Dust-Free Bagging and Streamlined Cleaning
Omnisal, part of the FB HOLDING Group alongside Czech company Fosfa a.s., is a leading FSSC 22000-certified supplier of phosphate blends used by major food manufacturers. These blends serve as emulsifiers, stabilizers, and acid regulators in products such as meat, cheese, dairy, bakery goods, and fish — with a critical impact on texture, pH, flavor, and shelf life.
Looking to meet growing global demand for phosphorus derivatives, Omnisal needed to replace its outdated bagging line with a solution that guarantees dust-free operation, protects employees, and simplifies cleaning. Moreover, quick and efficient product changeovers were essential to minimize downtime.
Focus on Food Safety
The highest standards of hygiene were non-negotiable. The new system had to meet strict food industry requirements to avoid any risk of contamination. For this reason, Greif-Velox developed a tailored solution built around its high-speed BVPV 4.40 air packer — a system designed for both performance and cleanliness.
Precise Filling Without Product Segregation
The BVPV 4.40 offers a unique air-assisted filling process: phosphate powders are conveyed on an air stream precisely calibrated to their bulk density, grain size, and flow characteristics. A key design feature is the packer’s V-shaped filling chamber, which ensures smooth material flow and prevents segregation or bridging — a common issue with phosphate- based products that often results in inconsistent product behavior during downstream use.
The design safeguards product integrity and dosing accuracy, helping preserve critical properties such as solubility and functionality.
Hygienic Design for Clean Operation
To protect both product and personnel, the bagging system is enclosed and built according to hygienic design principles. All components are made of corrosion-resistant stainless steel, and FDA-certified valves enhance compliance with food safety regulations. The patented Aspiration Shield, developed by Greif-Velox, combines dust extraction with a physical barrier: any particles escaping prior to sealing are collected and reintegrated into the filling process, ensuring maximum cleanliness and efficiency.
Fast Product Changeovers with Clean-in-Place
Switching between phosphate variants is streamlined thanks to an innovative combination of clean-in-place (CIP) technology, a specially designed discharge system, and an automated air-rinsing unit. The integrated cleaning system reduces residual product in the hopper by more than 95% compared to standard solutions — significantly lowering cleaning time and waste.
Instead of taking several hours, cleaning now takes less than one hour. This not only minimizes the risk of cross-contamination but also shortens downtime and increases overall equipment effectiveness.
Ultrasonic Sealing and Quality Control
A contamination-free final product is further ensured through the patented ValvoSeal ultrasonic sealing system, which applies multiple sealing lines to increase tear resistance by up to 60%. Before sealing, the ValvoDetect system checks for correct bag positioning and removes defective bags before they reach the palletizer. This reduces the chance of leaky bags or contaminated pallets reaching logistics.
Increased Throughput, Seamless Integration
Capable of filling up to 120 valve bags or 10–12 FIBCs per hour with bulk densities up to 1.29 kg/l, the BVPV 4.40 system far outperforms the previously used setup. Integrated with conveyors and palletizing robots, the full-line system automatically arranges bags securely and space-efficiently on pallets, ensuring safe transport and hygiene compliance throughout the process.
“All the strengths of the system were already evident during factory acceptance testing at Greif-Velox’s site in Lübeck,” says Dalibor Kucha from Omnisal. “Now that it’s running in full production, it proves its value every day.”
