WILPAC Detergent and Home Care Packaging Lines: Dust-Controlled Powder Bagging and Corrosion-Resistant Liquid Filling

Home care products are bought every week, so the packaging hall runs at retail speed and rarely gets a long stop for maintenance. Two very different products share the same room. Laundry powder is hygroscopic, abrasive and extremely dusty, so a bag that is not sealed cleanly cakes in the warehouse, and a filling head that leaks powder coats the whole line within minutes. Liquid detergent is a concentrated brine of surfactants, fragrance and enzymes that attacks ordinary carbon steel, swells standard nitrile seals and foams violently the moment it drops into a bottle. Retailers add a third demand on top of both: exact net content, no leakage on the pallet, and a cap torque that a consumer can open but a courier cannot loosen.

On the powder side WILPAC builds vertical form fill seal machines fed by a servo auger with a fast bulk phase and a slow dribble phase, weighing by load cells and cutting off within plus or minus one per cent of target on a three kilogram bag. A dust extraction hood at the sealing jaws pulls displaced air away from the film so that no powder is trapped inside the seal, which is the single most common cause of leaking detergent bags. Controlled vibration settles the product before sealing, and a gusseted bag forming set with a laser-scored handle and a tear notch produces a pack that stands on the shelf. A checkweigher rejects out-of-tolerance bags, a metal detector protects the brand, and an inkjet printer applies batch and date. The same platform runs 400 gram to one kilogram refill pouches by changing the forming tube and the dosing screw.

On the liquid side the line uses 316L stainless wetted parts with PTFE and EPDM seals, and fills from the bottom of the bottle to keep foam under control. Volumetric piston filling handles viscous gel, while a mass flow meter delivers the accuracy a five litre pack needs. Bottles then pass an induction sealer, a torque-controlled capping head that records the applied torque for every single cap, and a vision station that rejects a missing cap, a skewed label or a visible drip at the bottle base. Refill pouches are filled through the spout on a separate station, with spout insertion, a squeeze leak test and cartoning in the same enclosure. Quick-change format parts let one line move from a 750 millilitre bottle to a three litre jug in a single shift.

One controller runs the whole hall, holds the fillers back when the case packer is blocked, and keeps powder and liquid recipe data separate so that a changeover never mixes a bleach formula into a colour-care product. Clean-in-place circuits, batch traceability by printed code, consumption and efficiency reporting, and remote diagnostics are standard. WILPAC supplies corrosion-resistant contact parts, foam-control filling profiles, explosion-protection options for combustible powder, and operator training, and supports detergent and home care producers across Europe, the Middle East, Africa, Latin America and Southeast Asia.