.

UPGRADES

Technology is constantly changing. The manufacturer/ processor/ packer needs to be up-

to-date with the best that industry can offer. We can help with: improved Colby and
Sapac technology, industry advances, further automation, new equipment integration
and modem support.

PRODUCT QUALITY

Product quality can mean the difference

between poor market image and increased
sales. Colby has always placed great emphasis
on the quality of our goods and services. We
have the knowledge to assist our clients with
their quality problems.

SYSTEM EFFICIENCY

Many plants run at reduced efficiency. The

causes can be ineffective systems, procedures
and designs. Improvement is often achieved by
systematic analysis provided you have industry
knowledge. We have that knowledge and can
help you achieve system efficiency.
S Y S T E M

I N T E G R A T I O N

“The whole is more A truly integrated filling line is far more than a series of machines running in
sequence. It is the product of a clear understanding of throughput, accuracy, shelf
than the sum of its
life and quality standards. The types of powders to be handled, the variety of
parts.” packaging sizes and the frequency of product changeover must also be taken into
Aristotle, circa 345 BC account.

Successful filling line design also requires the careful selection of complementary
machines and components from all over the world, the provision of buffers to
ensure minimum disruption to operations and specialised software which can
integrate and control both machine and system performance.

Each of these issues is important and can only be implemented

effectively based on specialist knowledge, experience and
expertise.

Successful integration of new

equipment can be the most critical
part of any installation. Choosing
the right partner for your needs
is essential.

OrbSticle Puzzle courtesy of R&A Media Inc.

S A N I T A R Y

D E S I G N

All Colby systems can be designed

and manufactured to ensure world-
class sanitary standards will be met.
We regularly supply equipment and
systems for use in USDA, MAF and
other similarly regulated plants.

Tool-free disassembly can allow for

easy inspection and cleaning of
individual components and
machines.

Colby’s main strength however, is

the ability to engineer complete
systems for use on sanitary products.
We understand the need for sanitary,
clean room design as well as HVAC
systems rated for the highest
filtration and humidity control
requirements.

Colby can help with your complete

sanitary plant design.
 C O L B Y
B U L K F I L L I N G

Colby USA

Colby Europe

Colby Australia

Colby NZ

Colby Offices
Installation Sites

Colby Powder
Systems Pty Ltd

AUSTRALIA EUROPE NEW ZEALAND USA

Colby Powder Systems Pty Ltd GEA Process Engineering Avalon Engineering Ltd Niro Inc.
24 Narabang Way Nederland 12 - 18 Foreman Road 1600 O’Keefe Road
Belrose . Sydney Postbus 2064 . 7420 AB Hamilton Hudson
NSW 2085 Deventer . Netherlands Wisconsin 54016

Ph: +61 2 9486 5400 Ph: +31 (0) 570 66 33 66 Ph: +64 7 849 3414 Ph: +1 715 386 9371
Fax: +61 2 9486 5566 Fax: +31 (0) 570 66 33 77 Fax: +64 7 849 3494 Fax: +1 715 386 9376

GEA Powder Systems

Avapac . Colby . Sapac