Abstract: A column of cups guided by their rims in elongated slots is spaced into desired cup pitch by one or more linear stars from which the cups can be transferred for packaging. The linear stars have lugs engaging and spacing the cups. In another aspect of the invention, cups are manipulated into patterns for final grouping and packaging and by a plurality of cup orienting pickers engaging, inverting and re-orienting the cups. In one final packaged cup group of two or more layers, alternating cups in each layer are inverted and a top lid of a cup in an upper layer is disposed on a top lid of a cup in a bottom layer, while a bottom of a cup in an upper layer is disposed on a bottom of a cup in a lower layer, and in an alternating pattern.

Abstract: Improved product handling and transfer apparatus includes rotatable product buckets for receiving product and re-orienting product for packaging in diverse configurations or containers. Buckets preferably include channels spanned by deposited product or receiving product therein, with bucket turning as appropriate to a packaging configuration. Flat bottom buckets and methods are disclosed.

Abstract: A column of cups guided by their rims in elongated slots is spaced into desired cup pitch by one or more linear stars from which the cups can be transferred for packaging. The linear stars have lugs engaging and spacing the cups. In another aspect of the invention, cups are manipulated into patterns for final grouping and packaging and by a plurality of cup orienting pickers engaging, inverting and re-orienting the cups. In one final packaged cup group of two or more layers, alternating cups in each layer are inverted and a top lid of a cup in an upper layer is disposed on a top lid of a cup in a bottom layer, while a bottom of a cup in an upper layer is disposed on a bottom of a cup in a lower layer, and in an alternating pattern.

Abstract: An asymmetric article-carrying puck is driven by a linear star conveyor through an angular rotation orienting section to orient the pucks and articles therein irrespective of random initial orientation. In one embodiment, an upper puck plate carries the article while a separated lower puck plate defines a rotational orienting circular gear rack with a rotation-stopping bridge, separating ends of the rack and inclined from a base of one end tooth in the rack to a crest of another end tooth in the rack. The lower puck plate can be a combination of two circular plates with the circular gear rack interposed therebetween and within the periphery of the circular plates. Pucks can be accumulated in mutual engaged positions and separated by the linear star into preselected pitch while transported and turned. Integral pucks can be used. The structural details and methods are disclosed.

Abstract: A transport drive system for a carton transport conveyor includes a shaft, a first pair of drive members, a second pair of drive members, and a phase adjustment hub connected to the shaft. A first set of drive members includes a drive member of the first pair and a drive member of the second pair, and the first set of drive members is rotationally fixed with respect to the shaft. A second set of drive members includes another drive member of the first pair and another drive member of the second pair, and the second set of drive members is rotationally fixed with respect to the phase adjustment hub. The phase adjustment hub is angularly adjustable with respect to the shaft to adjust the angular phase of the sets, while the pairs are adjustably spaced one from the other.

Abstract: Improved product handling and transfer apparatus includes rotatable product buckets for receiving product and re-orienting product for packaging in diverse configurations or containers. Buckets preferably include channels spanned by deposited product or receiving product therein, with bucket turning as appropriate to a packaging configuration. Flat bottom buckets and methods are disclosed.

Abstract: An adjustable pouch machine comprises a vertical sealer module forms transverse seals between two plies of a pouch web to partially define a plurality of pouches. Rollers selectively tension and relax the web on the vertically oriented wheel, allowing them to drop away from heated lands on emergency and cycle stops. A filler wheel has a plurality of adjustable gripper units mounted directly thereon for transporting independent separate pouches cut from the pouch web. An adjustable knife is selectively provided with changeable knife hub sets to handle a variety of pouch sizes where a filler wheel alternately first fills and seals pouches in a train. Gear linkage accommodates variation in distance between hubs of different sets. Various embodiments, apparatus and methods are described.

Abstract: An asymmetric article-carrying puck is driven by a linear star conveyor through an angular rotation orienting section to orient the pucks and articles therein irrespective of random initial orientation. In one embodiment, an upper puck plate carries the article while a separated lower puck plate defines a rotational orienting circular gear rack with a rotation-stopping bridge, separating ends of the rack and inclined from a base of one end tooth in the rack to a crest of another end tooth in the rack. The lower puck plate can be a combination of two circular plates with the circular gear rack interposed therebetween and within the periphery of the circular plates. Pucks can be accumulated in mutual engaged positions and separated by the linear star into preselected pitch while transported and turned. Integral pucks can be used. The structural details and methods are disclosed.

Abstract: An adjustable pouch machine comprises a vertical sealer module forms transverse seals between two plies of a pouch web to partially define a plurality of pouches. Rollers selectively tension and relax the web on the vertically oriented wheel, allowing them to drop away from heated lands on emergency and cycle stops. A filler wheel has a plurality of adjustable gripper units mounted directly thereon for transporting independent separate pouches cut from the pouch web. An adjustable knife is selectively provided with changeable knife hub sets to handle a variety of pouch sizes where a filler wheel alternately first fills and seals pouches in a train. Gear linkage accommodates variation in distance between hubs of different sets. Various embodiments, apparatus and methods are described.

