Flexible pouch filling and heat sealing line for flexible pouches and containers for supporting and moving the flexible pouches
A flexible pouch is provided which has panels (3, 5). A transparent strip (13) is provided on one of the panels and a translucent filter (13a) on the other. The panels are heat sealed together to close the pouch and the integrity of the heat seal is determined by shining ultraviolet light through the clear strip and inspecting the translucent filter (13a) so that imperfections in the seal can be identified. Pouches are packaged into containers (25) which include slots (50) and the full containers are stacked for transport through the plant for further processing in a retort, cooler or the like. This enables a large number of pouches to be easily transported through the plant for further processing after they have been filled and heat sealed. The heat sealing line may include a vision system, or the vision system may be a stand-alone item for inspecting the seal to determine the integrity of the seal. The vision system includes a UV light source for directing UV light through the transparent strip and a camera for inspecting the translucent filter (13a) to obtain an image of the filter (13a). The image is processed to identify dark regions which enable the integrity of the seal to be determined.
This invention relates to a flexible pouch, filling and heat sealing line and associated apparatus for flexible pouches, and containers for supporting and moving the flexible pouches.
BACKGROUND ARTFlexible pouches which are generally referred to as doy pouches or pillow pouches comprise a front and back panel which are sealed along opposite edges. A gusset is arranged between the panels at the base of the pouch and the top of the pouch is heat sealed after the pouch is filled in a filling and heat sealing line.
In general, food products or other products which can deteriorate, are packaged in such pouches and it is therefore required that the pouches be properly sealed in order to provide sufficient shelf life for the product contained in the packages. If the product is not properly sealed, the product is likely to deteriorate in a very short time period, thereby spoiling the product. This generally makes the product unusable.
Such pouches are becoming increasingly more common and provide a convenient manner for storing and selling food products. However, these types of pouches do make handling more difficult in a plant in which the food product is packaged into the pouches. The reason for this is that the pouches are generally flexible in nature and do not stably stand on their own. Thus, the transportation of the pouches after the pouches have been filled and sealed throughout the plant for further processing and packaging is difficult.
SUMMARY OF THE INVENTIONA first invention is concerned with a pouch which facilitates easy visual inspection of the pouch by a vision system to ensure the integrity of the sealed pouch, and so that pouches which are not properly sealed can therefore be rejected.
This invention may be said to reside in a flexible pouch comprising:
a front panel;
a rear panel;
the front and rear panels being joined along opposite side edges;
a closed base;
an open end opposite the base through which a product can be loaded and which is to be closed by a seal which joins the front and rear panels together; and
a transparent region in at least one of the front and rear panels which overlaps the region of the front and rear panels at which the seal is to be formed to facilitate inspection of the seal to determine the integrity of the heat seal.
The transparent region increases the ease by which a vision system can inspect the seal to determine the integrity of the seal or determine if the seal is faulty. The transparent strip more easily allows light to be transmitted through the front and rear panels in the vicinity of the seal so that that light can then be detected to determine the integrity of the seal.
Preferably, a translucent filter of constant colour is provided on one of the panels so the seal, when formed, is between the translucent filter and the said at least one of the front and rear panels, so if the seal is properly formed, a substantially uniform intensity of light will be transmitted through the filter. Thus, if the seal is not properly formed and food particles or other contaminants are located in the seal thereby destroying the integrity of the seal, the amount of illumination transmitted through the filter is not constant, thereby enabling “dark spots” to be detected to provide an indication that the seal is not properly formed, and therefore to allow the pouch to be rejected.
Preferably, the transparent region is provided adjacent a top edge of the front panel of the pouch.
Preferably, the transparent region includes a fluorescing material which fluoresces when subjected to light of a particular wavelength to produce white light, and wherein when the front and rear panels are sealed together, the transparent region and the adjacent portion of the other of the front or rear panel forms a continuous waveguide for transmission of white light so that any failure of the seal where the panels do not seal will allow light to disperse, thereby breaking the integrity of the waveguide so that those regions are identifiable by inspection of the said adjacent portion.
Preferably, the said adjacent portion is translucent to define a filter which can be detected by a camera so that dark regions indicative of an improperly formed seal can be identified.
Preferably, the fluorescing material fluoresces when subjected to ultraviolet light.
Preferably, the ultraviolet light has a wave length of from 320 to 350 nm.
Preferably, the closed base is defined by a gusset at the base of the pouch connected to the front and rear panels for closing the base of the pouch.
A second invention is concerned with a container for receiving sealed pouches to enable the pouches to be manoeuvred through a processing system after the pouches have been filled and sealed.
This invention may be said to reside in a container for receiving and supporting flexible pouches, comprising:
a container body having an open top and an open bottom so water can drain through the open top, over the pouches supported in the container and out through the open bottom;
a plurality of support elements, each for supporting side edges of the pouch;
first cooperating locator means on an upper portion of the container body;
second cooperating locator means on a lower portion of the container body; and
wherein two like said containers are able to be stacked one above the other by the first cooperating locator means of one container engaging the second cooperating locator means of the other container.
The container of the invention enables the pouches to be held within the container for transport around the plant for further processing and also enables the containers to be stacked one above the other so that a number of the containers can be moved together on a pallet for further processing.
Preferably, the support elements each comprise a pair of spaced apart slots for receiving the side edges of the pouch, each slot having a guide entrance formed by a pair of inclined surfaces which incline outwardly from the slot and downwardly toward the slot to form a guide for guiding the edges of the pouch into the slots.
This feature enables pouches to be dropped from above the container and for the side edges of the pouches to be easily and conveniently guided into the slots so that the slots support the pouch.
Preferably, the container includes two rows of opposed slots so that the pouches are supported in pairs in the container.
Preferably, the first cooperating locator means comprises at least one a tapered pin, and the second cooperating locator means comprises at least one hole.
Preferably, the container body includes opposed side walls and opposed end walls, and a first said tapered pin is provided on a block fixed to an upper portion of one of the side walls, and a second said tapered pin is provided on a block fixed to an upper portion of the other side wall diametrically opposite the first pin.
Preferably, the container body includes a flange extending at least partway along each side wall, one of said flanges having a first said hole in vertical alignment with the first pin, and the other said flange having a second said hole in vertical alignment with the second said pin.
Preferably, the flanges extend along the entire length of the side walls.
Preferably, the slots are provided in rails which extend between the opposite ends of the container body.
Preferably, the open bottom of the container body comprises a plate, the said flanges being integral with, and part of, the plate, and at least one aperture in the plate for forming the open bottom.
Preferably, the plate includes a plurality of rectangular apertures for forming the open bottom of the container.
In one embodiment of the invention the container is formed from a plurality of container modules, each module having a pair of said support elements, and connector elements for connecting the modules together to form the container.
Preferably the connector elements comprise at least one bore passing through each module so that modules can be located in side-by-side relationship with the bores forming a channel through the modules, and a rod for location in the aligned channel to connect the modules together.
Preferably the modules include two bores extending substantially at right angles with respect to one another so that when the modules are located together to form the container, pins are extended through the respective channels formed by the bores so that the pins connect the modules together in both a first direction of the container and a second direction perpendicular to the first direction.
Preferably the pins include at least one screw threaded end for receiving a nut.
The pins may have an opposite end which includes a screw threaded end for receiving a nut or a pin head to thereby locate the rods in the aligned channels.
A third invention relates to a pallet for supporting the containers so that a number of containers can be stacked on the pallet and the pallet can be moved through the processing plant for further processing of the product contained within the pouches which are supported in the containers. This invention also enables the containers to be properly located on the pallet and stably supported so that once a pallet is positioned, the position of the containers on the pallet can be determined to enable the containers to be lifted by a robot.
This aspect of the invention may be said to reside in a pallet for receiving a plurality of containers for receiving pouches containing a product, including:
a pallet body; and
a plurality of locator elements on the pallet body for registering with cooperating locator elements on the containers so that when the containers are loaded onto the pallet, the cooperating locator elements on the containers engage the locator elements on the pallet to securely support and locate a first layer of the containers on the pallet.
This aspect enables a number of containers to be securely loaded and accurately located on the pallet, and for the containers to be stacked one above the other in layers so that the pallets can be manoeuvred through the processing plant on the pallets and accurately located for engagement by a robot.
Preferably, the pallet includes handle receiving elements for receiving a handle to facilitate movement of the pallets after loading the pallets onto a trolley.
Preferably, the cooperating locator elements comprise tapered pins which project upwardly from the pallet body.
Preferably, the pallet body has a lower surface, the lower surface having a plurality of grooves for registering with conveyor elements to enable the pallet to be moved on a conveyor.
Preferably, the pallet body is formed from longitudinally extending and transversely extending frame elements, a plurality of beams being formed on an upper surface of the frame elements, and the tapered pin being provided on the beams.
A further invention is concerned with the manner in which the pouches are moved through the plant after packaging of a product in the pouches and sealing of the pouches.
This invention may be said to reside in a packaging system plant, including:
a filling and heat sealing line for filling pouches with a product and sealing the filled pouches;
a container for receiving filled and sealed pouches from the line, and for supporting a plurality of the pouches;
a transporter for receiving the containers loaded with the pouches to form a stack of the containers, and for enabling the stack of containers to be moved from one place to another;
an ancillary processing station for receiving the containers transported by the transporter and for performing an ancillary treatment step on the filled pouches while housed in the stack of containers; and
a packaging station for receiving the transporter carrying the stack of containers to enable the pouches to be removed from the containers and packaged for distribution.
According to this invention, the packages are retained in the containers as the packages are moved from the filling and heat sealing line and transported about the plant for further processing to the packaging station. This enables convenient and easy manoeuvrability of the pouches to other treatment stages within the plant, and for those treatment stages to take-place while the pouches are properly supported. Thus, handling and movement of the pouches is much easier throughout the plant between filling and packaging for distribution.
Preferably, the ancillary treatment stage comprises a retort for receiving the pouches.
