Doypack Packing Machine

Free Custom Layout Design: Optimize your floor plan, get expert machine placement planning at no cost.

Comprehensive Technical Documentation & Troubleshooting Guides: Minimize downtime with instant access to manuals and common issue solutions.

Real-Time Remote Video Support: Connect directly with senior engineers for rapid resolution of complex problems.

Global Shipping Simplified: Hassle-free DDP/DDU delivery to your doorstep, worldwide.

Local Installation & Training: On-site setup, commissioning, and operator training by our certified technicians. Enjoy true peace of mind.

Annual Performance Review: Proactive check-ins to ensure your equipment operates at peak efficiency year after year.

Within pre-made pouch packaging lines, the core decision of selecting a multi-head weigher or tablet capsule gummy counting machine as the supporting equipment hinges on the attributes of the material being handled. These two technologies offer distinct advantages and are suited to specific applications. Selecting the wrong machine can lead to compromised efficiency, insufficient accuracy, high material waste, or even operational failure.

The selection criteria, strengths, and limitations of each device are analyzed in detail below, based on key material characteristics:

1. Material Properties

Physical Form

Granules, Flakes, Sticks, Chunks(Regular/Irregular Solids): Both multihead weigher and counting filling machine are possible options; final selection depends on other properties.

Fine Particle: Typically better suited for counting machine.

Powders, Pastes, Liquids, Viscous Materials: Neither multi-head weigh filler nor automatic counting machines are suitable. These require volumetric filling equipment (Auger Fillers, Piston Fillers, Liquid Fillers) or net weight scales.

Individual Weight/Size

Large & Relatively Uniform Individual Weight: (Large Biscuits, Chocolate Bars, Whole Fruit, Toy Parts) Multi-head combination weighers generally offer advantages in efficiency and cost-effectiveness.

Very Small or Highly Variable Individual Weight: (Small Pills, Seeds, gummy bear, Small Hardware) Automatic electronic counting machines excel in precision and minimizing waste. Multi-head weighers struggle with accuracy control for very lightweight items, and small items are prone to loss through “fly-away” (aeration) within the weigh buckets during operation.

2. Multi-Head Weighers

Material is distributed from a main vibration feeder into multiple (typically 8-24) independent weigh buckets (weigh hoppers). A computer system continuously reads the weight in each bucket and uses a combination weighing algorithm to rapidly identify the group of buckets whose combined weight is closest to the target weight. The selected buckets discharge simultaneously into a collection funnel below, directing the material into the packaging pouch.

Advantages

High Speed: The combination weighing principle enables exceptionally high weighing speeds (typically 100-200 pouches/minute, with high-speed models exceeding 300 pouches/minute), making it the preferred choice for maximizing production output.

High Accuracy: For free-flowing materials with moderate individual weights, multi-head weighers achieve very high weighing accuracy (±0.1g to ±1g or better, depending on material and target weight). The combination algorithm effectively compensates for individual feed variations.

Broad Weight Range: Capable of handling packaging specifications ranging from a few grams to several kilograms by adjusting the target weight and bucket size, offering strong adaptability.

Ideal for Free-Flowing Materials: Processes granules, flakes, chunks, and other free-flowing materials smoothly and efficiently.

Relatively Easy Cleaning & Maintenance: Features a relatively standardized structure; parts contacting the material (vibration feeder, buckets) are typically detachable for cleaning.

Disadvantages

Struggles with Poorly Flowing Materials: Materials prone to sticking, clumping, being oily, or moist can easily clog in the vibration feeder, buffer hoppers, or weigh buckets, leading to uneven feeding, reduced accuracy, or even machine stoppage.

Challenges with Small/Very Light Materials: Extremely small or lightweight items (tiny seeds, small pills) are susceptible to airflow dispersion (“fly-away”) within the weigh buckets, causing material loss. Accuracy advantages also diminish for very small target weights.

