Chips Packing Machine – Multihead Weigher Packing Machine
Chips Packing Machines for Snack Manufacturers
In the highly competitive snack food industry, the packaging process is just as critical as the frying or seasoning stages. For manufacturers of potato chips, banana chips, and extruded snacks, the challenge lies in packaging a lightweight, fragile, and voluminous product at high speeds without breakage. This is where the Chips Packing Machine integrated with a Multihead Weigher becomes indispensable. Modern snack packaging demands not only speed but also aesthetic appeal and airtight sealing to preserve freshness. These advanced systems have revolutionized the production floor, replacing manual and semi-automatic methods with fully automated lines that ensure consistency, hygiene, and scalability.
Why Multihead Weigher Technology is Ideal for Chips & Extruded Snacks?
The specific physical characteristics of chips—irregular shapes, varying densities, and high fragility—make them difficult to weigh using traditional linear weighers. Multihead Weigher Technology solves this by using a sophisticated algorithm to calculate the optimal combination of weights. The system is ideal because it offers unmatched accuracy, reducing the costly “product giveaway” (overfilling) that eats into profit margins. Furthermore, these machines are designed for gentle handling. The drop distances are calculated to minimize impact, ensuring that the consumer opens a bag of whole chips rather than crumbs.
Read Our Article: Namkeen Packing Machine – Complete Solution for Modern Snack Packaging
How a Multihead Weigher Chips Packing Line Works – Step-by-Step Process
The operation of a chips packing line is a seamless ballet of automation.
- Feeding: The process begins with the chips being fed into a vibratory feeder or Z-bucket elevator.
- Weighing: The product reaches the top of the multihead weigher, where it is dispersed into pool hoppers and then weigh hoppers. The computer instantly calculates which combination of hoppers equals the target weight (e.g., 50g).
- Combining & Discharging: The selected hoppers open simultaneously, dropping the precise portion into the timing hopper.
- Forming & Filling: The vertical form fill seal (VFFS) machine pulls the packaging film over a forming shoulder/collar to create a tube. The weighed chips fall into this tube.
- Sealing & Cutting: Horizontal jaws seal the bag (top of the current bag and bottom of the next one) and a knife cuts them apart, delivering a finished pack.
Key Components of a Chips Packing Machine with Multihead Weigher
A complete packing line is an ecosystem of synchronized components:
- Infeed Conveyor/Vibratory Feeder: Regulates the flow of chips to the elevator.
- Z-Bucket Elevator: Gently lifts the product vertically to the weigher without breakage.
- Multihead Weigher: The “brain” of the operation, typically featuring 10, 14, or more heads for precision weighing.
- Platform: A sturdy structure to hold the weigher, often with safety railings for cleaning staff.
- VFFS Machine: The “bagger” that forms the film into pouches.
- Discharge Conveyor: Transports finished bags to the packing table or rotary table.
Our Other Machine: Horizontal PFS (Pick-Fill-Seal) Machine
Weighing Accuracy & Product Giveaway Control in Chips Packaging
One of the most significant ROI factors for a Chips Packing Machine is the control of product giveaway. In manual packing, ensuring a minimum weight often means overfilling by 5-10%. A multihead weigher drastically reduces this margin to a fraction of a gram. By utilizing combination weighing, the machine selects the best combination of buckets that sums up closest to the target weight. Over millions of packets per year, saving just 1-2 grams of chips per bag translates to massive savings in raw material costs.
Pouch Styles and Packaging Formats for Potato Chips & Snack Pellets
- Pillow Packs: The standard, cost-effective cushion-shaped bag seen everywhere.
- Gusseted Pouches: Bags with expandable sides for more volume, often used for larger quantities.
- Euro-Hole/Hanging Packs: Bags with a punched hole at the top for retail display on hooks.
- Family Packs: Large volume bags that require robust sealing to prevent bursting.
- Chain Bags: A string of small packets connected together, popular for single-serve retail.
Material of Construction & Hygiene Standards for Snack Food Machinery
Hygiene is non-negotiable in the food industry. Premium chips packing lines are constructed with SS304 (Stainless Steel) for all contact parts, with SS316 options for highly corrosive or salt-heavy environments. The design focuses on “easy cleanability,” featuring waterproof (IP65/IP66 rated) weighers that can be washed down. Tool-free removal of buckets and chutes allows operators to quickly sanitize the machine during product changeovers, preventing cross-contamination between different flavors.