Preferably, the retort is a shower type retort.
In another embodiment, the ancillary treatment stage comprises a cooling station for cooling heated pouches. In this embodiment, there may also be provided the drying station for drying the pouches.
The retort provides hot water to the packages which is able to be sprayed and flow through the containers to heat and pasteurise and/or cook the food product within the pouches whilst the pouches are supported in the containers.
Preferably, the system includes a disperser plate for location on the stacked containers, the disperser plate having a plurality of holes so that hot water flows onto the disperser plate and through the plurality of holes, and then passes down through the containers and over the pouches to treat the pouches.
Preferably, the system includes stacking means for stacking the containers on the transporter after the containers have been loaded with the pouches.
Preferably, the stacking means comprises a robot for engaging a loaded container and moving the loaded container from a loading station to the transporter.
Preferably, the container includes a container body having an open top and an open bottom so water can drain through the open top, over the pouches supported in the container and out through the open bottom;
a plurality of support elements, each for supporting side edges of the pouch;
first cooperating locator means on an upper portion of the container body;
second cooperating locator means on a lower portion of the container body; and
wherein two like said containers are able to be stacked one above the other by the first cooperating locator means of one container engaging the second cooperating locator means of the other container.
Preferably, the support elements each comprise a pair of spaced apart slots for receiving the side edges of the pouch, each slot having a guide entrance formed by a pair of inclined surfaces which incline outwardly from the slot and downwardly toward the slot to form a guide for guiding the edges of the pouch into the slots.
This feature enables pouches to be dropped from above the container and for the side edges of the pouches to be easily and conveniently guided into the slots so that the slots support the pouch.
Preferably, the container includes two rows of opposed slots so that the pouches are supported in pairs in the container.
Preferably, the first cooperating locator means comprises at least one a tapered pin, and the second cooperating locator means comprises at least one hole.
Preferably, the container body includes opposed side walls and opposed end walls, and a first said tapered pin is provided on a block fixed to an upper portion of one of the side walls, and a second said tapered pin is provided on a block fixed to an upper portion of the other side wall diametrically opposite the first pin.
Preferably, the container body includes a flange extending at least partway along each side wall, one of said flanges having a first said hole in vertical alignment with the first pin, and the other said flange having a second said hole in vertical alignment with the second said pin.
Preferably, the flanges extend along the entire length of the side walls.
Preferably, the slots are provided in rails which extend between the opposite ends of the container body.
Preferably, the open bottom of the container body comprises a plate, the said flanges being integral with, and part of, the plate, and at least one aperture in the plate for forming the open bottom.
Preferably, the plate includes a plurality of rectangular apertures for forming the open bottom of the container.
Preferably, the transporter comprises a pallet.
Preferably, the pallet includes a pallet body; and
a plurality of locator elements on the pallet body for registering with cooperating locator elements on the containers so that when the containers are loaded onto the pallet, the cooperating locator elements on the containers engage the locator elements on the pallet to securely support and locate a first layer of the containers on the pallet.
Preferably, the pallet includes handle receiving elements for receiving a handle to facilitate movement of the pallets after loading the pallets onto a trolley.
Preferably, the cooperating locator elements comprise tapered pins which project upwardly from the pallet body.
Preferably, the pallet body has a lower surface, the lower surface having a plurality of grooves for registering with conveyor elements to enable the pallet to be moved on a conveyor.
Preferably, the pallet body is formed from longitudinally extending and transversely extending frame elements, a plurality of beams being formed on an upper surface of the frame elements, and the tapered pin being provided on the beams.
In another embodiment, the transporter comprises a continuous conveyor for conveying stacked containers to the ancillary processing station.
Preferably, the conveyor passes through the ancillary processing station and then to the packaging station.
The container may be a continuous conveyor or a plurality of separate conveyors with indexing mechanisms for moving containers from one of the conveyors to another of the separate conveyors.
This invention may be said to reside in a method of manoeuvring pouches in a packaging plant, comprising:
filling pouches with a product and sealing the filled pouches;
loading filled and sealed pouches into containers so the pouches are supported in the containers;
stacking the containers loaded with the pouches on a transporter;
moving the stacked containers on the transporter to an ancillary processing station for performing an ancillary treatment step on the filled pouches while housed in the stack of containers; and
moving the stacked containers on the transporter to a packaging station to enable the pouches to be removed from the containers and packaged for distribution.
Preferably, the ancillary treatment stage comprises a retort for receiving the pouches.
Preferably, the retort is a shower type retort.
Preferably, the method includes locating a disperser plate on the stacked containers, the disperser plate having a plurality of holes so that in the retort hot water flows onto the disperser plate and through the plurality of holes, and then passes down through the containers and over the pouches to treat the pouches.
In another embodiment, the ancillary treatment stage is a cooling station for cooling heated pouches.
In one embodiment, the transporter comprises a pallet upon which the containers are stacked and which pallet is moved to the ancillary processing station, and then to the packaging station.
In another embodiment, the transporter comprises at least one conveyor for conveying the stacked containers to the ancillary processing station, and then to the packaging station.
A further invention relates to a container handling system for supplying containers so that pouches can be loaded into containers, and then loading the containers onto a pallet so that a plurality of loaded containers can be moved about a processing plant.
This invention may be said to reside in a system for handling containers which are to be loaded with pouches to facilitate movement of the pouches through a processing plant, including:
a carriage for receiving an empty container;
first carriage moving means for moving the carriage from a container receiving position to a first container release position and returning the carriage to the container receiving position;
loading means for loading the container into the carriage when the carriage is in the container receiving position;
indexing means for receiving the container from the carriage at the release position and for indexing the container past a loading station at which filled and sealed pouches are loaded into the container as the container is indexed past the loading station;
a second carriage for receiving loaded containers from the indexing means;
second carriage moving means for moving the second carriage from a loaded container receiving position to a second container release position; and
unloading means for moving the loaded container from the second carriage at the second release position and stacking the loaded container on a pallet.
Preferably, the first carriage has first clamping means for clamping the container when loaded into the first carriage so that the container is moved with the carriage as the carriage is moved from the receiving position to the release position, and which is disengaged from the container at the first release position to enable the container to drop onto the indexing means.
Preferably, the indexing means comprises a continuous loop carrying a plurality of abutment elements for engaging the container and indexing the container as the continuous loop is indexed.
Preferably, the continuous loop comprises a pair of continuous chains driven by a motor and sprocket assembly.
Preferably, the abutment members comprise a plurality of bars which extend between the continuous chains and define receiving spaces for receiving the container so that the container is engaged by one of the bars and indexed with the continuous chains and bars.
Preferably, the indexing means includes guide means for receiving a container so that the container can slide on the guides as the container is indexed by the indexing means.
Preferably, the system includes lifting means at the loaded container receiving position so that the container is lifted from the indexing means into a position for engagement by the second carriage.
Preferably, the second carriage includes second clamping means for engaging the container when received by the second carriage so that the container can be moved by the second carriage to the second release position.
Preferably, the loading means and the unloading means comprise a robot for performing both the loading of the empty containers into the first carriage and the unloading of filled containers from the second carriage.
Preferably, the carriages have sensors for detecting when a container is received in the first and second carriages.
Preferably, the system further includes a pallet moving conveyor for moving a pallet, from which the empty container is removed, to a stacking location, at which a filled container is deposited by the unloading means.
Preferably, the system further includes a supply conveyor for supplying pallets loaded with empty containers to the empty container unloading station, and a discharge conveyor for receiving pallets stacked with loaded containers and for transporting the stacked pallet to a discharge station.
Preferably, the pallet moving conveyor extends between the supply conveyor and the discharge conveyor, and includes a first lifting means for lifting the empty pallet above the supply conveyor so the empty pallet can be conveyed by the pallet conveyor to the stacking station, and lowering means at the stacking station for lowering the pallet onto the discharge conveyor.
A further invention is concerned with the movement of pallets, from an unloading station at which empty containers are removed from the pallet, to a stacking station and which loaded containers are stacked on the pallets.
This invention may be said to reside in a pallet handling apparatus for receiving pallets stacked with containers, from which the containers are to be unloaded, so the containers can be loaded with pouches, and then stacked on an empty pallet, said apparatus comprising:
a supply conveyor for conveying pallets stacked with containers to a container unloading station so the containers can be unloaded at the unloading station and supplied to a pouch loading station at which pouches are loaded into the containers;
a discharge conveyor for conveying pallets from a stacking station upon which loaded containers are stacked on a pallet, to a pallet discharge station;
a pallet moving conveyor extending between the unloading station and the stacking station for conveying an empty pallet from the unloading station to the stacking station;
first pallet transfer means at the unloading station for transferring a pallet from the supply conveyor at the unloading station onto the pallet moving conveyor; and
second conveyor transfer means at the stacking station for transferring the pallet from the moving conveyor onto the discharge conveyor.
Thus, pallets are able to be moved to an unloading station where the pallets are unloaded and then the empty pallet is moved to a stacking station so the pallet can be stacked with containers which are filled with pouches. The stacked pallet can then be moved to a discharge station for discharge of the pallet and stacked containers so the pallet and containers can then be moved to further processing stations where further treatment of the filled pouches is to take place. This further treatment may include supply of the pouches to a retort and then packaging of the pouches in boxes.
Preferably, the supply conveyor includes a plurality of chain conveyor section.
Preferably, the discharge conveyor includes at least one chain conveyor which extends from the stacking station towards the discharge station, and a discharge roller conveyor at the discharge station.
Preferably, the pallet moving conveyor includes an intermediate chain conveyor section and the first transfer means comprises a first roller conveyor at the unloading station, lifting means for raising the first roller conveyor relative to the at least one supply chain conveyor so that lifting of the first roller conveyor engages the pallet and lifts the pallet above the at least one supply chain conveyor so the pallets can then move on the first roller conveyor and onto the intermediate chain conveyor, a second roller conveyor at the stacking station, lowering means connected to the second roller conveyor for lowering the second roller conveyor to lower the pallet onto the at least one discharge chain conveyor section.