Potential Damage to Fragile Items: The tumbling action in the vibration feeder and bucket discharge can cause impact and friction, potentially damaging very fragile products (potato chips).

Difficulty with Irregular/Entangling Materials: Long, flat, or stringy items can become entangled or jam in the vibration feeder tracks or bucket inlets.

Provides Weight, Not Count: Outputs a target weight, not an exact piece count. Unsuitable for applications requiring precise quantities ( items sold by unit count).

3. Electric Counting Machines

Count bottling machines isolate individual items using physical separation or vision recognition technology and count them. Common types include:

Counting and filling machine: Items queue on vibrating tracks and are counted via photoelectric sensors.

CCD camera inspection counting machine: High-speed cameras capture images of falling items, and image processing software identifies and counts individual units.

Advantages

Delivers Exact Piece Count: The only solution for applications requiring precise counts (pharmaceuticals, gummy bear, candy, electronic components).

Superior Handling of Poorly Flowing Materials: Generally outperforms multi-head weighers in processing moist, oily, or sticky materials with reduced clogging risk.

Excels with Small Pellets: Ideal for high-precision, low-waste counting of small pills, seeds, and candies.

Handles Irregular Shapes Effectively: Advanced vision counters can accurately identify and count items with diverse and challenging geometries.

Low Material Loss: Counting typically avoids weigh bucket inversion, minimizing loss from “fly-away” or product residue.

Low Noise: Fewer vibratory components compared to multi-head weighers typically results in lower noise levels.

Disadvantages

Slower Speed: Absolute speed is generally lower than multi-head weighers (especially for tiny items). High-speed vision counters may reach 100-150 pcs, but this translates to lower packaging speeds (60-90 pouches/minute for 100 piece packs) compared to high-speed weighers.

Weight Accuracy Depends on Unit Uniformity: Counting accuracy is 100%, but package weight accuracy relies entirely on consistent individual item weight. Significant weight variation (irregular-sized dried fruits, nuts) causes large package weight fluctuations.

Sensitivity to Item Clumping: If two or more items stick together and are counted as one, under-counting occurs. (Solution Example: Our specialized candy counter tackles clumping via 4 key features:)

Spiked Hopper Agitator: Prevents gummies from stacking vertically.

Anti-Clumping Distribution Roller: Ensures even batch dispersion by preventing adhesion.

Teflon Dimple Panels: Fully separate gummies and enable smooth, fast sliding.

Enlarged PTFE Discharge Port: Reduces clogging, increasing speed by 58%.

Complex Equipment Selection: Different counter types vary significantly in material suitability, requiring expert knowledge and testing for optimal selection.

High Cost of Vision Counters: Initial investment for high-performance vision counting systems can be substantial, often exceeding multi-head weigher costs.

Limited Capability for Large/Heavy Items: Counting very large chunks (whole chocolate bars, large toys) is often structurally impractical, slower, and less cost-effective than using multi-head weighers.

4. Summary & Equipment Selection Guide

5. Best Practice Recommendations for Supporting Products Selection

Conduct Rigorous Material Testing: Submit actual material samples to ruidapacking for testing. See firsthand the equipment’s processing capabilities, accuracy, speed, and material loss with your specific product.

Plan for Future Production Needs: If you might package materials with different properties in the future, prioritize equipment with compatibility or flexibility to handle diverse products.

Ensure Seamless Production Line Integration: Guarantee your chosen dosing equipment integrates smoothly with both upstream feeding systems (elevators, storage bins) and the downstream packaging machine.

Match performance: Verify compatibility in speed and mechanical/physical interfaces to prevent bottlenecks.

Prioritize Supplier Support & Service: Select a supplier with strong technical expertise and a proven track record of responsive, high-quality after-sales service and support.

By carefully evaluating your material’s key properties and thoroughly understanding the core strengths and limitations of multi-head weighers and automatic bottle counting machines, you can confidently select the most suitable, efficient, and cost-effective dosing solution for your pre-made pouch packing line.