Integration of Nitrogen Flushing for Extended Shelf Life of Chips
Crispiness is the hallmark of a good chip. To prevent oxidation (which leads to rancidity) and sogginess, these machines integrate Nitrogen Flushing systems. As the VFFS machine forms and fills the bag, food-grade nitrogen gas is injected to displace the oxygen. This Modified Atmosphere Packaging (MAP) not only extends shelf life but also creates a cushion inside the bag (the “puffy” look) that protects the fragile chips from crushing during transport and handling.
PLC, HMI & Servo Control in Multihead Weigher Packing Machines
Modern packing lines are driven by PLC (Programmable Logic Controller) systems and operated via HMI (Human Machine Interface) touchscreens.
- Recipe Management: Operators can save presets (e.g., “50g Salted” or “100g Spicy”). Switching products takes just one touch.
- Servo Control: Servo motors control the film pulling and sealing jaws, ensuring precise bag length and consistent seal integrity, even at high speeds.
- Diagnostics: The system can self-diagnose errors (like a jam or open door) and alert the operator, minimizing downtime.
Handling Different Types of Chips and Snacks on One Packing Line
Flexibility is a major advantage of the multihead weigher system. A single line can often handle a diverse range of products including potato chips, banana chips, tortilla nachos, extruded corn snacks, namkeen mixtures, and fryums/pellets. While the core machine remains the same, adjustments can be made to the weigher settings (amplitude of vibration) and the bag former size to accommodate different product flow characteristics and bag dimensions.
Production Capacity, Speed Options, and Line Configurations
- 10-Head Weighers: typically offer speeds of 40-60 bags per minute (BPM).
- 14-Head Weighers: can achieve 80-130 BPM depending on bag size.
- Twin configurations: High-speed lines may use a 16 or 20-head weigher feeding two separate VFFS machines simultaneously to double output. Scalability is built-in; manufacturers can start with a single line and add parallel lines as demand grows.
Our Other Machine: Multihead Weigher Packing Machine
Quality Control & Check Weighing in Chips Packaging
- Metal Detectors: Identify and reject bags containing any metallic contaminants.
- Check Weighers: A dynamic scale that weighs every finished bag. If a bag is under- or overweight (due to a rare error), it is automatically pushed off the line by a rejection arm. This ensures that every carton shipped to the retailer meets strict weight and safety compliance standards.
Energy Efficiency, Maintenance, and Operating Cost Advantages
While the initial investment in a multihead weigher line is higher than a linear weigher, the Operating Cost (OpEx) is significantly lower. These machines are energy-efficient, utilizing servo drives that consume power only on demand. Maintenance is streamlined due to modular parts—if one weigh bucket fails, it can be isolated while the rest continue to run. The reduction in manual labor (one operator can manage multiple lines) and the drastic cut in film and product wastage contribute to a healthy bottom line.
Choosing the Right Chips Packing Machine Manufacturer & Supplier
- Experience: proven track record in handling fragile snacks.
- Customization: ability to tailor the bag former size or conveyor height to factory constraints.
- After-Sales Support: availability of spare parts and local technicians.
- Export Capability: adherence to international safety standards like CE or ISO.
Future Trends: Smart, IoT-Enabled Multihead Weigher Chips Packing Lines
The future of chips packaging is digital. Industry 4.0 is bringing IoT-enabled packing lines where machines communicate real-time data to the cloud. Factory managers can monitor production speeds, bag counts, and downtime remotely via smartphones. Predictive maintenance algorithms will analyze vibration and heat data to predict component failure before it happens, allowing for scheduled repairs that prevent costly unplanned shutdowns.
CEO
With over 10 years of experience in the packaging machinery industry, Rohan Thomas leads Fair Pack Machineries (Pvt) Ltd., a trusted manufacturer and exporter of advanced packaging solutions. The company specializes in automatic and semi-automatic filling, sealing, and conveyor systems designed for powders, granules, liquids, solids, and pastes. Under his leadership, Fair Pack serves diverse sectors including food, FMCG, pharmaceuticals, automobile, and industrial applications, providing machinery that combines innovation, reliability, and efficiency.
With a strong presence in both Indian and international markets, Fair Pack Machineries is known for its commitment to quality, customer support, and turnkey packaging solutions. Rohan focuses on driving growth through technology-driven products, global partnerships, and ensuring clients receive tailored solutions that meet international standards. His vision is to strengthen Fair Pack’s reputation as a global partner in packaging machinery while enabling businesses to scale with sustainable and cost-effective systems.
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