Preferably, the first raising means comprises a ram and guide assembly for moving the first roller conveyor in a vertical direction between a raised and lowered position.
Preferably, the second moving means comprises at least one ram and guide assembly for moving the second roller conveyor in a vertical direction between a raised and lowered position.
Preferably, the intermediate chain conveyor includes at least one drive sprocket and a motor for driving the sprocket, and therefore the chain conveyor.
Preferably, the first and second roller conveyors have a first drive motor and a second drive motor respectively for driving at least one of the rollers of each of the first and second roller conveyors.
Preferably, the plurality of chain conveyor sections each includes a drive sprocket and at least one motor for driving each conveyor chain section.
Preferably, the discharge chain conveyor section includes a sprocket and at least one motor for driving the discharge chain conveyor section.
Preferably, the discharge roller conveyor includes idler rollers so that the pallet can be rolled manually or under the influence of gravity on the first roller conveyor.
Preferably, a pallet trolley is provided for supplying pallets stacked with empty containers to the supply conveyor and for receiving pallets stacked with loaded containers from the discharge conveyor, the trolley including an upper roller conveyor section including a plurality of rollers so that pallets can be rolled off the trolley onto the supply conveyor and off the discharge conveyor onto the trolley, locking means for locking the pallet to the trolley so the trolley can then be moved to transport the pallet and the containers from one place to another.
Preferably, a trolley support is provided at a supply end of the supply conveyor and at a discharge station of the discharge conveyor, the support comprising a pair of guide channels for receiving the wheels of the trolley, and allowing the trolley to be registered with the supply conveyor or the discharge conveyor, wheel locking means for locking the trolley to the trolley support to hold the trolley stationary relative to the supply conveyor or discharge conveyor to enable the pallet to be moved from the trolley onto the supply conveyor or off the discharge conveyor onto the trolley.
Preferably, the locking means comprises a spring biased catch which is engaged by the pallet as the pallet is moved onto the trolley, and moved against the bias of the spring to locate behind a portion of the pallet to lock the pallet to the trolley.
Preferably, the locking means includes a lever for pivotal movement to move the catch out of engagement with the portion of the pallet so the pallet can be released from the trolley.
Preferably, the supply conveyor includes a chain conveyor section which forms the unloading station, the chain conveyor section having a pair of chains and means for circulating the chains about a continuous loop so a pallet can be moved on the section, and wherein the first pallet transfer means includes a subassembly mounted to the chain conveyor section, the subassembly carrying a first roller conveyor formed of a plurality of rollers, means for raising and lowering the subassembly and first roller conveyor relative to the chain conveyor section so that when a pallet is on the chain conveyor section at the unloading station, the subassembly can be raised to engage the pallet and lift the pallet above the chains of the chain conveyor section so the pallet can then be moved on the first roller conveyor in a direction transverse to the direction of movement on the chain conveyor section, and wherein the moving means is for lowering the subassembly so the roller conveyor is moved below the chains of the chain conveyor section to allow another pallet to move along the chain conveyor section; and
the discharge conveyor including a discharge conveyor chain section which defines the stacking station, the discharge chain conveyor section including a pair of chains for moving a pallet on the discharge chain conveyor section, a second subassembly mounted to the discharge chain conveyor section, and including a second roller conveyor, second moving means for raising the second subassembly and the second roller conveyor relative to the discharge chain conveyor section so that in a raised position of the subassembly and the second roller conveyor, the pallet is able to move along the pallet moving conveyor and onto the second roller conveyor, the second moving means also being for lowering the second roller conveyor to deposit the pallet on the chains of the discharge chain conveyor section; and
the first subassembly, the first roller conveyor and the second subassembly and the second roller conveyor forming part of said pallet moving conveyor so that a pallet can be rolled from the first conveyor section along the pallet moving conveyor to the second roller conveyor.
Preferably, the supply conveyor chain section includes abutments for receiving a pallet to locate the pallet on the supply conveyor chain section so the pallet is accurately, located at the unloading station.
Preferably, holding means are provided on the supply conveyor chain section for engaging the pallet and holding the pallet at the unloading station.
Preferably, second holding means are provided at the discharge chain conveyor section for releasably holding the pallet at the stacking station.
Preferably, a container indexing means is provided for indexing containers past a loading station at which pouches are loaded into the containers;
container loading and unloading means for unloading an empty container from a pallet at the unloading station and depositing the container on the indexing means for indexing past the pouch loading station; and
collecting a loaded container and depositing the loaded container onto a pallet at the stacking station.
A further invention concerns monitoring the integrity of a seal of a pouch to determine whether the seal has been properly formed, and therefore whether the pouch should or should not be rejected.
This invention may be said to reside in a filling and heat sealing line for filling pouches with product, comprising:
a filling station for loading a product into the pouches;
a heat sealing station for heat sealing filled pouches;
moving means for moving the pouches from the filling station to the heat sealing station;
a vision system;
pouch moving means for moving pouches from the heat sealing station past the vision system;
said vision system including:
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- (a) a light source for producing light so that light is transmitted through a transparent region on one side of the sealed pouch which overlaps a heat seal produced by the heat sealing station;
- (b) at least one camera for receiving light transmitted through the seal;
- (c) processing means for determining from the light received by the camera the integrity of the seal to determine whether the pouch should or should not be rejected.
Thus, as the pouches are filled and heat sealed, the pouches can then be monitored to determine the integrity of the seal, and if the seal is not properly formed, the pouch can be rejected before the pouch is moved for further processing and packaging into boxes.
Preferably, the pouch includes a transparent strip which overlaps the heat seal to facilitate transmission of light through the region of the pouch in the vicinity of the heat seal to in turn facilitate determination of whether the seal has been properly formed.
Preferably, the processing means compares the light received by the cameras with a grey scale to provide an indication of whether the seal is properly formed.
Preferably, the system includes a reject station which is activated by the processing means if a seal is determined to be inadequate so the pouch is rejected from the line at the reject station.
Preferably, the reject station comprises a moveable door over which the pouches pass and which is open to enable the pouches to drop through the door.
Preferably, the processing means is for determining whether pixels of the at least one camera see light intensity on a grey scale above a predetermined grey scale value, and also determines whether a second predetermined number of adjacent pixels have a grey scale value above that predetermined number, and if so, produce the signal indicative of the seal not being properly formed so that the pouch can be rejected at the reject station.
Preferably, the pouch is provided with notches and the processing means identifies the notches to in turn use the identified notches as a point of reference for determining the inspection region defined by the transparent strip which is positioned at a known location with respect to the notches.
This invention also provides a seal integrity monitoring system for inspecting the integrity of a seal in a pouch which has a transparent region on one side of the pouch, a translucent region on the other side of the pouch, and a seal formed between the transparent region and the translucent region, comprising:
a light source for producing radiation and directing the radiation through the transparent region;
a camera for viewing the translucent region and for producing an image of the translucent region; and
a processor for processing the image captured by the camera to determine the integrity of the seal.
Preferably the seal is a heat seal and the transparent region comprises a transparent region in a first panel of the pouch and the translucent region is a translucent coating on a second panel of the pouch which is connected to the first panel by the seal, the first panel including a fluorescing material at least in the vicinity of the transparent region, so that when the light source directs the light through the transparent region, the fluorescing material fluoresces to produce white light, and if the first and second panels are properly sealed together, a continuous waveguide is provided for transmission of the white light to the translucent coating, and if the seal is not properly formed, a continuous waveguide is not formed, thereby allowing light to disperse where the seal is not properly formed so those parts of the seal appear as a dark region on the translucent region.
Preferably the light source is an ultraviolet light source for producing ultraviolet light of a wavelength from 320 to 350 nanometers.
Preferably the camera comprises a CCD array type camera.
Preferably the processor processes the images captured by the camera by determining pixels which have a grey value above a predetermined value, thereby providing the indication of an improperly formed part of the seal.
Preferably the processor determines that the seal is satisfactory if a band of a predetermined thickness of properly formed seal can be defined from one side of the pouch to the other side of the pouch.
This invention also provides a seal integrity monitoring method for inspecting the integrity of a seal, the pouch having a first panel with a transparent region, a second panel having a translucent region on an outer surface of the second panel, and the seal being formed between the first and second panels at the transparent region and translucent region, the method comprising:
irradiating the translucent region so that the radiation passes into the translucent region, and if the seal is properly formed, the first and second panels at the seal form a continuous waveguide for directing radiation onto the translucent region, and if the seal is not properly formed, light is dispersed at the improperly formed seal, thereby producing a dark region at the translucent region;
detecting the translucent region with a camera to obtain an image of the translucent region; and
processing the image captured by the camera to identify any dark regions appearing at the translucent region to thereby determine the integrity of the seal.
Preferably the radiation has a wavelength of from 320 to 350 nanometers.
Preferably the camera is a CCD array camera and the processing step determines the grey scale value of pixels of the CCD array in order to identify dark regions in the image.
Preferably the transparent region includes a fluorescing material so that when the light is directed to the transparent region, the fluorescent material fluoresces so that the fluorescing light then passes through the continuous waveguide to the translucent region, or if the seal is not in tact, is dispersed at the regions where the seal is not in tact so that dark regions are produced at the translucent region.
BRIEF DESCRIPTION OF THE DRAWINGSA preferred embodiment of the invention will be described, by way of example, with reference to the accompanying drawings, in which:
With reference to
As shown in
In another embodiment, rather than provide the PEN layer 1a″, the PET layer 1a may simply be a solid layer of PET and the fluorescing material may be provided by coating a UV absorbing layer or lacquer onto the inner surface of one of the layers which make up the panels 3 and 5, such as the inner surface of the barrier layer 1b.
