Fully Automated Bagging Lines

Active Weighing Solutions Fully Automated Bagging Lines for filling and palletising open mouth bags with free-flowing product.

Active Weighing Solutions fully automated Bagging Lines are custom engineered to suit each bag filling, closing and palletising application.

Through design specification, 3D CAD modelling, manufacture, factory testing, installation, and commissioning, we work with you to engineer the best solution for your bagging line application.

We consider:

  • weighing accuracy needed,
  • bagging rate specification,
  • bag variety and physical properties
  • inherent characteristics of the bulk material being bagged
  • operations safety,
  • labour and workflows,
  • budget, and
  • integration with existing plant and available space

Our engineers have the knowledge and depth of experience to design automated bagging lines – from simple systems through to fully automated systems with robotic palletising. We will work with you to implement the bagging solution that meets your production need.

Bulk Material Feed Device for Weighing and Bagging

Selecting the best feed device for an application depends greatly on the characteristics and material handling properties of the product to be bagged. The best options are also subject to bagging rate and weighment accuracy specifications.

The feed and weighing method is selected to deliver the highest bag filling accuracy for the bulk material being handled. The range of feed options includes:

  • gravity fed
  • single screw fed
  • twin screw fed
  • vibratory fed
  • belt fed
All feed options are designed and manufactured by Active Weighing Solutions. These devices deliver materials typically to a Net Weigher.

Net Weighers

Net Weighers reliably deliver the most accurate weighing solution for most free-flowing bulk materials. An Active Weighing Solutions Net Weigher is sized to suit the bulk material and the anticipated bag filling weighment rate. For higher speed bagging rates and very high filling accuracy, an Active Weighing Solutions Duplex Net Weigher provides a reliable outcome.


Accuracy ± 20 grams – depending upon the bulk material and flow characteristics

Automatic Bagging Machine

Australian designed and built, the GR900-15 Automatic Bagging Machine brings the best features of any comparable imported machine, with the added benefit of local maintenance expertise and locally sourced consumables and maintenance spares.

Designed for continuous operation and up to 15 bags per minute bagging rate, this machine requires very little operator oversight.

The GR900-15 bagging machine will reliably pick, place, fill and close a wide range of bag types and sizes. It will implement self-recovery actions if an issue in picking and placing occurs. The bagging rate is pre-programmed and bagging targets can be reliably met while workers attend to other tasks.


  • High capacity bag storage carousel
    • Standard carousel holds up to 900 bags
  • Safe operator access to recharge bag magazines without interrupting production
  • Easy change over for a range of bag widths and lengths
  • Intuitive graphic touch screen for the operator to:
    • Set weighment set point
    • Set bagging rate
    • Set required batch run
    • Start, stop, run and troubleshoot
  • High-reliability bag picking and placing
    • Handles even low friction co-efficient (smooth) bags
    • Self-recovery actions if a bag doesn’t pick or place correctly
    • Sensors to ensure no product spillage
  • Bag gusset retention
    • Holds bag manufacturers gusset throughout placing, filling and closing operations, ensuring perfect closure and bag presentation
  • Unique traction drive system holds filled bags securely
    • Bag guides not required.
    • Operators have clear access to remove a bag if needed.
  • Accommodates integrated bag sewing and heat sealing


  • Bag sewing with thread break detection
  • Vision System to detect poorly sewn or closed bagging problems
  • Bag air expel to assist in bag conditioning for palletising

Transfer Conveyors

We design and build transfer conveyors needed to connect the automatic bagging machine output to downstream automatic bagging line palletising processes. These conveyors are custom engineered to the required widths and lengths to suit the site application. Built to last, these conveyors may be powder coated or stainless steel.

We can supply the complete conveying system or integrate with existing production line conveyors and always built to last.

Check Weighing and reject system

A checkweigher and reject system is located in the bagging line prior to palletising operations. Set to weigh the filled bag to a high accuracy level, a checkweigher will push any over or under-weight bags to a reject position away from the main transfer line.

The core of this system is a trade approved platform scale. A standalone model sourced from specialist suppliers may be integrated to the line or an Active Weighing Solutions model can be designed to perform the function.

Metal detection system

We will source suitable metal detection equipment manufactured by others and integrate its operation into the flow of the line.

Traceability label or ticketing system

Supply chain track and trace has become increasingly important on the grounds of safety and trust in brands. While Australian regulations govern minimum requirements for the food industry, traceability is also a necessity for many exported products. Active Weighing Solutions will integrate a labelling system suited to your product and industry.

Bag conditioning equipment

The product inside a filled bag will tend to be unevenly distributed when it leaves the bagging machine. Bag conditioning is needed to bring the shape to a relatively even profile. This may involve a combination of vibration and bag flattening.

Robot palletisers require bags of consistent shape and size to create stable bag stacks. Selection and design of bag conditioning equipment will depend largely on characteristics of the bagged bulk material, the variability of the bags to be handled, the robot, and the downstream customer preferences. Our engineers will consider all these factors in determining the most cost-effective bag conditioning solution for the application.

Automatic pallet dispenser

An Active Weighing Solutions standard design Pallet Dispenser will hold up to 12 timber pallets and is refilled via forklift. Pallet Dispenser operation is controlled through the Fully Automated Bagging Line integrated PLC. Empty pallets feed from the base of the dispenser at the rate determined by the PLC programme for the application.

Automatic Slip Sheet Applicator

An automatic Slip Sheet Applicator will place a pallet-sized sheet of paper, thin board, cardboard, or plastic on an empty pallet. This is typically actioned as the pallet is conveyed from the Pallet Dispenser to the palletising station. The slip sheet applicator function is integrated to the bagging line with speed and operation controlled though the Bagging Line PLC programme.

Palletising Conveyor

The Palletising Conveyor will drive an empty pallet, possibly loaded with a slip sheet, to a stationary position and hold while the robot palletiser stack bags in the programmed pattern. Controlled by PLC, when this process is completed, this conveyor will activate to transfer the filled pallet to the next stage of the Automatic Bagging Line.

Robot Palletising System

Our engineers work with leading robot manufactures and suppliers to select and program a robot palletising system suitable to bag palletising job at hand. Selection depends on multiple criteria, including:

  • the variety of bag weights and sizes to be packed and therefore the number of programmed packing recipes,
  • the space available for the robot cell (or cells), and
  • the required palletising speed.

Pallet Stretch Wrapper

Adding a pallet wrapping machine to an automatic line increases the quality of the palletised output. Product transit damage is also reduced when a stretch wrapped barrier is created to hold the stacked bags. Our engineers work with leading stretch wrapping manufacturers and suppliers to choose a model with the right:

  • stretch film capacity,
  • level of automation, and
  • programming flexibility.

Pallet accumulation and indexing conveyors

Active Weighing Solutions pallet accumulation and indexing conveyors are custom engineered to the length and program requirements of each application. This conveying system will deliver and hold packed pallets in the required programmed sequence for forklift or other transport system method to move packed pallets into the transport supply chain.

Safety Features

Active Weighing Solutions engineers work to Australian Standards and to any additional customer requirements to promote a safe working environment. We are experienced in integrating, for example dust extraction systems, light curtain systems and fencing into our automated bagging line systems.

Please contact us to discuss the best combination of equipment to suit your application

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Automatic Bagging Machine GR900-15

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