Haver & Boecker are committed to perfecting the packing process for powdery products.
In the town of Oelde, Germany stands the Haver & Boecker Institute, a 1,000m2 test facility dedicated to studying the properties of its customers’ powdery products.
Here, a team of 10 specialists ranging from technicians to engineers develop efficient filing systems and select the most suitable packaging materials for process reliability and efficiency.
“Every product behaves differently during flow, filling, and storage,” Haver & Boecker Institute general manager Thomas Hilling said.
“Our task is to understand these behaviours and match them with the optimal technology and the customer’s specific expectations. That’s how we guarantee process reliability and efficiency from start to finish.”
The foundation: Product analysis and filling trials
At the core of the Institute’s work are product analyses and filling trials, processes that are critical to developing high-performance, reliable filling systems.
“Product assessment with respect to flow behaviour, filling, and storage is the foundation for designing suitable filling technology,” Hilling said.
Standardised test methods are used to analyse how a material behaves in various stages of handling.
These results form the basis for defining the correct filling principle, technical details and requirements, and packaging type. The Institute’s technical facilities, equipped with 15 filling systems, allow experts to perform full-scale filling tests to validate theoretical findings.
Hilling said every project is unique. Even materials sold under the same name can vary significantly due to differences in raw materials or production processes.
“That’s why we always consider the packing triangle as a single interdependent system,” he said.
The design of the bag also plays a decisive role. Factors such as air permeability, material strength, and closure type can directly influence filling performance and product stability. These variables are reviewed and optimised as part of every Institute project.
Evolving products, increasing complexity
Product diversity has grown enormously.
“Thirty years ago, the building materials industry mainly dealt with cement, lime, and gypsum,” Hilling said. “Today, manufacturers often offer more than 120 different formulations, many of which are much finer and more complex.”
The trend toward finer particle sizes and the inclusion of chemical additives has redefined the requirements for modern filling technology. Finely ground materials have higher surface areas and increased reactivity, demanding advanced sealing, aeration, and dust control capabilities.
Beyond construction materials, the Institute encounters a wide spectrum of products – from chemical powders to food and agricultural materials.
“Every now and then we still get something completely unexpected,” Hilling said.
“Recently we had spice liquorice powder from Turkey and even bat droppings used as fertiliser from Australia. Each product brings its own challenges.”
Rising customer expectations
As products evolve, so too do customer demands.
“Expectations have increased across all industries,” Hilling said.
“Customers want higher filling capacities, tighter weight tolerances, often beyond legal calibration limits, and greater automation.”
Cleanliness, ease of product changeovers, and energy efficiency are now key factors in every design. Sustainability has also become a central priority.
“Our customers want to minimise waste and product loss,” Hilling said.
“Filling must be resource-efficient and clean, and packaging must reliably protect the product. Even visual presentation and usability features such as carrying handles or easy-open systems are recognised as competitive advantages.”
This shift has positioned the Institute as not only a technical testing centre but also a strategic partner helping customers meet modern performance and environmental standards.
Further to this is ongoing regulatory developments such as the Australian Packaging Covenant Organisation’s national regulatory framework and the European Packaging and Packaging Waste Regulation which a putting a strong focus on the requirement for more sustainable packaging.
In turn, this is creating a need from manufacturers for more innovative recycled bag materials, functionality and design.
The Institute’s reputation for precision and reliability is reflected in its growing customer base.
“We welcome about 3,000 visitors each year,” Hilling said.
“That number alone shows how much trust our customers place in us.”
Because the filling line is often the final link in a customer’s production process, its performance is critical. A poorly optimised system can jeopardise the entire operation.
“Our database now contains more than 22,000 product analyses,” Hilling said.
“This accumulated knowledge allows us to make accurate comparisons and informed recommendations. Customers appreciate that we not only look at the machine technology, but also all the parameters influencing filling. That’s our expertise, and it builds trust.”
The Institute acts as a central service provider within the Haver & Boecker Group and beyond. It collaborates closely with internal divisions and subsidiaries such as Haver Engineering Meißen, Ibau Hamburg, Feige Filing, Behn+Bates, Aventus, and Newtec Bag Palletizing.
As a global company Haver & Boecker operates test institutes with a similar setup in China, India, Brazil, and the USA to be close to its customers.
Externally, the Institute maintains partnerships with plant engineering firms, trade associations including EUROSAC and PSSMA, as well as universities and packaging material manufacturers.
“Over time, raw material producers – especially in paper and plastics – have come to us for testing before their products reach the market,” Hilling said.
“That keeps us constantly informed about the latest developments and trends.”
Continuous innovation is driven by market demands, customer feedback, and internal initiative. “New ideas come from many directions, sometimes directly from customers, sometimes from our engineers,” Hilling said.
“We often test concepts even before there’s a specific customer request. This proactive approach allows us to identify opportunities for improvement early on.”
Economic efficiency and functional reliability remain central considerations.
“There are many innovative technologies out there,” he said, “but they must withstand real-world conditions. That’s why we test extensively before implementation.”
One of the company’s latest solutions is its QUAT2RO, a modular digital-solutions suite designed to bring ‘smart factory’ level transparency, control, and efficiency to industrial packing and bulk-material processing plants.
QUAT2RO combines real-time monitoring, AI-powered quality control, and advanced process analytics that can be tailored to a facility’s specific needs, from simple real-time dashboards to full integration of mixing, filling, packing and logistics.
Knowledge and transfer training
Training plays an essential role in maintaining HAVER & BOECKER’s technical excellence. Each year, around 50 new employees from the headquarters in Oelde, subsidiaries, and external partners receive instruction at the Institute.
“In addition, we train service engineers and apprentices as part of their vocational programs,” Hilling said.
Since 2024, the HAVER Academy has expanded this offering, providing structured learning modules for customers.
“It’s important that everyone involved, from engineers to sales staff. The better prepared they are, the smoother their future projects will run,” Hilling said.
With approximately 100 billion bags filled worldwide each year, the challenges of precision, efficiency, and sustainability continue to grow. Yet, for Hilling and his team, this constant evolution is exactly what keeps their work engaging.
“Every product behaves differently, every bag design is new, and every customer brings specific expectations,” he said.
“That makes our work exciting, and it keeps us moving forward. As Haver & Boecker grows and technology advances, so will the Institute. If we maintain our passion for innovation and precision, our future will be just as strong as our tradition.”