The pouch may be provided in different sizes, and in particular, in different lengths, as illustrated by the dotted lines in
The PET layer 1a is shown in
The pouch 1 is printed to provide the getup of the pouch and also information including trade marks, product descriptions and other material which may be of aesthetic characteristic to provide the finished appearance of the pouch when the panels 3 and 5 are formed and connected together to form the pouch 1. The printing is shown by reference numeral 1e in
Typical dimensions of the layers which form the panels 3 and 5 are about 12 microns for the PET layer 1a, 0.4 microns for the barrier layer 1b, 25 microns for the strengthening layer 1c, and 110 microns for the polypropylene or polyethylene layer 1d.
The print layer 1e is simply a layer of print which may be applied by a suitable printing machine or device. As is most apparent from
The printed layer 1e is provided on an inner surface of the layer 1a, rather than an outer surface of the layer 1a, to protect the print when the sealed pouch is subjected to further processing, such as in a retort, as will be described hereinafter. If the print is provided on the outer surface, the print may well be damaged in the further processing steps.
Thus, the pouch according to the preferred embodiment is provided with a transparent strip 13 adjacent top 15 which forms the opening to the pouch, and through which product is to be loaded into the pouch. The strip 13 overlaps seal region 17 which is to be formed when the pouch is filled and then passed through a heat sealing unit, as will be described hereinafter. The seal 17 is positioned between the panel 3 and the region 13a so the pouch is transparent from the outer surface of panel 3 to the region 13a of the strip 13. In the embodiment shown, the strip 13 is arranged below upper edges 18 of the panels 3 and 5 which form the open top 15 prior to heat sealing of the panels 3 and 5. However, in other embodiments, the transparent strip 13 may extend all of the way up to the top edge 18.
As will be described in more detail hereinafter, to facilitate inspection of the seal, ultraviolet light is directed from the side on which the transparent strip 13 is provided so the light enters the transparent strip 13 to pass through the pouch. The panel 5 is provided with a translucent filter which is provided by at least the printed region 13a of the print layer 1e adjacent the strip 13. The filter region 13a is preferably of uniform colour to provide a uniform filter region adjacent the transparent strip 13. Most preferably, the colour of the print which forms the filter layer 13a is green, but other colours could also be used. In other words, whilst the print layer 1e may be multi-coloured in the remainder of the pouch 1, the part of the print layer 1e which forms the filter 13a is of a single colour which may simply be one of the colours which make up the remainder of the print layer 1e, but most preferably is green.
The transparent strip 13 may be provided simply by ensuring that the strip 13 at the panel 3 is not printed on when the pouch is printed. The strip 13 may be defined by a definite border where the printing terminates, or may simply be a blank region at the seal so that when exposed to the vision system, light is able to pass through the transparent panel 5 at the seal, through the panel 5 and through the filter 13a.
In the embodiment shown, a hole 20 is punched through the panels 3 and 5 above the transparent strip 13 so that the pouch can be hung from a hook or rail ready for sale.
Notches 21 are cut into the side edges 7 and 9. The notices 21 are provided to enable the pouch 1 to be torn open when the contents of the pouch is to be used by a consumer.
The transparent strip 13 facilitates inspection of the sealed package by a vision system 98 (
The vision system generally comprises an ultraviolet light source 225 and a camera 230 (
A determination on whether the seal 17 is sufficient depends on the particular circumstances or regulations which may be in force in particular jurisdictions. For example, having regard to the nature of the product which is to be contained in the pouch 1, the seal 17 may be regarded as satisfactory provided that there is a continuous band of a predetermined width, say, 3 mm, from one edge 7 of the pouch to the other edge 9 of the pouch, notwithstanding the fact that small areas of improperly-formed seal (such as that shown in
In the preferred embodiment of the invention, the region 17 is slightly narrower than the width of the filter 13a, and therefore the region which is inspected by the vision system so the top and bottom edges of the seal can be seen, thereby making it easier to identify the top and bottom of the seal, and therefore ensuring that an integral seal 17 is actually formed.
FIGS. 2 to 5 are views of a container for receiving and supporting a plurality of the pouches of the type described with reference to
The base plate 35 extends beyond the side walls 29 to form flanges 43 which are part of and integral with the base plate 35.
A block 44 is connected in the top corner of the wall 29 and an identical block 45 is connected in the top diametrically opposite corner of the wall 27. The blocks 44 and 45 carry a tapered pin head 46 which form a first cooperating locating element for enabling a number of the containers to be stacked one above the other and locked in position relative to one another.
As best shown in
As will be described in more detail hereinafter, two of the containers shown in FIGS. 2 to 5 can be stacked one above the other by locating one container above the other so that the pins 46 of a lower one of the containers are received in the holes 47 of the upper container. The engagement of the pins 46 in the holes 47 securely locate the containers together in a stable stack.
The rails 39 are connected to the walls 29 and 27 by screws 38 and extend along the walls 29 and 27 between the end walls 31 and 33. The rail 41 is arranged centrally between the rails 39 and also extends between the walls 31 and 33. The rail 41 is secured to the walls 31 and 33 by screws (not shown). As shown in
The slots are shown in more detail in
Four beams 67 are connected onto the frame member 63 and 65 and carry tapered pin heads 69, which are identical to the pin heads 46 previously described, and which are located so that when an initial layer of containers 25 is stacked on the pallet 62, two of the pins 69 will locate in the holes 47 in the flanges 43 of the containers 25 to securely locate the container 25 in position on the pallet 62. In the preferred embodiment of the invention, the pallet 62 is designed to carry an initial layer of 3×3 containers 25.
One of the end frame members 65 is provided with a pair of sleeves 71 which are intended to receive a handle (not shown) which can be connected to the sleeves 71 and disconnected as desired, to provide a handle for enabling the pallet 62 to be manoeuvred when the pallet is loaded on a trolley (which will be described hereinafter).
As is shown in
When the pallet 62 is stacked with loaded containers 25 containing pouches 1, a diffuser plate 77 can be located on the upper layer of containers 25. The diffuser plate 77 has a peripheral frame 79 and an upper surface 81 which is provided with a plurality of holes 85. The purpose of the diffuser plate 77 is to diffuse water which is provided in a retort, and which flows down through the containers 25 and over the pouches 1. The diffuser plate 77 diffuses and disperses the water so the water more gently trickles down through the containers and over the pouches 1 of the entire array of pouches provided in the stacked containers 25. This prevents direct spraying of water in the retort onto individual pouches which may soften those packages because of the heat of the water if a sufficient quantity of high pressure water is directed at a particular pouch. The diffuser plate 77 diffuses and disperses the water so that it more gently flows over the pouches, thereby reducing the flow rate of the water so the water will not result in a high pressure being applied to various parts of particular pouches which may damage the pouches.
The peripheral frame 79 may be provided with openings 83 which are provided to register with pins 46 on the containers 25 in the uppermost layer of containers 25 stacked on the pallet 62 to securely locate the diffuser plate 77 in place on the stacked containers 25.
The pouch is then passed through the vision system 98 where the pouches are monitored for seal integrity and if the seal is regarded as faulty, the pouches are ejected at reject station 100. If the pouches are properly sealed, they pass to pouch loading station 102 where the pouches drop into containers 25.
The system includes a supply conveyor 104 and a discharge conveyor 106. Pallets 62 are loaded onto the supply conveyor 104 and conveyed by the supply conveyor 104 from pallet receiving end 104′ to unloading station 104″. The empty containers supported on pallet 62′ at the unloading station are unloaded from the pallet 62′ by robot 105. The robot 105 is conventional in design, except for the head which engages the containers 25, and therefore will not be described in detail. The head of the robot will be described hereinafter. The robot 105 lifts a container from the pallet 62′ and deposits the container in a container supply mechanism 106. The mechanism 106 will be described in detail hereinafter, and includes a indexing mechanism 108 which indexes the containers beneath the loading station 102 so that two pouches (P1,
When a pallet 62′ at the unloading station 104″ has been fully unloaded and is empty, the pallet 62′ is conveyed by a pallet moving conveyor 110 which passes beneath the robot 105 from the unloading station 104″ to a stacking station 106″ on the conveyor 106 and which is occupied by the pallet 62a shown in
The robot 105 therefore stacks loaded containers 25 on the pallet 62a and when the pallet 62a is fully stacked, the pallet 62a is conveyed by the conveyor 106 to discharge end 106′.
The pallets are then collected by a trolley (which is shown in FIGS. 16 to 21) and the pallet 62 with the stack of loaded containers 25 is then pushed to retort 112 and the pallet and containers loaded with pouches is located in the retort 112 for processing. As previously explained, the diffuser plate 77 is located on the stacked containers 25 before the stacked containers and pallet 62 is loaded into the retort 112. The pouches which are contained within the containers 25 are thereby treated, and water from the retort is able to flow through the open top of the containers 25, over the pouches and out through the open bottom so the water flows down through the stack of containers and over all of the pouches to properly treat the pouches. After the product in the pouches 1 has been sterilised in the retort 112, the pallet 62 is removed from the retort 112 and moved to a packaging station 114 where the pouches are removed from the containers 25 and packed in cardboard boxes for distribution. Thus, this embodiment of the invention enables the pouches to be conveniently and easily handled after the pouches are filled and sealed so that the pouches can be further treated in the retort 112 and then moved to the packaging station for packaging.
