USS High-Rate Bulk Bag Filling Station with USS Pallet Dispenser and Gravity Conveyor

The USS ULTRA-BAGGER™ Bulk Bag Filling Machine

Dispense Pallet -> Fill -> Weigh -> Pack -> Convey -> Repeat

The USS ULTRA-BAGGER™ is our highest-rate bulk bag filling station. When you need to fill a lot of bags quickly, with little downtime and maintenance…this is the bagging station you’re looking for.

Enhance your operations with the USS ULTRA-BAGGER™ FIBC (Super Sack) bulk bag filling machine, featuring a comprehensive range of advanced features designed to save on labor costs and ensure measurement accuracy. This turn-key package includes automatic pallet dispensing, retractable bag hooks for easy operator access, automatic weighing, densification, and conveying.

Why Choose the USS ULTRA-BAGGER™?

High-Speed Operation: The USS ULTRA-BAGGER™ is our highest-rate bulk bag filling station, perfect for quickly filling large quantities of bags with minimal downtime and maintenance.
Precision and Efficiency: This PLC-run station seamlessly fills, weighs, and packs your material in one smooth operation. Our patented densifier increases bag capacity by up to 20%, optimizing space and storage efficiency. It’s so effective that clients can stack filled bags on top of each other.
Customizable Options: Available with or without conveyors, the USS ULTRA-BAGGER™ is accessible from all four sides and can be oriented to fit your specific location. Attachments for filling drums, boxes, and totes are also available.
Versatile Pallet Dispenser: Our pallet dispenser accommodates both wood and molded pallets, dispensing them in-line or at a 90-degree angle. When combined with a powered conveyor, this feature fully automates your operation.

Optimize Your Material Handling with USS ULTRA-BAGGER™

Experience unparalleled efficiency, precision, and flexibility with the USS ULTRA-BAGGER™ bulk bag filling station. Contact us today to learn how this state-of-the-art system can enhance your material handling processes and deliver exceptional value to your operations.

FIBC Supersack Bulk Bags Densified and Stacked by a US Systems Bagger — FIBC Bulk Bags Densified and Stacked by a US Systems Bagger

The USS ULTRA-BAGGER™ Bulk Bag Filling Station fills the same way, the right way, every time. Savings are realized in manpower required, filling accuracy, reduced bulk bag cost, improved storage, and reduced shipping charges.

Download our Bulk Bag Filling Station Product Guide PDF

US Systems Bulk Bag Filling Station Diagram

A US Systems Ultra-Bagger™ System for Powdered Milk

This video is an “oldie but goodie” look at the main features of our bagging station. Check it out!

Features and Benefits:

Food-grade neoprene cuff inflates to seal bag
PLC-controlled automation
Intuitive HMI (touchscreen available)
Motorized height adjustment for easy maintenance
Painted carbon steel construction
Latch mechanisms offer positive loop control
Latch mechanisms automatically release once bag is full
Latch mechanisms move toward operator for quick bag hanging
Exhaust filter available or use existing dust collection system
Optional automatic pallet dispenser available
All features are optional, customizations welcome. Call USS to discuss your needs.

Seamless Inflatable Cuff

The USS ULTRA-BAGGER™ Seamless Inflatable Cuff, manufactured of food-grade neoprene, expands against the inside of the bulk bag fill spout, sealing the opening to guard against product contamination and to control dust. All product contact points are constructed of stainless steel. An internal passage in the product fill spout allows the evacuation of dust during the filling cycle. A remote push button is provided to inflate and deflate the cuff.

FIBC Supersack Bulk Bag Bagger Spout with inflatable cuff — USS ULTRA-BAGGER™ Stainless Steel Spout with Food-Grade Neoprene Inflatable Cuff

Top View of Supersack Bagger Showing Inflating Mechanism, Dust Collection, and Motorized Height Adjustment — Top View of Bulk Bagger Showing Inflating Mechanism, Dust Collection, and Motorized Height Adjustment

Bag Inflation, Motorized Height Adjustment, Product Valve

A system to inflate the bulk bag before starting the filling cycle is housed within the air intake filter. An exhaust air filter assembly can be added or a connection to your existing dust collection system can be made to capture displaced air from the bulk bag.

The motorized height adjustment includes a motor, a gear reducer, lead screws with bronze nuts in each leg, and chain and sprockets to tie the system together. The upper and lower limits are controlled by a proximity switch.