Abstract: The invention is a sealing system and a method of operation thereof. A sealing system which forms spaced apart thermal seals along a moving at least one web (60) by contact of the moving the at least one web with heated portions (74) of sealing elements (56) mounted on a sealing wheel (50) during rotation in accordance with the invention includes seal forming elements (56) which peripherally contact the at least one web to form the thermal seals by heat transfer to the at least one web; and wherein each seal forming element has an outer section (62) on which is located at least one electrical heater (78), an inner section (64) which contacts the sealing wheel and an intermediate section (70) which includes thermal insulation (68) which insulates the outer section from the inner section.

Abstract: A cartoner has an intermediate transfer disposed between each article infeed area and an adjacent bucket conveyor to transfer separate rows of select article count into buckets on the adjacent bucket conveyor. The intermediate transfer runs only the length necessary to feed rows into a bucket for one tier or group of articles. Row selecting and forming devices on, or extending from, buckets or bucket walls are eliminated. A sheet feeder feeds partitions over the upstream end of a group receiving bucket conveyor for deposit on a lower group of articles on which an upper group is to be formed.

Abstract: Methods of selectively packaging clips of tissues in flat or boutique cartons include depositing clips on carriers and turning and dropping clips into transverse channels in the carrier floors from where fat clips can be pushed into flat cartons, or selectively depressing the mid-portion of clips spanning the channels into the channels to form U-shaped clips which can be pushed into boutique cartons.

Abstract: A pouch machine includes a modular feeder having feeder components mounted in a module. The pouch machine has a common socket for receiving a selected one of a plurality of feeder modules in operative position proximate a pouch filler apparatus.

Abstract: The invention is a sealing system and a method of operation thereof. A sealing system which forms spaced apart thermal seals along a moving at least one web (60) by contact of the moving the at least one web with heated portions (74) of sealing elements (56) mounted on a sealing wheel (50) during rotation in accordance with the invention includes seal forming elements (56) which peripherally contact the at least one web to form the thermal seals by heat transfer to the at least one web; and wherein each seal forming element has an outer section (62) on which is located at least one electrical heater (78), an inner section (64) which contacts the sealing wheel and an intermediate section (70) which includes thermal insulation (68) which insulates the outer section from the inner section.

Abstract: A bucket on a bucket conveyor has a movable member or wall movable to a laid down position for receiving a horizontally disposed item. The member or wall is moved to reorient the item into an upright position for loading into a carton with another item later introduced into the bucket on another side of the movable member from the first item. Multiple items, inserts and/or multiple products can be handled. Methods and apparatus are provided.

Abstract: A blank feeder includes a blank stack with blanks inclined forwardly in a magazine section and rearwardly in a discharge section so the stack has two effective top ends, one for supply and one for feeding. Blank inclination is reversed intermediate the stack ends without separating blanks in the stack during inclination reversal. Methods and apparatus are disclosed.

Abstract: Tissue clips are placed on the upper level of bi-level product buckets, with the length of the tissue clips in the machine direction. The lower level of the product bucket is comprised of a full-width transverse channel whose width is greater than the width of the tissue clips but less the length of the tissue clips. To package flat packages of tissues, extensible pushers turn the tissue clips 90 degrees so they drop into the transverse channels. Subsequently flat overhead tamps descend and the tissue clips are pushed through guide buckets into the end of the flat-pack cartons. To package boutique packages of tissues, the extensible pushers are disengaged so the length of the tissue clips remain in the machine direction spanning the transverse channels. Subsequently, narrow tamps descend, pushing the center of the tissue clips into the transverse channels, forming the tissue clips into the beginning of a U-shape ready for pushing through guide buckets into the side of boutique cartons.

Abstract: A blank feeder includes a blank stack with blanks inclined forwardly in a magazine section and rearwardly in a discharge section so the stack has two effective top ends, one for supply and one for feeding. Blank inclination is reversed intermediate the stack ends without separating blanks in the stack during inclination reversal. Methods and apparatus are disclosed.

Abstract: A non-contact rotary knife apparatus which perforates a seal area between two adjacent pouches in a continuous web by using perforating blades, preferably on the minor hub, and anvils on the major hub with the anvils having elongated, spaced apart recesses for receiving but not touching the teeth of the perforating blade. Thus, a major knife hub is mounted for rotation and has perforating anvils spaced about the exterior of the major knife hub. Each of the perforating anvils has elongated, spaced-apart recesses. A minor knife hub is also mounted for rotation proximate to the major knife hub and has perforating blades spaced about the exterior of the minor knife hub. Each of the perforating blades has an edge with spaced perforating teeth disposed along the edge.

Abstract: A single level filler wheel for filling pouches with multiple products including a filler wheel having at least two sets of funnels defined within the wheel and spouts attached to the underside of the wheel, alternating spouts communicating with funnels of each set so that products dispensed on the wheel into two different feed paths are respectively received by the respective funnel sets and transferred directly into alternating spouts for filling at least two products, one into each alternate pouch. The total product drop is halved with respect to dual level filling devices and through-put speeds can be significantly increased. Multiple products in excess of two and varied feed drops can be provided by adding funnel sets, alternating spouts differently and the like. Methods and apparatus are disclosed.