The frame member 122 carries a plate 139 which has an opening 141. As is most clearly seen in
When a pallet is rolled onto the trolley 20 on the rollers 133, frame member 65′ (see
The support 116 is designed to raise the trolley to the required level so that the pallet will be at the exact height for rolling onto the conveyor 104 with the groove 73 registering with chains 140 of the conveyor 104. When the chains are moved, as will be described hereinafter, the pallet is therefore conveyed along the conveyor 104 to the unloading station 104″ described with reference to
The support 116 is best shown in FIGS. 17 to 19 and comprises a pair of channel sections 141 and 142 which have an enlarged open end 143 which tapers to a more narrow section 145. The channel sections 141 and 142 are supported on legs 146 which are designed to ensure that the trolley 120, when loaded onto the support 116, is at the height of the conveyor 104 (or the conveyor 106) as previously described. The support 116 includes a wheel lock 148 for securely holding the trolley 120 on the support 116 during unloading of a pallet from the trolley 120 (and reloading of the pallet from conveyor 106 onto the trolley). As best shown in
Each module 25″ has a base 800 and a pair of upstanding pouch support elements 801 which include the aligned slots 50 which are configured in the same manner as shown in
As is best shown in
Each of the modules 25′ is provided with a first bore 807 which passes through the base 25″ of the module in a first direction, and a second bore 808 which is arranged slightly above or below the bore 807 and which passes through the bases 25′ in a direction perpendicular to the bores 807.
A container of a predetermined size can be formed from the modules by locating the modules together so as to form a desired configuration of pouch carrying pockets (which, in the example shown in
It should be understood that, whilst not shown in
The container of
The plate 203 is connected to a chain conveyor which is driven by a sprocket and servo motor so that the entire mechanism shown in
As the pouches are indexed to the pressing station 96, a ram 220 is moved to push plate 221 inwardly towards plate 223 so as to squeeze the pouches 1 so the contents of the pouches 1 are compressed to spread the product in the pouches throughout the entire length of the pouch. In
As previously described, and as shown in more detail with reference to
With reference to FIGS. 27 to 31, which show the indexing mechanism 106 in more detail, the mechanism comprises a pair of continuous chains 240 which are interconnected by abutment bars 241. The bars 241 are carried by the chains 240 as the chains circulate about sprockets 242 shown in
With reference to
The loaded containers 25 eventually reach a lifting station 260 which is occupied by the container 25′″ in
FIGS. 32 to 38 show more detail of the indexing mechanism 106, and in particular, the carriages 402. With reference to those figures, and in particular
The linear bearings 410 are mounted on frame portion 414 of the indexing mechanism 106 which is arranged above the indexing chain 240.
The clamps 250 comprise a clamp plate 420 and a ram 421. The plate 420 is connected to ram arm 422 of the ram 421. Thus, when the ram arm 422 is extended, the clamp plate engages the sides of the container 25 to securely hold the container 25 in the carriage 400, and when retracted, allow the container 25 to drop from the carriage 400 into the space between two bars 241 carried by the indexing chains 240, as has previously been described.
The plate 412 and the belt 415 are contained within a housing 431 (only shown in
The carriage 400, as is shown in
As previously described, the container 25 is indexed by the belt 240 and the bars 241 to the collection station where the carriage 402 collects the container 25, as is shown in
When the container 25 has been moved to the position shown in
The carriages 400 and 402 may include sensors for detecting when a container 25 is loaded in the carriage to provide a signal indicative of the presence of a container to facilitate sequence of movement of the carriages 400 and 402 in the indexing mechanism 106.
As shown in
When the arm 463 is retracted, as shown in
The section 272 will be described in more detail with reference to
The section 272 includes an end abutment 286 against which pallet 62 can engage to properly locate the pallet at the end of the section 272 and properly at the unloading station 104″, previously described. A pivotally mounted finger, which is mounted on pivot pin 288, is provided for engaging the opposite end of the pallet 62 to that which abuts the abutment 286 so the pallet 62 is properly locked and securely held in position at the loading station 104″ for unloading by the robot 105. This ensures that the pallet 62 and the containers 25, which are stacked on the pallet, are in a known position so the robot can, due to prior programming, know exactly where each container is, and therefore move to each container in sequence and lift the container from the pallet 62 and load the container into the carriage, previously described.
As is best shown in
The chain conveyor section 272 which forms the unloading station 104″ also carries the subassembly, 273 previously described. The subassembly 273 is also shown in
The subassembly 273 comprises opposite frame sections 290 (only one of which is shown) and only one of which can be seen in
The frame sections 290 sit on curved frame supports 293 which form part of the frame 275 of the conveyor section 272. A ram 294 is fixed to the frame 275 and has a ram arm 295. The ram arm 95 is connected to a bar 296 by a pivot connection 297. The bar 296 is connected to a pair of cross bars 299 (only one shown in
Thus, when the ram arm 295 is moved in the direction of Arrow N in
As is best shown in
Upward movement of the frame 290 is guided by slots 306 in the frame which receives a pin 307 which is fixed to the frame 275. Thus, the engagement of the pin 307 in the slot 306 restrains the frame 290 and therefore the subassembly 273 for vertical movement relative to the remainder of the conveyor section 272 so the rollers 305 do move vertically upwardly and engage in the slots 75 in the underside of the pallet 62.
When the rollers 305 have been engaged in the slots 75, the pallet 62 is able to roll on the rollers into the plane of the paper in
The axles 291, and therefore the rollers 305, are driven by a motor (not shown) which drives shaft 308. The shaft 308 has sprockets 309 connected to it and the axle 291 has sprockets 310. Chains 311 extend around the sprockets 309 and 310 so drive is transmitted from the motor and shaft 308 to the axle 291. Additional chains and sprockets can be connected between the remaining axles 291 so each of the axles 291, and therefore the rollers 305 carried by those axles, are also driven. Obviously, when the axles 291 are driven and the rollers 305 are in engagement with the pallet 62, the pallet is driven along the rollers which forms part of the pallet moving conveyor 110, previously described with reference to
The moving conveyor 110 comprises the section 272, previously described, and in particular, the subassembly 273 which carries the roller conveyor previously described, a central conveyor section 320, and a second conveyor section 272′ which is identical in structure to the conveyor section 272. The section 272′ forms the stacking station 106″ of the discharge conveyor 106. The second 272, in terms of the subassembly 273, is structured exactly the same as the subassembly in the section 272 except that in this embodiment the subassembly 273 is initially held in the raised position so that a pallet 62, which has been driven off the section 272 and onto the section 320, can then be driven onto the section 273 by the rollers 305. Until the pallet abuts end abutment 321. At this stage, the ram 294 is activated to lower the subassembly 273 and therefore the roller conveyor formed by the roller 305, so that the pallet 62 is lowered onto the chains of the conveyor section 272′ so those chains register in the grooves 73 on the underneath side of the pallet 62. The pallet 62 is locked in position on the section 272′ by fingers 287, identical to those previously described, so the pallet is securely and accurately located on the section 272′ so that loaded containers 25 can then be stacked on the pallet 62. After the pallet has been stacked, the loaded pallet 62 can be moved on the chains of the section 272′ and along the conveyor 106 to discharge end 106′ as has been previously described. Thus, the section 272′ forms part of the pallet moving conveyor 110 and also part of the discharge conveyor 106.
The mid section 320 of the moving conveyor 110 is shown in more detail in
The discharge conveyor 106 is shown in
As best seen in
Thus, in this embodiment, rather than transport the stacked containers 25 on a pallet as in the previous embodiment, the stacked containers are transported by way of a conveyor belt system through the plant for further processing and then for eventual packaging into boxes or cases.
As previously explained, vision system 98 monitors the integrity of the heat seals formed on the pouches and rejects pouches if the heat seal is not properly formed. The vision system comprises cameras 230 which are mounted in suitable camera houses and UV light source 225. The pouches 1 are moved relative to the cameras 230 and UV light source 225, such that the transparent strip 13, previously described, faces the light source 225 so ultraviolet light is directed from the light source 225 to the strip 13, as explained with reference to
The control software compares the intensity of light received by each pixel in the inspection area of the camera with a grey scale which runs from 0 which is indicative of white light to 255, indicative of no light at all, or in other words “black light”. If the seal is properly formed, the intensity of the light detected by the pixels of the cameras 230 should be on the grey scale range of between 0 and, for example, 130. If the pixel identifies an intensity on the grey scale of above, for example, 150, this is indicative of some contaminant or other imperfection in the heat seal.
The vision system may be formed as an integral filling and heat sealing line, as previously described, although the vision system is preferably mechanically separate from the heat sealing line so as to not be subject to vibrations of the filling and heat sealing line. However, the vision system may be a totally separate unit which can be provided for an existing heat sealing line, or a stand-alone vision system which can be used to inspect sealed pouches after the pouches have been filled or heated, or after they have gone through some other treatment, such as a retort or the like.
The vision system, if provided as a separate unit, operates in exactly the same manner as previously described and as will be described hereinafter. However,
The housing 600 may be supported on legs 607. The conveyor 605 extends beyond the housing 600, as best seen in
The camera 230 is connected to a processor 610, which is schematically shown in
If the vision system is a stand-alone system, the vision system may include its own reject station or reject pouches can be determined simply by visual inspection of a monitor driven by the processor 610, and defective pouches 1 manually or mechanically collected.
The next step in the software routine is to determine the size of the contaminant, and this is done by a blob extraction routine which determines the number of adjacent pixels which have a grey scale value of above 150. If only scattered single pixels have a grey scale value above 150, then this can be taken to indicate that there is no problem with the heat seal and the pouch is properly formed. However, if a number of adjacent pixels, for example 50 pixels, produce a grey scale value above 150, this is indicative of a contaminant of significant size being located in the heat seal which has destroyed the integrity of the heat seal, and therefore may allow air to enter the pouch, which would destroy the contents of the pouch. Thus, the grey scale reading for a number of pixels, such as 50, provides an indication that the heat seal is not properly formed and that the pouch should therefore be rejected.
The control system or processor 610 (see
The processor 610 may also be programmed to determine whether a properly formed seal 17 is in existence by determining if there is a continuous band of a width of more than, for example, 3 mm, from one edge 7 of the pouch to the other edge 9, as previously described with reference to
Furthermore, the seal may also be regarded as improperly-formed even if such a band can be identified, but there is nevertheless region 700 which are of a size greater than a predetermined area. The reason for rejection may not be that this will enable air to enter the contents of the pouch, and may simply be that the seal is not regarded as aesthetically suitable, and therefore the package may be undesirable from a consumer's point of view, and therefore should be rejected. As previously described, the blob size of the region 700 can be determined by the number of adjacent pixels which are above a particular gray level and if the number of pixels exceeds the predetermined limit, the pouch can be rejected on the basis that the seal is not aesthetically pleasing even though it may be satisfactory to safeguard the contents of the pouch.