The product valve to control the flow of your material is attached to your product source. A flexible hose then connects the valve to the bulk bag filling machine.

Why Do Our Customers Love the Ultra-Bagger™ Densifier So Much?

Not all densification methods are created equal. Vibrating a bag may help the material settle but doesn’t cut it for our most demanding customers. High Frequency, Low Amplitude vibration doesn’t PACK material. That’s why our customers prefer the Ultra-Bagger’s™ High Amplitude, Low Frequency densification method.

Densification Magic: High Amplitude, Low Frequency

Our unique patented densifier lifts the bulk bag and drops it downward using the sheer bulk weight to compact material into spaces between particles – pushing air out of the material so it occupies a smaller volume.

We have customers able to stack bulk bags 2-high in the warehouse, effectively doubling the storage capacity of their facilities.

Vibrating a bulk bag or box may help, but it is not as good as “packing” the material using its own momentum from the force of gravity.

What Customers Have to Say About It

One of our customers we have a long relationship with wrote to us:
“With 28 years of experience in the Bulk Bag industry I have found that the low amplitude high impact method of settlement has been one of the best methods for settling bulk bags. Especially when dealing with bags that are palletized. Lift and drop method of settling while the bag is under complete control is superior to most other methods of settling that I have experienced. Vibration of a bag that is on a pallet is dampened to the extent that the actual effect is minimum.”

Another customer who has purchased 9 fill stations over the last 15 years specifies:
“Densifier shall be a “lift and drop design. Simple bag vibration is unacceptable.” This is a large chemical manufacturer who has multiple plants and has tried many solutions, finally to be satisfied with our method.

If densification is an important feature of your filling system give USS a call for a free consultation.

SuperSack Warehouse with Hundreds of Bulk Bags filled by a US Systems Bulk Bag Filling Station

WHEN YOU NEED BULK BAGS PACKED FULL, THERE IS NO COMPETITION WITH OUR PATENTED DENSIFYING SYSTEM.

USS Bulk Bag Filling - Empty and Full Bags

Field Photos of Installations:

US Systems FIBC Big Bag Bagging Station with Pallet Dispenser, Bagger, and Conveyors

US Systems Power Roller Conveyor for Palletized Bulk Bags

Automation

Our systems feature industrial-duty NEMA-rated control panels that significantly enhance the automation of your processes. These advanced control panels ensure that your system operates smoothly with minimal downtime, thereby improving overall efficiency and productivity.

Key Features of Our Control Panels:

NEMA-Rated Panels:
- Designed to meet rigorous standards, these panels provide superior protection and reliability, ensuring long-lasting performance in harsh industrial environments.
Disconnect Switch:
- Facilitates the safe disconnection of electrical power to your system, allowing for maintenance and emergency shutdowns without compromising safety.
Primary Circuit Protection:
- Protects your system from electrical faults and overloads, minimizing the risk of damage and maintaining operational continuity.
Industrial-Duty Buttons, Selector Switches, and Door Devices:
- Robust and durable components that offer reliable control and easy operation, designed to withstand heavy usage in demanding industrial settings.
PLC – Programmable Logic Controller:
- Provides advanced automation capabilities, enabling precise control over various processes and functions within your system. The PLC can be programmed to execute complex tasks and ensure efficient operation.
Motor Starters:
- Ensure the smooth starting and stopping of motors, reducing mechanical stress and prolonging the lifespan of your equipment.
HMI – Human Machine Interface:
- Offers an intuitive and user-friendly interface for operators to monitor and control the system. The HMI displays real-time data and allows for easy adjustments to optimize performance.
LED Indicator Lights:
- Provide visual status updates, allowing for quick identification of system conditions and enhancing operational awareness.
Variable-Speed Controls:
- Enable precise regulation of motor speeds, optimizing energy consumption and improving process control.
Touchscreen:
- A responsive and interactive display that simplifies system management, offering easy access to settings, controls, and diagnostic information.
Remote Networking Capability:
- Allows for remote monitoring and control of your system, enabling timely interventions and adjustments from any location, improving responsiveness and flexibility.
Data Collection:
- Facilitates the gathering and analysis of operational data, providing insights into system performance and helping identify areas for improvement. This feature supports predictive maintenance and process optimization.