Transforming a Major Indonesian Rice Supplier with YILONG’s Bag-in-Bag Rotary Pouch Packaging Line
Background
An established agricultural supplier in Indonesia specializes in producing and exporting white rice, multigrain blends, brown rice, and premium tri-color rice. Their products are distributed to supermarkets, wholesalers, and export clients across Southeast Asia and the Middle East.
As consumer preferences shifted toward pre-packed, retail-ready rice, the company faced new challenges. Their traditional manual packaging process—once sufficient for bulk supply—became a bottleneck when demand for pre-packed 1kg–5kg rice surged.
They turned to YILONG to modernize their packaging operations.
Challenges Before Automation
1. Inconsistent Weighing Accuracy
Manual filling and weighing resulted in large fluctuations:
Errors up to ±8g
Frequent underweight complaints from retailers
Excess giveaway cost due to overfilling
This hurt both brand image and profitability.
2. Heavy Dust & Hygiene Concerns
Rice generates dust during conveying and filling.
In manual packaging:
Dust accumulated around workstations
Hygiene inspections took longer
Workers were exposed to airborne particles
The factory needed a cleaner, more controlled system to meet export standards.
3. Limited Output
The manual workflow required:
Multiple workers
Slow filling
Frequent rechecking and resealing
Daily output struggled to meet the increasing export volume.
4. Large Packaging Size Variations
The supplier required high flexibility:
1kg, 2kg, 5kg self-standing pouches
Kraft paper pouches, laminated pouches, aluminum pouches
The existing semi-auto equipment could not adapt efficiently to this variety.
5. Rising Labor Costs & Workforce Shortage
Finding trained workers for repetitive manual weighing and sealing tasks became increasingly difficult.
YILONG’s Tailored Solution
To solve these challenges, YILONG installed a Bag-in-Bag Rotary Pouch Packaging Machine, combined with:
Automatic pouch feeder
Precision electronic weighing system
Dust isolation and exhaust design
Multi-format pouch compatibility
Continuous rotary motion for high throughput
This fully automated system was engineered specifically for granular, free-flowing products like rice.
Key Machine Features
✦ Precision Weighing (±1g Accuracy)
A high-speed load cell ensures every bag meets weight regulations, helping the customer maintain consistent quality across all product SKUs.
✦ Dust-Control Enclosure
A sealed filling chamber helps:
Reduce airborne dust
Maintain a hygienic workspace
Meet international food packaging standards
✦ High Productivity
The system’s continuous rotary operation increased speed by 120%, supporting both local and export market needs.
✦ Wide Pouch Compatibility
The machine handles:
1kg–5kg stand-up pouches
Kraft paper pouches
Plastic laminated bags
Aluminum foil bags
This allows fast switching between product categories and sizes.
✦ Labor Reduction & Cost Savings
Only 2 operators are needed to monitor the entire line, significantly lowering long-term operating costs.
Implementation & Training
YILONG engineers traveled to Indonesia for:
Factory layout optimization
Installation and calibration
Operator training on recipe settings, weight adjustments, and cleaning
Safety and hygiene protocol guidance
Within a few days, the machine achieved stable, high-precision operation.
Results After Integration
1. Weighing Accuracy Improved from ±8g → ±1g
Retailer complaints dropped dramatically, and packaging uniformity reached international standards.
2. 120% Increase in Daily Output
The supplier could now confidently accept larger export orders.
3. 60% Reduction in Labor Requirements
Only two operators are needed for inspection and oversight.
4. Cleaner, Safer, More Professional Factory Environment
Dust emissions decreased significantly, improving hygiene and safety.
5. Secured a Long-Term Contract with a Major Supermarket Chain
Better packaging consistency and appearance helped the supplier qualify for premium retail partnerships.
Client Testimonial
“YILONG’s solution elevated our entire production capability. The weighing accuracy and clean operation make our products export-ready. This system paid for itself within months.”
Conclusion
By upgrading to YILONG’s Bag-in-Bag Rotary Pouch Packaging Machine, the Indonesian rice supplier achieved massive improvements in capacity, accuracy, hygiene, and workforce efficiency—helping them secure stronger retail partnerships and expand internationally.
