ZSYAN SY-WDJ5000A Vertical Automatic Mesh Bag Weighing & Clipping System
1. Quick Answer & Overview
Overview & Quick Answer: The ZSYAN SY-WDJ series vertical
mesh bag packaging machine is an automated produce bagging system designed for packing bulb and root crops into tubular knitted mesh bags with dual galvanized iron wire clip closures. Operating at 20 to 35 bags per minute across a 200g to 5000g dosing envelope, the machine integrates automatic tube mesh pulling, continuous electronic weighing, thermal wine-glass labeling, and pneumatic wire clipping into a unified AISI 304 stainless steel chassis. Controlled via a 7-inch PLC interface with 99 recipe memories, the system maintains bag length tolerance within ±15mm and product drop clearance to minimize surface abrasions. Operating under 0.6 MPa pneumatic pressure with 2.2 kW power draw, it replaces 3 to 4 manual clipping operators, delivering full capital expenditure payback within 2.8 to 4.2 operational months in continuous commercial packhouse environments.
2. System Architecture & Workflow
The engineering flow diagram below maps the continuous sequence of automated operations—from infeed metering to final hermetic discharge:
[Infeed Hopper / Elevating Conveyor]
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[Multi-Head Combination Computer Weigher (±0.5% Accuracy)]
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[Low-Impact Centering Buffer Funnel]
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[Tubular Mesh Sleeve & Thermal Label Feeding Track]
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[Pneumatic Dual-Jaw Wire Clipper & Bottom Bag Forming]
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[Automated Produce Drop & Top Gather Necking Mechanism]
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[Top Clip Swaging & Guillotine Thermal Label Cutoff]
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[Soft-Landing Discharge Chute & Take-Away Incline Conveyor]
The system pairs seamlessly with automated 10-head or 14-head combination weighers. Produce falls into the specialized low-abrasion forming tube where tubular knitted mesh is continuously indexed by dual high-friction rubber belts. An automated thermal ribbon label dispenser feeds wine-glass or banner labels directly into the throat of the pneumatic clipping assembly, creating a tamper-evident package with an integrated carrying handle in a single 1.8-second cycle.
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3. Technical Specifications Matrix
Direct horizontal engineering benchmark comparing ZSYAN equipment against conventional machinery and manual packaging:
| Performance Parameters | ZSYAN SY-WDJ2500A / 5000A | Conventional Rotary Clipper | Manual Pliers Clipping Line |
|---|
| Forming & Closure Mode | Continuous tubular sleeve + Pneumatic dual wire clips | Pre-formed net bags + single clip | Manual net stuffing + foot-pedal clamp |
| Operating Speed | 20 – 35 bags/min (continuous servo cycle) | 12 – 18 bags/min | 5 – 8 bags/min per operator |
| Packaging Range | 200g – 5,000g (interchangeable forming tubes) | 500g – 2,500g | Uncontrolled (manual dependent) |
| Bag Length Precision | ±15 mm (optical registration sensor) | ±35 mm (mechanical stop) | Visual estimation (±50 mm) |
| Produce Damage Rate | < 0.15% (cushioned drop gate) | 0.8% – 1.5% | 1.2% – 2.0% (handling drops) |
| Compressed Air Requirement | 0.6 MPa, 0.3 m³/min | 0.6 MPa, 0.45 m³/min | Manual / 0.5 MPa pneumatic gun |
| Electrical Rating | 2.2 kW, 1-Phase 220V 50/60Hz | 3.5 kW, 3-Phase 380V | 0.5 kW (conveyor only) |
| Machine Dimensions | 1,450 × 1,200 × 2,200 mm | 1,800 × 1,500 × 2,400 mm | 3,500 × 1,200 mm (table cluster) |
| FOB Reference Price | USD $11,500 – $16,800 | USD $22,000 – $32,000 | USD $2,500 (benches & clamps) |
4. Mathematical ROI & Payback
Financial payback model quantifying direct labor reduction, material optimization, and overfill elimination:
Direct Annual Net Savings (S) = [Labor Reduction] + [Netting Material Savings] + [Giveaway Reduction]
Where:
- Labor Reduction: 3 operators eliminated × $14,000/year base salary = $42,000
- Netting Material Savings: 12% mesh reduction via automated tensioning = $4,800
- Produce Giveaway Reduction: 15g overfill eliminated per bag on 1.2M bags/yr = $6,200
Total Annual Net Economic Benefit (S) = $53,000 USD
Machine Purchase Capital Expenditure (Capex) = $15,800 USD
Payback Horizon = (Capex / S) × 12 Months
= ($15,800 / $53,000) × 12 = 3.58 Months
By deploying the SY-WDJ5000A, commercial packing facilities amortize equipment procurement within less than 4 months of single-shift operation. When running peak seasonal harvest schedules (16 hours/day), full capital recovery is achieved in approximately 55 operating days.
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5. Engineering FAQs
Practical technical answers addressed to plant managers, automation engineers, and procurement directors (Click to expand technical response):
The ZSYAN SY-WDJ series utilizes a hybrid servo-pneumatic architecture. Bag pulling and mesh sleeve indexing are driven by an industrial Delta servo motor connected to dual synchronous high-friction PU belts, guaranteeing millimetric length accuracy. The clipping jaw assembly is actuated by high-frequency SMC pneumatic cylinders rated for over 15 million cycles, utilizing coiled galvanized iron wire stock to form custom-crimp staples on the fly rather than expensive pre-formed clips.
The machine incorporates a tiered cascade deceleration funnel lined with food-grade polyurethane foam. When bulbs descend from the multi-head scale, they strike angled baffles that reduce terminal drop velocity by 65% before entering the mesh tube. Furthermore, the drop gate opens synchronously with the descending stroke of the bag carriage, ensuring produce transfers with near-zero free-fall height.
The equipment is engineered to run extruded tubular polyethylene (PE) netting, knitted raschel mesh sleeves, and biopolymer PLA biodegradable mesh fabrics ranging from 120mm to 280mm lay-flat widths. The built-in label feeder handles standard wine-glass punched ribbon tags, pre-printed polypropylene banner tape (cross-stitched into the clip), or self-adhesive barcode stickers applied inline.
Communication is managed via an onboard Omron PLC with integrated Ethernet/IP and RS-485 Modbus RTU ports. The packaging machine sends ready-to-fill permissive dry contacts to the multi-head computer combination scale, holding the hopper discharge until the clip cycle completes. Downstream, it feeds bag-ready signals to take-away elevators and metal detector/checkweigher reject gates.
Daily maintenance requires draining the pneumatic water separator and cleaning onion skin dust with dry compressed air. The galvanized iron wire spool (approx. 5,000–8,000 closures per coil) can be reloaded in 90 seconds through a quick-thread guide. Punch dies and cutting blades have an operating lifespan of approximately 600,000 cycles and can be re-sharpened or replaced in under 15 minutes using standard hex keys.
6. Technical Inquiries & Quotes
Ready to Automate Your Packaging Facility?
Consult directly with ZSYAN factory engineers for custom pouch specifications, line layouts, and direct FOB quotations within 24 hours.