Preferably, the cameras 230 are Cognex-in-sight 1000 made by Cognex Inc. of the United States of America, or cameras sold under the name Genius MX System made by Applied Vision LLC of the USA.
As previously described, the pouches 1 are transported along a defined path between the camera 230 and the lights 225. The camera to pouch distance is chosen to provide the maximum optical magnification of the seal area of the pouch, while allowing for some misplacement of the pouch by the handling mechanism. When a pouch 1 is moved into the inspection station of the vision system 98, an image acquisition trigger is sent from a programmable logic controller (described with reference to
At step 1001 in
If the vision system is not able to identify the landmark feature, the pouch is automatically rejected when it leaves the inspection station 98.
Mathematical rules or algorithms are programmed into the processor 610 during the design of the vision system or at initial setup to provide a process for evaluating the values in the bitmap and their relationship with each other.
At step 1003, the inspection algorithms are applied to the bitmap which will actually define the seal area relative to the landmark feature which has already been identified. Feature can be found by scanning the bitmap in a specific sequence commensurate with the shape of the object in the image to thereby search for changes in contrast in the bitmap. Changes in contrast occur where the light passing through or around the pouch seal is modified, as has been previously explained with reference to
Overlapping inspection windows or zones are then placed across the seal area, ensuring a 100% coverage of the seal. Each inspection zone is scanned to detect lack of adhesion and/or contaminants between the panels which inhibit the transmission of light through the seal creating the dark regions which have been previously described with reference to
The processor 610 also maintains an inspection record of the results to generate audible or visual alarms if acceptable reject levels are exceeded, as per step 1006.
Sensors 508 and 509 are associated with the clamp cylinders 290 of the sections 272 and 272′ for determining whether those cylinders are extended or retracted, and thereby to determine whether the pallet 62 is clamped in position or available for movement. The motors to transfer a pallet 62 from those sections is therefore not operated until the cylinder is retracted and the finger 287 removed away from the pallet so the pallet can be moved. Sensors 510 and 511 are associated with the rams 294 associated with the sections 272 and 272′ to determine whether the roller conveyor 305 is in the raised or lowered position ready to transfer a pallet to the pallet moving section 320, and then to the section 272′ of the discharge conveyor 106. Sensor 512 is associated with a robot 105 and determines whether a container 25 is gripped and held by the head 105a of the robot. Sensor 513 is the sensor which is associated with the carriage 400 for determining whether the container has been deposited in the carriage, and sensor 514 is associated with the clamps 250 of the carriage 240 for determining whether those clamps are in the clamping position or release position.
Sensors 515 and 516 are associated with the loading station 102 and determine when pouches fall through the doors 227 and into the container 25.
Sensor 517 determines the position of the lifting ram 261 and the plate 262 and the sensor 518 is associated with the clamps 250 and the carriage 402 for determining whether those clamps are in the clamping position or the release position. Sensors 519, 520 and 521 are associated with the carriage 400 and determine the home position of the carriage and whether the carriage has over travelled or under travelled during movement of the carriage from the position at which the carriage receives the container 25 to the position at which the carriage releases the container 25 to the indexing chain 240.
Sensor 522 is associated with the indexing chain 240 and is used to determine the home position of the indexing chain 240 so the indexing chain 240 can be returned to a home position if needed.
The robot 105 is also controlled by the PLC 500 so that operation of he robot is sequenced with the movement of the pallets 62 and containers 25 through the system.
Claims
1. A flexible pouch comprising:
- a front panel;
- a rear panel;
- the front and rear panels being joined along opposite side edges;
- a closed base;
- an open end opposite the base through which a product can be loaded and which is to be closed by a seal which joins the front and rear panels together; and
- a transparent region in at least one of the front and rear panels which overlaps the region of the front and rear panels at which the seal is to be formed to facilitate inspection of the seal to determine the integrity of the heat seal.
2. The pouch of claim 1 wherein a translucent filter of constant colour is provided on one of the panels so the seal, when formed, is between the translucent filter and the said at least one of the front and rear panels, so if the seal is properly formed, a substantially uniform intensity of light will be transmitted through the filter.
3. The pouch of claim 1 wherein the transparent region is provided adjacent a top edge of the front panel of the pouch.
4. The pouch of claim 2 wherein the transparent strip includes a fluorescing material which fluoresces when subjected to light of a particular wavelength to produce white light, and wherein when the front and rear panels are sealed together, the transparent region and the adjacent portion of the other of the front or rear panel forms a continuous waveguide for transmission of the white light so that any failure of the seal where the transparent strip and the said adjacent portion do not seal will allow light to disperse, thereby breaking the integrity of the waveguide so that those regions are identifiable by inspection of the said adjacent portion.
5. The pouch of claim 4 wherein the said adjacent portion is translucent to define a filter which can be detected by a camera so that dark regions indicative of an improperly formed seal can be identified.
6. The pouch of claim 4 wherein the fluorescing material fluoresces when subjected to ultraviolet light.
7. The pouch of claim 1 wherein the closed base is defined by a gusset at the base of the pouch connected to the front and rear panels for closing the base of the pouch.
8. A container for receiving and supporting flexible pouches, comprising:
- a container body having an open top and an open bottom so water can drain through the open top, over the pouches supported in the container and out through the open bottom;
- a plurality of support elements, each for supporting side edges of the pouch;
- first cooperating locator means on an upper portion of the container body;
- second cooperating locator means on a lower portion of the container body; and
- wherein two like said containers are able to be stacked one above the other by the first cooperating locator means of one container engaging the second cooperating locator means of the other container.
9. The container of claim 8 wherein the support elements each comprise a pair of spaced apart slots for receiving the side edges of the pouch, each slot having a guide entrance formed by a pair of inclined surfaces which incline outwardly from the slot and downwardly toward the slot to form a guide for guiding the edges of the pouch into the slots.
10. The container of claim 8 wherein the container includes two rows of opposed slots so that the pouches are supported in pairs in the container.
11. The container of claim 8 wherein the first cooperating locator means comprises at least one a tapered pin, and the second cooperating locator means comprises at least one hole.
12. The container of claim 8 wherein the container body includes opposed side walls and opposed end walls, and a first said tapered pin is provided on a block fixed to an upper portion of one of the side walls, and a second said tapered pin is provided on a block fixed to an upper portion of the other side wall diametrically opposite the first pin.
13. The container of claim 8 wherein the container body includes a flange extending at least partway along each side wall, one of said flanges having a first said hole in vertical alignment with the first pin, and the other said flange having a second said hole in vertical alignment with the second said pin.
14. The container of claim 13 wherein the flanges extend along the entire length of the side walls.
15. The container of claim 9 wherein the slots are provided in rails which extend between the opposite ends of the container body.
16. The container of claim 8 wherein the open bottom of the container body comprises a plate, the said flanges being integral with, and part of, the plate, and at least one aperture in the plate for forming the open bottom.
17. The container of claim 16 wherein the plate includes a plurality of rectangular apertures for forming the open bottom of the container.
18. The container of claim 8 wherein the container is formed from a plurality of container modules, each module having a pair of said support elements, and connector elements for connecting the modules together to form the container.
19. The container of claim 18 wherein the connector elements comprise at least one bore passing through each module so that modules can be located in side-by-side relationship with the bores forming a channel through the modules, and a rod for location in the aligned channel to connect the modules together.
20. The container of claim 19 wherein the modules include two bores extending substantially at right angles with respect to one another so that when the modules are located together to form the container, rods are extended through the respective channels formed by the bores so that the rods connect the modules together in both a first direction of the container and a second direction perpendicular to the first direction.
21. The container of claim 20 wherein the rods include at least one screw threaded end for receiving a nut.
22. The container of claim 21 wherein the rods may have an opposite end which includes a screw threaded end for receiving a nut or a pin head to thereby locate the rods in the aligned channels.
23. A pallet for receiving a plurality of containers for receiving pouches containing a product, including:
- a pallet body; and
- a plurality of locator elements on the pallet body for registering with cooperating locator elements on the containers so that when the containers are loaded onto the pallet, the cooperating locator elements on the containers engage the locator elements on the pallet to securely support and locate a first layer of the containers on the pallet.
24. The pallet of claim 23 wherein the pallet includes handle receiving elements for receiving a handle to facilitate movement of the pallets after loading the pallets onto a trolley.
25. The pallet of claim 24 wherein the cooperating locator elements comprise tapered pins which project upwardly from the pallet body.
26. The pallet of claim 23 wherein the pallet body has a lower surface, the lower surface having a plurality of grooves for registering with conveyor elements to enable the pallet to be moved on a conveyor.
27. The pallet of claim 23 wherein the pallet body is formed from longitudinally extending and transversely extending frame elements, a plurality of beams being formed on an upper surface of the frame elements, and the tapered pin being provided on the beams.
28. A packaging system plant, including:
- a filling and heat sealing line for filling pouches with a product and sealing the filled pouches;
- a container for receiving filled and sealed pouches from the line, and for supporting a plurality of the pouches;
- a transporter for receiving the containers loaded with the pouches to form a stack of the containers, and for enabling the stack of containers to be moved from one place to another;
- an ancillary processing station for receiving the containers transported by the transporter and for performing an ancillary treatment step on the filled pouches while housed in the stack of containers; and
- a packaging station for receiving the transporter carrying the stack of containers to enable the pouches to be removed from the containers and packaged for distribution.
