1. The Client Brief & Challenge
A producer of whole macadamias for export had an older pouch line that was slow and inconsistent. The new brief called for accurate weighing, consistent opening and sealing of zipper pouches, and a steel nut-opening key in every pack.
- Whole-nut flow: Large macadamias could bridge at the pouch opening as a weighed batch entered the pack.
- Zipper-pouch handling: The stiff zipper and pouch base had to open before the nuts and key could be inserted, then close and seal consistently.
- Key placement and inspection: The steel key needed its own controlled feed and placement step, with inspection after the pouch was filled.
- Restricted production-room layout: The nut feed had to reach the weigher through a wall from another room while the packing line fitted the available space.
2. The Process Plant Network Solution
PPN integrated a new rotary pouch-packing line with product feeding, a multihead weigher, a custom nut-entry chute, a custom key-feed system and camera-guided robotic placement. The line opens the zipper pouch, weighs and fills the nuts, inserts a key, seals the pouch and sends it through final pack checks.
A flexible stainless-steel chute helps guide whole nuts into the pouch without blocking its narrow opening. Keys move through a purpose-built elevator, unscrambler and conveyors; a camera locates each key for robotic pick-and-place, while excess keys return to the feed hopper.
The line was configured for 225 g and 400 g zipper-pouch formats, with adjustments at the pouch packer and weigher for changeovers. An extended bucket elevator carries nuts through a wall from the adjoining room to the weighing station.
System Equipment Composition
New Equipment
- Nut-feed hopper and extended bucket elevator to the multihead weigher.
- Multihead weigher and custom flexible chute for filling whole macadamias.
- Rotary zipper-pouch packer for opening, filling and sealing.
- Custom key elevator, vibratory unscrambler, feed conveyors and return chute.
- Product metal detection before key insertion.
- Finished-pack checkweigher and key-inspection X-ray.
- Pack-off turntable.
Proof of Concept & Workshop FAT Testing
PPN carried out a factory acceptance test before packing down and delivering the line. The system was then installed and commissioned at the customer’s site.
3. Implementation & Timeline
Design for the available space
The layout routed nut feeding from an adjoining room through a wall and allowed the equipment to fit the production room.
Custom build and integration
PPN developed the flexible nut-entry chute and the key elevator, unscrambler, feed conveyors and return path alongside the pouch-packing equipment.
Factory test and dispatch
After factory acceptance testing, the line was packed down and delivered to the customer.
On-site installation
PPN’s team installed the line with assistance from the customer’s staff.
Commissioning and operation
PPN commissioned the installed system and ran the integrated line at the customer’s site.
4. Results & Business Impact
- An integrated pouch line: The new system brought weighing, zipper-pouch packing, key placement and pack inspection together for the export product.
- A higher-speed packing process: The integrated line ran at 45–60 pouches per minute.
- Automatic key placement: Camera-guided pick-and-place replaced the manually inserted key shown in the earlier process.
