Moretto: Storage, where it all begins

Big bags treatment

BAGGY

The big bag is a standard container for storing non-hygroscopic granular materials such as polythene and polypropylene. The BAGGY system has a large bag support that enables it to be emptied without losing any material. Thanks to the modular construction, once the big bag has been emptied, it is easily disassembled and stacked to save space.

BIG BAGS UNLOADER

To handle the emptying of 800-1.000 kg and 1.500 kg big bags, Moretto offers SBB system. Loading operations can be carried out using a forklift or lifting crane. The system features a large granule collection tank, a suction valve and a safety ring for secure opening of the big bag’s spout. The version designed for processing flakes and/or regrind materials includes integrated shakers and safety protections.

Available options:  

• Pulsed suction probe
• Forced fluidification
• Lower bridge-breaker for flakes
• Capacitive and/or vibrating level sensors.

FILLBAG

To fill big bags with granules, regrinds, flakes – or when regrind materials need to be stored for transport to another location – the FILLBAG is the right solution. An inflation system keeps the bag open at all times, streamlining the filling operations.  

Available options:

• Weighing of the bag contents on pallet
• Printer for reports and/or weight labels.

OKTOBAG

OKTOBAG is the system developed by Moretto for the complete emptying of big bags. Using a floating arm movement – known as the WAVE system – plastic granules are directed toward the centre of the bag, where a suction probe ensures efficient recovery while preventing material loss. The system is also suitable for emptying octabins, with the floating arms acting on the inner polythene bag to facilitate material discharge.

Three versions are available:

• BLUE version with manual movement and control;
• SKY version with programmable arms;
• LUX version for medical applications.

An optional empty-bag detection valve is available to signal when the big bag has been fully discharged.

OKTOMATIK

The patented system OKTOMATIK enables the emptying of up to 15 octabins per hour – i.e. one every four minutes – making it ideal for high-throughput operations. It is particularly suited for transferring granules to a larger silo, which can be connected to an automatic conveying system. The OKTOMATIK unloader can empty octabins containing up to 1.500 kg of hygroscopic materials or technical polymers. The inner polythene bag safeguards the contents from environmental contamination and prevents granule dispersion.

TILTER

TILTER is a device designed for emptying gaylords and/or octabins with capacities ranging from 500-600 kg to 1.000 kg. Granules are extracted using a suction system, provided the suction probe remains submerged in the material. Once the level drops, the tilting platform shifts the container, directing the remaining granules toward a bottom corner. This ensures complete emptying without the need for operator intervention.

How to prevent human error

During the production process, it is possible for a machine to be fed with the wrong material. This can happen for several reasons, and as production departments are mostly automated, the error may not be realised until it is too late. It is better to take preventive measures to avoid these situations. Moretto offers DAILY BINS, a series of containers with interlocking lids. These are equipped with an RFID tag that identifies the container as being intended for a certain type of granule. The lid is unlocked when a barcode and/or QR code reader recognises the same code stored on the tag that identifies the DAILY BINS container. The correct material can then be loaded into the container, eliminating the risk of error.

This controlled process is facilitated by a range of containers available in 10 different sizes. Once the appropriate material is loaded into a container, a tag bearing the material’s name is attached. The network-connected RFID reader then verifies that the material identified in the container matches the programmed specifications. If confirmed, it authorises the transfer to the injection moulding machine (IMM). This automation ensures a controlled process, minimising unnecessary manual intervention and allowing operators to dedicate more time to quality control.

SILCONTROL

Large plastic consumers are supplied with raw materials in 25-tonne batches, which are typically delivered via road or rail tankers. Naturally, these quantities are stored in silos, which are often numerous. However, tanker deliveries do not always arrive as scheduled, posing the risk that upon arrival, the silo may not be sufficiently emptied to accommodate the entire load. Sometimes, deliveries are partial top-ups, in which case the contents of the silo must match the type of material being delivered. Upon arrival at the silo area, an operator assigned to receive raw materials attends to the delivery. The delivery note specifies the material to be supplied through a printed barcode, as ordered by the purchasing department. The operator scans this barcode, activating SILCONTROL, which verifies that the identified material was indeed ordered. SILCONTROL knows the target silo to be loaded, ensuring that the tanker is completely emptied. SILCONTROL then performs an additional safety check: the selected silo automatically opens its loading hose inlet and waits for the hose to be connected. Then, it transfers the contents of the tanker to the correct silo, thereby actively avoiding the risk of error.

In applications with very high consumption this system is essential.

SVS bag unloader

The SVS 800 bag unloader is an automatic system for emptying plastic granule bags. It can accommodate a full 1.000 kg pallet. A layer of five bags is picked up by the claws, cut, and after a programmable shaking action, the fallen granules are collected and made available for pressure or vacuum conveying to one or more storage silos. This fully automatic process can empty up to eight hundred bags per hour.

An empty bags compression system is also available. Emptied pallets are stacked in a dedicated station.

Available options:

• Roller conveyor for pallets to be emptied, up to 5;
• Thrust loading group for transferring to silos;
• Station for empty pallets;
• Customisable layout in line or T-shape;
• Machine complaint with CE regulation;
• Machine complaint with Industry 4.0 standards;
• MOWIS Ready.

The SVS 800 prevents any granule loss, recovering 100% of the raw material.

We have set out a number of applications and controls related to the management of raw materials in granules. These examples are well-known and cover the main operations that can be performed using specialised machinery. The main aim is to avoid human error by transferring controls to digital systems, which can help with day-to-day management.

Computers are well suited to repetitive and sequential tasks, while humans, endowed with critical vision and intuition can devote themselves to higher-level tasks.

The storage solutions mentioned above are exclusive to Moretto, a company rooted in people, intelligence and passion. Experience, competence and innovation are the pillars that guide the Moretto business in pursuing a fundamental goal: satisfying customer requests and exceeding expectations with technologies designed to create added value and optimise processes. The result is unique, high-performance systems that last over time and offer a concrete solution to any plastics processing need.

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