29. The system of claim 28 wherein the ancillary treatment stage comprises a retort for receiving the pouches.
30. The system of claim 29 wherein the retort is a shower type retort.
31. The system of claim 28 wherein the ancillary treatment stage comprises a cooling station for cooling heated pouches.
32. The system of claim 28 wherein the system includes a disperser plate for location on the stacked containers, the disperser plate having a plurality of holes so that hot water flows onto the disperser plate and through the plurality of holes, and then passes down through the containers and over the pouches to treat the pouches.
33. The system of claim 28 wherein the system includes stacking means for stacking the containers on the transporter after the containers have been loaded with the pouches.
34. The system of claim 33 wherein the stacking means comprises a robot for engaging a loaded container and moving the loaded container from a loading station to the transporter.
35. The system of claim 28 wherein the container includes:
- a container body having an open top and an open bottom so water can drain through the open top, over the pouches supported in the container and out through the open bottom;
- a plurality of support elements, each for supporting side edges of the pouch;
- first cooperating locator means on an upper portion of the container body;
- second cooperating locator means on a lower portion of the container body; and
- wherein two like said containers are able to be stacked one above the other by the first cooperating locator means of one container engaging the second cooperating locator means of the other container.
36. The system of claim 35 wherein the support elements each comprise a pair of spaced apart slots for receiving the side edges of the pouch, each slot having a guide entrance formed by a pair of inclined surfaces which incline outwardly from the slot and downwardly toward the slot to form a guide for guiding the edges of the pouch into the slots.
37. The system of claim 35 wherein the container includes a plurality of rows of opposed slots so that the pouches are supported in side by side relationship in the container.
38. The system of claim 35 wherein the first cooperating locator means comprises at least one a tapered pin, and the second cooperating locator means comprises at least one hole.
39. The system of claim 35 wherein the container body includes opposed side walls and opposed end walls, and a first said tapered pin is provided on a block fixed to an upper portion of one of the side walls, and a second said tapered pin is provided on a block fixed to an upper portion of the other side wall diametrically opposite the first pin.
40. The system of claim 35 wherein the container body includes a flange extending at least partway along each side wall, one of said flanges having a first said hole in vertical alignment with the first pin, and the other said flange having a second said hole in vertical alignment with the second said pin.
41. The system of claim 40 wherein the flanges extend along the entire length of the side walls.
42. The system of claim 36 wherein the slots are provided in rails which extend between the opposite ends of the container body.
43. The system of claim 35 wherein the open bottom of the container body comprises a plate, the said flanges being integral with, and part of, the plate, and at least one aperture in the plate for forming the open bottom.
44. The system of claim 43 wherein the plate includes a plurality of rectangular apertures for forming the open bottom of the container.
45. The system of claim 35 wherein the transporter comprises a pallet.
46. The system of claim 45 wherein the pallet includes a pallet body, and a plurality of locator elements on the pallet body for registering with cooperating locator elements on the containers so that when the containers are loaded onto the pallet, the cooperating locator elements on the containers engage the locator elements on the pallet to securely support and locate a first layer of the containers on the pallet.
47. The system of claim 46 wherein the pallet includes handle receiving elements for receiving a handle to facilitate movement of the pallets after loading the pallets onto a trolley.
48. The system of claim 47 wherein the cooperating locator elements comprise tapered pins which project upwardly from the pallet body.
49. The system of claim 48 wherein the pallet body has a lower surface, the lower surface having a plurality of grooves for registering with conveyor elements to enable the pallet to be moved on a conveyor.
50. The system of claim 46 wherein the pallet body is formed from longitudinally extending and transversely extending frame elements, a plurality of beams being formed on an upper surface of the frame elements, and the tapered pin being provided on the beams.
51. The system of claim 35 wherein the transporter comprises a continuous conveyor for conveying stacked containers to the ancillary processing station.
52. The system of claim 51 wherein the conveyor passes through the ancillary processing station and then to the packaging station.
53. A method of manoeuvring pouches in a packaging plant, comprising:
- filling pouches with a product and sealing the filled pouches;
- loading filled and sealed pouches into containers so the pouches are supported in the containers;
- stacking the containers loaded with the pouches on a transporter;
- moving the stacked containers on the transporter to an ancillary processing station for performing an ancillary treatment step on the filled pouches while housed in the stack of containers; and
- moving the stacked containers on the transporter to a packaging station to enable the pouches to be removed from the containers and packaged for distribution.
54. The method of claim 53 wherein the ancillary treatment stage comprises a retort for receiving the pouches.
55. The method of claim 54 wherein the retort is a shower type retort.
56. The method of claim 53 wherein the method includes locating a disperser plate on the stacked containers, the disperser plate having a plurality of holes so that in the retort hot water flows onto the disperser plate and through the plurality of holes, and then passes down through the containers and over the pouches to treat the pouches.
57. The method of claim 53 wherein the ancillary treatment stage is a cooling station for cooling heated pouches.
58. The method of claim 53 wherein the transporter comprises a pallet upon which the containers are stacked and which pallet is moved to the ancillary processing station, and then to the packaging station.
59. The method of claim 53 wherein the transporter comprises at least one conveyor for conveying the stacked containers to the ancillary processing station, and then to the packaging station.
60. A system for handling containers which are to be loaded with pouches to facilitate movement of the pouches through a processing plant, including:
- a carriage for receiving an empty container;
- first carriage moving means for moving the carriage from a container receiving position to a first container release position and returning the carriage to the container receiving position;
- loading means for loading the container into the carriage when the carriage is in the container receiving position;
- indexing means for receiving the container from the carriage at the release position and for indexing the container past a loading station at which filled and sealed pouches are loaded into the container as the container is indexed past the loading station;
- a second carriage for receiving loaded containers from the indexing means;
- second carriage moving means for moving the second carriage from a loaded container receiving position to a second container release position; and
- unloading means for moving the loaded container from the second carriage at the second release position and stacking the loaded container on a pallet.
61. The system of claim 60 wherein the first carriage has first clamping means for clamping the container when loaded into the first carriage so that the container is moved with the carriage as the carriage is moved from the receiving position to the release position, and which is disengaged from the container at the first release position to enable the container to drop onto the indexing means.
62. The system of claim 60 wherein the indexing means comprises a continuous loop carrying a plurality of abutment elements for engaging the container and indexing the container as the continuous loop is indexed.
63. The system of claim 62 wherein the continuous loop comprises a pair of continuous chains driven by a motor and sprocket assembly.
64. The system of claim 62 wherein the abutment members comprise a plurality of bars which extend between the continuous chains and define receiving spaces for receiving the container so that the container is engaged by one of the bars and indexed with the continuous chains and bars.
65. The system of claim 60 wherein the indexing means includes guide means for receiving a container so that the container can slide on the guides as the container is indexed by the indexing means.
66. The system of claim 60 wherein the system includes lifting means at the loaded container receiving position so that the container is lifted from the indexing means into a position for engagement by the second carriage.
67. The system of claim 60 wherein the second carriage includes second clamping means for engaging the container when received by the second carriage so that the container can be moved by the second carriage to the second release position.
68. The system of claim 60 wherein the loading means and the unloading means comprise a robot for performing both the loading of the empty containers into the first carriage and the unloading of filled containers from the second carriage.
69. The system of claim 60 wherein the carriages have sensors for detecting when a container is received in the first and second carriages.
70. The system of claim 60 wherein the system further includes a pallet moving conveyor for moving a pallet, from which the empty container is removed, to a stacking location, at which a filled container is deposited by the unloading means.
71. The system of claim 60 wherein the system further includes a supply conveyor for supplying pallets loaded with empty containers to the empty container unloading station, and a discharge conveyor for receiving pallets stacked with loaded containers and for transporting the stacked pallet to a discharge station.
72. The system of claim 70 wherein the pallet moving conveyor extends between the supply conveyor and the discharge conveyor, and includes a first lifting means for lifting the empty pallet above the supply conveyor so the empty pallet can be conveyed by the pallet conveyor to the stacking station, and lowering means at the stacking station for lowering the pallet onto the discharge conveyor.
73. A pallet handling apparatus for receiving pallets stacked with containers, from which the containers are to be unloaded, so the containers can be loaded with pouches, and then stacked on an empty pallet, said apparatus comprising:
- a supply conveyor for conveying pallets stacked with containers to a container unloading station so the containers can be unloaded at the unloading station and supplied to a pouch loading station at which pouches are loaded into the containers;
- a discharge conveyor for conveying pallets from a stacking station upon which loaded containers are stacked on a pallet, to a pallet discharge station;
- a pallet moving conveyor extending between the unloading station and the stacking station for conveying an empty pallet from the unloading station to the stacking station;
- first pallet transfer means at the unloading station for transferring a pallet from the supply conveyor at the unloading station onto the pallet moving conveyor; and
- second conveyor transfer means at the stacking station for transferring the pallet from the moving conveyor onto the discharge conveyor.
74. The apparatus of claim 73 wherein the supply conveyor includes a plurality of chain conveyor section.
75. The apparatus of claim 73 wherein the discharge conveyor includes at least one chain conveyor which extends from the stacking station towards the discharge station, and a discharge roller conveyor at the discharge station.
76. The apparatus of claim 73 wherein the pallet moving conveyor includes an intermediate chain conveyor section and the first transfer means comprises a first roller conveyor at the unloading station, lifting means for raising the first roller conveyor relative to the at least one supply chain conveyor so that lifting of the first roller conveyor engages the pallet and lifts the pallet above the at least one supply chain conveyor so the pallets can then move on the first roller conveyor and onto the intermediate chain conveyor, a second roller conveyor at the stacking station, lowering means connected to the second roller conveyor for lowering the second roller conveyor to lower the pallet onto the at least one discharge chain conveyor section.
77. The apparatus of claim 76 wherein the first raising means comprises a ram and guide assembly for moving the first roller conveyor in a vertical direction between a raised and lowered position.
78. The apparatus of claim 77 wherein the second moving means comprises at least one ram and guide assembly for moving the second roller conveyor in a vertical direction between a raised and lowered position.
