Project Overview
The objective of the modification was to improve nitrogen delivery efficiency by directing the nitrogen flow
directly into the dedicated nitrogen channel, eliminating previous leakage points and ensuring more
effective gas distribution.
Initial feedback from Globally recognised Belgium based snacks brand following the production trial has
been very positive, demonstrating the potential for significant operational and commercial benefits.
Production Trial Conditions
Parameter Details
Production site Globally recognised Belgium based snacks brand, Belgium
Machine IM206
Bag weight 365 g
Production speed 45 bags per minute
Modified former Width 250 mm
Nitrogen channel Modified design
Trial results and performance
The production trial demonstrated a substantial improvement in nitrogen utilisation following installation of the modified forming set.
Nitrogen setting
23
Modified former
Residual oxygen
1.61%
Achieved at 45 bpm
Original forming set:
* Nitrogen flow had to operate at maximum capacity to maintain acceptable residual oxygen levels.
* The high nitrogen setting contributed to increased film waste.
* Nitrogen delivery was less efficient due to the previous leakage points.
Modified forming set
* Nitrogen flow is directed straight into the nitrogen channel.
* The nitrogen setting was reduced to 23.
* A residual oxygen level of just 1.61% was achieved at the tested production speed.
* Effective residual oxygen control was maintained despite the lower nitrogen setting.
These results indicate that the modified design delivers nitrogen more effectively, reducing the need to operate the system at maximum capacity.
Key benefits identified
Improved nitrogen efficiency
* More effective gas delivery through the dedicated nitrogen channel, with less reliance on maximum nitrogen flow settings.
Potential reduction in film waste
* Lower nitrogen settings may help reduce packaging film waste associated with the original configuration.
Improved process stability
* Maintaining low residual oxygen levels at a reduced nitrogen setting indicates improved control of the gas-flushing
process under the tested conditions.
Conclusion:
The production trial at Globally recognised Belgium based snacks brand confirmed a positive performance improvement following installation of the modified nitrogen channel former.
Achieving a residual oxygen level of 1.61% with the nitrogen setting reduced to 23 demonstrates the potential to optimise nitrogen consumption while maintaining effective packaging performance at 45 bags per minute.
The results support further implementation of the modification, subject to validation across additional production conditions and confirmation of the actual nitrogen savings and film waste reduction.
Final assessment:
The modified former has demonstrated a significant improvement in nitrogen delivery efficiency, with potential benefits in nitrogen consumption, packaging waste and process stability.
Following the positive trial results, Globally recognised Belgium based snacks brand has requested that this modification become standard on all new forming sets from 190 mm width onwards, as well as a retrofit modification for the existing 250 mm forming sets at Globally recognised Belgium based snacks brand, starting with the current fleet at this site.
