Having set up Hassia in India in 1998 (now Rovema India), I have had the opportunity to deal with diverse types of customers and powders. Packaging powders in general, and in flexible pouches in particular, is one of the most challenging applications in packaging.

If you pack powders, are planning to do so in the near future, or are planning automation, this series of articles may interest you. Powders are manufactured using a wide range of processes, and their diverse physical properties pose specific challenges. You will find here a series of articles that will address various issues and help you develop a to-do list.

Weight Variation

Weight variation and excess give-away is one of the key issues in powder packing. It is a challenge because powder properties are not constant — therefore filling and packing must incorporate a strategy to address this.

Case 1 — Skimmed Milk Powder (Private Dairy)

Many years ago, we supplied a VFFS machine to pack skimmed milk powder to a private dairy. The customer packed stored powder and complained that pouch weights were gradually going up over time. We found the issue outside the machine — in the way the powder was stored. We resolved it by writing a SOP for powder storage.

Case 2 — SMP (Cooperative Sector)

A farmer (co-owner in a cooperative) purchased a 1 kg pack of skimmed milk powder and found it weighed 1,047 gms. He lodged a complaint and I was summoned by the MD. On studying the plant, the problem was found in the feeding system — something our team had flagged during installation. We helped the customer install a new feeding system, eliminating the issue.

Case 3 — Home & Personal Care MNC

After much persuasion, we were allowed to evaluate the packaging process at a large MNC. We found the average give-away was 15 gms per pack. We reduced it by 6 gms — resulting in annual savings of ₹10 million per machine per annum. The customer eventually ordered many more machines, including overseas sites.

Case 4 — Agrochemical Export Customer

An export customer was fighting with their machine supplier to return a machine due to weight variation. Neither party could solve the issue. On evaluation, the problem was in the product feeding system — not the machine. Issues can be outside the equipment. An objective evaluation is necessary.

Product in Seal

Product in seal is another critical issue in powder packing. It leads to leaking bags and reduced shelf life.

Case 1 — Rodent Attacks (FMCG MNC)

A senior executive asked if I knew of a rodent-repellent film. Rodents were attacking and puncturing bags of a powdered beverage. On investigation, the pouch had product in the seal — this allowed rodents to identify the content and puncture the bags. By eliminating product in the seal, the problem was solved.

Case 2 — Seal Leakages (Beverage & Confectionery)

A leading company called about seal leakages with a dusty, hygroscopic powder. On visiting, the machine was fully coated with product — the original colour was invisible. We addressed the problem by suggesting a change in the dosing system. The customer had doubts but we demonstrated and delivered — now they use our dosing design fully.

Air in the Bag

Optimising cost of primary and secondary packaging involves optimising package size — extracting trapped air from the product and reducing headspace without getting product in the seal. The difference between tapped and loose bulk density is often around 20%. Several approaches can be used to remove air effectively.

Summary

Powder packing is a genuine challenge. As manufacturers, we want to supply the right weight, ensure shelf life, and deliver on time. The package must also deliver point-of-purchase value.

There are many hidden savings potentials in the packaging process which, when evaluated with expert help, can improve efficiency and reduce costs. It is advisable to get an audit done at least once every two years.