79. The apparatus of claim 76 wherein the intermediate chain conveyor includes at least one drive sprocket and a motor for driving the sprocket, and therefore the chain conveyor.
80. The apparatus of claim 76 wherein the first and second roller conveyors have a first drive motor and a second drive motor respectively for driving at least one of the rollers of each of the first and second roller conveyors.
81. The apparatus of claim 76 wherein the plurality of chain conveyor sections each includes a drive sprocket and at least one motor for driving each conveyor chain section.
82. The apparatus of claim 76 wherein the discharge chain conveyor section includes a sprocket and at least one motor for driving the discharge chain conveyor section.
83. The apparatus of claim 76 wherein the discharge roller conveyor includes idler rollers so that the pallet can be rolled manually or under the influence of gravity on the first roller conveyor.
84. The apparatus of claim 73 wherein a pallet trolley is provided for supplying pallets stacked with empty containers to the supply conveyor and for receiving pallets stacked with loaded containers from the discharge conveyor, the trolley including an upper roller conveyor section including a plurality of rollers so that pallets can be rolled off the trolley onto the supply conveyor and off the discharge conveyor onto the trolley, locking means for locking the pallet to the trolley so the trolley can then be moved to transport the pallet and the containers from one place to another.
85. The apparatus of claim 74 wherein a trolley support is provided at a supply end of the supply conveyor and at a discharge station of the discharge conveyor, the support comprising a pair of guide channels for receiving the wheels of the trolley, and allowing the trolley to be registered with the supply conveyor or the discharge conveyor, wheel locking means for locking the trolley to the trolley support to hold the trolley stationary relative to the supply conveyor or discharge conveyor to enable the pallet to be moved from the trolley onto the supply conveyor or off the discharge conveyor onto the trolley.
86. The apparatus of claim 85 wherein the locking means comprises a spring biased catch which is engaged by the pallet as the pallet is moved onto the trolley, and moved against the bias of the spring to locate behind a portion of the pallet to lock the pallet to the trolley.
87. The apparatus of claim 85 wherein the locking means includes a lever for pivotal movement to move the catch out of engagement with the portion of the pallet so the pallet can be released from the trolley.
88. The apparatus of claim 76 wherein the supply conveyor includes a chain conveyor section which forms the unloading station, the chain conveyor section having a pair of chains and means for circulating the chains about a continuous loop so a pallet can be moved on the section, and wherein the first pallet transfer means includes a subassembly mounted to the chain conveyor section, the subassembly carrying a first roller conveyor formed of a plurality of rollers, means for raising and lowering the subassembly and first roller conveyor relative to the chain conveyor section so that when a pallet is on the chain conveyor section at the unloading station, the subassembly can be raised to engage the pallet and lift the pallet above the chains of the chain conveyor section so the pallet can then be moved on the first roller conveyor in a direction transverse to the direction of movement on the chain conveyor section, and wherein the moving means is for lowering the subassembly so the roller conveyor is moved below the chains of the chain conveyor section to allow another pallet to move along the chain conveyor section; and
- the discharge conveyor including a discharge conveyor chain section which defines the stacking station, the discharge chain conveyor section including a pair of chains for moving a pallet on the discharge chain conveyor section,- a second subassembly mounted to the discharge chain conveyor section, and including a second roller conveyor, second moving means for raising the second subassembly and the second roller conveyor relative to the discharge chain conveyor section so that in a raised position of the subassembly and the second roller conveyor, the pallet is able to move along the pallet moving conveyor and onto the second roller conveyor, the second moving means also being for lowering the second roller conveyor to deposit the pallet on the chains of the discharge chain conveyor section; and
- the first subassembly, the first roller conveyor and the second subassembly and the second roller conveyor forming part of said pallet moving conveyor so that a pallet can be rolled from the first conveyor section along the pallet moving conveyor to the second roller conveyor.
89. The apparatus of claim 88 wherein the supply conveyor chain section includes abutments for receiving a pallet to locate the pallet on the supply conveyor chain section so the pallet is accurately located at the unloading station.
90. The apparatus of claim 88 wherein holding means are provided on the supply conveyor chain section for engaging the pallet and holding the pallet at the unloading station.
91. The apparatus of claim 90 wherein second holding means are provided at the discharge chain conveyor section for releasably holding the pallet at the stacking station.
92. The apparatus of claim 76 wherein a container indexing means is provided for indexing containers past a loading station at which pouches are loaded into the containers;
- container loading and unloading means for unloading an empty container from a pallet at the unloading station and depositing the container on the indexing means for indexing past the pouch loading station; and
- collecting a loaded container and depositing the loaded container onto a pallet at the stacking station.
93. A filling and heat sealing line for filling pouches with product, comprising:
- a filling station for loading a product into the pouches;
- a heat sealing station for heat sealing filled pouches;
- moving means for moving the pouches from the filling station to the heat sealing station;
- a vision system;
- pouch moving means for moving pouches from the heat sealing station past the vision system;
- said vision system including:
- (a) a light source for producing light so that light is transmitted through a transparent region on one side of the sealed pouch which overlaps a heat seal produced by the heat sealing station;
- (b) at least one camera for receiving light transmitted through the seal; and
- (c) processing means for determining from the light received by the camera the integrity of the seal to determine whether the pouch should or should not be rejected.
94. The line of claim 93 wherein the pouch includes a transparent strip which overlaps the heat seal to facilitate transmission of light through the region of the pouch in the vicinity of the heat seal to in turn facilitate determination of whether the seal has been properly formed.
95. The line of claim 93 the processing means compares the light received by the cameras with a grey scale to provide an indication of whether the seal is properly formed.
96. The line of claim 93 the system includes a reject station which is activated by the processing means if a seal is determined to be inadequate so the pouch is rejected from the line at the reject station.
97. The line of claim 96 wherein the reject station comprises a moveable door over which the pouches pass and which is open to enable the pouches to drop through the door.
98. The line of claim 93 wherein the processing means is for determining whether pixels of the at least one camera see light intensity on a grey scale above a predetermined grey scale value, and also determines whether a second predetermined number of adjacent pixels have a grey scale value above that predetermined number, and if so, produce the signal indicative of the seal not being properly formed so that the pouch can be rejected at the reject station.
99. The line of claim 93 wherein the pouch is provided with notches and the processing means identifies the notches to in turn use the identified notches as a point of reference for determining the inspection region defined by the transparent strip which is positioned at a known location with respect to the notches.
100. A seal integrity monitoring system for inspecting the integrity of a seal in a pouch which has a transparent region on one side of the pouch, a translucent region on the other side of the pouch, and a seal formed between the transparent region and the translucent region, comprising:
- a light source for producing radiation and directing the radiation through the transparent region;
- a camera for viewing the translucent region and for producing an image of the translucent region; and
- a processor for processing the image captured by the camera to determine the integrity of the seal.
101. The system of claim 100 wherein the seal is a heat seal and the transparent region comprises a transparent region in a first panel of the pouch and the translucent region is a translucent coating on a second panel of the pouch which is connected to the first panel by the seal, the first panel including a fluorescing material at least in the vicinity of the transparent region, so that when the light source directs the light through the transparent region, the fluorescing material fluoresces to produce white light, and if the first and second panels are properly sealed together, a continuous waveguide is provided for transmission of the white light to the translucent coating, and if the seal is not properly formed, a continuous waveguide is not formed, thereby allowing light to disperse where the seal is not properly formed so those parts of the seal appear as a dark region on the translucent region.
102. The system of claim 100 wherein the translucent region forms a filter for filtering the white light so that the filtered light is received by the camera and the processor processes the image of the filtered light to determine the integrity of the seal.
103. The system of claim 101 wherein the light source is an ultraviolet light source for producing ultraviolet light of a wavelength from 320 to 350 nanometers.
104. The system of claim 101 wherein the camera comprises a CCD array type camera.
105. The system of claim 104 wherein the processor processes the images captured by the camera by determining pixels which have a grey value above a predetermined value, thereby providing the indication of an improperly formed part of the seal.
106. The system of claim 105 wherein the processor determines that the seal is satisfactory if a band of a predetermined thickness of properly formed seal can be defined from one side of the pouch to the other side of the pouch.
107. A seal integrity monitoring method for inspecting the integrity of a seal, the pouch having a first panel with a transparent region, a second panel having a translucent region, and the seal being formed between the first and second panels so the seal is between the first panel and the translucent region, the method comprising:
- irradiating the transparent region so that the radiation passes into the transparent region, and if the seal is properly formed, the first and second panels at the seal form a continuous waveguide for directing radiation to the translucent region, and if the seal is not properly formed, light is dispersed at the improperly formed seal, thereby producing a dark region at the translucent region;
- detecting the translucent region with a camera to obtain an image of the translucent region; and
- processing the image captured by the camera to identify any dark regions appearing at the translucent region to thereby determine the integrity of the seal.
108. The method of claim 107 wherein the radiation has a wavelength of from 320 to 350 nanometers.
109. The method of claim 107 wherein the camera is a CCD array camera and the processing step determines the grey scale value of pixels of the CCD array in order to identify dark regions in the image.
110. The method of claim 106 wherein the transparent region includes a fluorescing material so that when the light is directed to the transparent region, the fluorescent material fluoresces to produce white light which passes through the continuous waveguide to the translucent region, or if the seal is not in tact, is dispersed at the regions where the seal is not in tact so that dark regions are produced at the translucent region.
111. The method according to claim 110 wherein the translucent region forms a filter for filtering the white light so that a predetermined colour of the white light passes through the filter and is detected by the camera to produce the image which is processed to determine the integrity of the seal.
Type: Application
Filed: Jun 4, 2003
Publication Date: Mar 9, 2006
Inventors: Robert Laing (Hawthorn), Lloyd Russell (Dural)
Application Number: 10/516,409
International Classification: B65B 61/20 (20060101); B65B 35/30 (20060101); B65D 33/14 (20060101); B65D 33/04 (20060101); B65D 30/00 (20060101);