The Story

Green Star Organic Milling is a U.S.-based producer of organic flours, grains, legumes, seeds, and other dry goods. As a clean-label manufacturer operating at high volumes, the company needed a packaging solution that could handle a broad range of products and bag sizes — without sacrificing speed, accuracy, or efficiency.

The challenge wasn’t just throughput: it was about flexibility. Green Star required a reliable machine that could seamlessly manage both powdery and granular products, in multiple bag formats, while maintaining consistent packaging quality. They were looking to improve their existing tooling setup, which was limiting performance — causing slowdowns, inconsistent fills, and increased downtime, especially when running 7-inch-wide bags.

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The Project

To solve this, Green Star partnered with ICA and installed an SP8M packaging machine, equipped with customized auger filling tooling precisely engineered to match their operational needs.

Thanks to ICA’s engineering team, the new setup now supports a wide range of products and formats — all on a single, integrated configuration. The SP8M provides the accuracy and flexibility needed to switch between flours, seeds, legumes, coffees, and even confectionery items, without extensive changeovers or multiple machines.

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The Results

By adopting the SP8M solution, Green Star gained:

• One machine, many possibilities — Multiple bag formats with a single setup
• Smooth handling of both powdery and granular products
• Improved packaging accuracy and speed
• Reduced downtime and labor costs
• Better shelf presentation and packaging consistency

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What they say about ICA

“We chose ICA for their strong industry reputation, technical expertise, and ability to deliver customized solutions. Their team was responsive, professional, and clearly understood our production needs. We would absolutely recommend ICA to any company seeking innovative, reliable, and performance-driven packaging solutions.”

Michael Mehari — Green Star Organic Milling – USA