Automated packing apparatus, system, and method

Abstract

An automated apparatus (100), a system (1000), and method (M) for packing leafy produce (10) into a tray (20) involving a plunger (30), the plunger (30) having an actuator arm (40) and a footpad (50), the footpad (50) having an upper surface (50a) and a lower surface (50b), being in moveable relation to the actuator arm (40), for contacting the leafy produce (10).

Description

TECHNICAL FIELD

The present invention relates to agricultural apparatuses, systems, and methods. More particularly, the present invention relates to agricultural apparatuses, systems, and methods for processing produce. Even more particularly, the present invention relates to agricultural apparatuses, systems, and methods for packing processed produce.

BACKGROUND ART

The currently existing art involves several machines for packing leafy produce, such as “spring mix,” spinach, lettuce, endive, arugula, mache, herbs, and the like. One such invention is a packing machine which fills a container with leafy produce, fits a lid onto such container having the produce, but damages the leafy produce at the rim of the container, thereby shortening the shelf life of the product. This problem in the related art occurs, because the leafy produce has a tendency to spring back upon loading into the container, to overhang the rim of the container, and to be subsequently damaged during fitting of the lid. To counteract this adverse result, agricultural processors have used manual labor for “post-packing” the leafy produce, e.g., using a production line of approximately six gloved workers who manually reposition the leafy produce in the container prior to thereon fitting the lid. Thus, a long-felt need is seen to exist for an automated apparatus, a system, and a method for efficiently packing leafy produce, eliminating damage thereto, and minimizing processing time.

DISCLOSURE OF THE INVENTION

The present invention involves an apparatus, a system, and a method for efficiently packing aproduct, such as leafy produce, eliminating damage thereto, and minimizing processing time. The present automated apparatus for packing leafy produce into a tray generally comprises a plunger, the plunger having an actuator arm and a footpad, the footpad having an upper surface and a lower surface and being in moveable relation to the actuator arm for contacting and plunging the leafy produce into the tray.

The present automated system for packing leafy produce into a tray generally comprises a conveyor, having a stepper for accommodating and moving a tray, a hopper for channeling the leafy produce, a feeder for receiving the channeled leafy produce and for filling the leafy produce into the at least one tray; and an automated packing apparatus for packing the leafy produce into the tray, the apparatus comprising a plunger, the plunger having an actuator arm and a footpad, the footpad having an upper surface and a lower surface and being in moveable relation to the actuator arm for contacting and plunging the leafy produce into the tray.

The present invention automated method for packing leafy produce into a tray generally comprises the steps of conveying and stepping a tray; channeling the leafy produce through a hopper; feeding the channeled leafy produce into the tray, thereby filling the tray; providing an automated packing apparatus for packing the leafy produce into the tray, the apparatus providing step comprising providing a plunger, the plunger providing step comprising providing the plunger with an actuator arm and a footpad, the footpad having an upper surface and a lower surface and being in moveable relation to the actuator arm for contacting and plunging the leafy produce into the tray; providing a sensor for detecting the presence of the tray and for supplying an electronic signal to the feeder to effect its opening for filling the tray with the leafy produce; packing the leafy produce into the tray using the automated packing apparatus; and applying a lid to the tray.

Advantages of the present invention include providing a tray filling machine, as a modular apparatus or as part of a complete production system, which promotes increased production levels, minimizes rejected product, and minimizes the number of workers in the production line. Other features of the present invention are disclosed, or are apparent, in the section entitled “Detailed Description of the Invention,” disclosed, infra.

BRIEF DESCRIPTION OF THE DRAWING

For a better understanding of the present invention, reference is made to the below-referenced accompanying Drawing. Reference numbers refer to the same or equivalent parts of the present invention throughout the several figures of the Drawing.

FIG. 1 is an upward perspective view of an automated packing system, comprising an automated packing apparatus, in accordance with the present invention.

FIG. 2 is a downward perspective view of the automated packing system, as shown in FIG. 1, comprising the automated packing apparatus, in accordance with the present invention.

FIG. 3 is an upward perspective view of an automated packing system, comprising an automated packing apparatus, shown without the support frame for clarity only, in accordance with the present invention.

FIG. 4 is an downward perspective view of an automated packing apparatus, shown in relation to a feeder, such as a product transfer chute and a funnel, with a mounting bracket, and without the support frame for clarity only, in accordance with the present invention.

FIG. 5 is a downward perspective view of an automated packing apparatus, shown without a mounting bracket and without the support frame for clarity only, in accordance with the present invention.

FIG. 6 is side view of an automated packing apparatus, wherein at least one plunger is disposed outside a feeder, such as a product transfer chute and a funnel, shown without a mounting bracket and without the support frame for clarity only, in accordance with a first embodiment of the present invention.

FIG. 7 is side view of an automated packing apparatus, wherein at least one plunger is disposed inside a feeder, such as a product transfer chute and a funnel, shown without a mounting bracket and without the support frame for clarity only, in accordance with a second embodiment of the present invention.

FIG. 8 is side view of an automated packing apparatus, wherein a plunger is disposed inside a feeder, such as a product transfer chute and a funnel, and comprises an articulating structure, and wherein the articulating structure is disposed at a periphery of a footpad at an upper surface, shown with the relative positions of the plunger and the footpad on a downstroke, without a mounting bracket, and without the support frame for clarity only, in accordance with a third embodiment of the present invention.

FIG. 9 is side view of an automated packing apparatus, wherein at least one sidewall of a feeder, such as a product transfer chute and a funnel, itself, acts as a footpad, and wherein the feeder comprises an articulating structure, and wherein the articulating structure is disposed at a periphery of the footpad, shown with the relative positions of the actuator arm and the footpad on a downstroke, without a mounting bracket, and without the support frame for clarity only, in accordance with a fourth embodiment of the present invention.

FIG. 10 is side view of an automated packing apparatus, as shown in FIG. 8, wherein the plunger is disposed inside a feeder, such as a product transfer chute and a funnel, and comprises the articulating structure, and wherein the articulating structure is disposed at a periphery of the footpad at the upper surface, shown with the relative positions of the actuator arm, the plunger, and the footpad on the downstroke, without a mounting bracket, and without the support frame for clarity only, in accordance with the third embodiment of the present invention.

FIG. 11 is side view of an automated packing apparatus, as shown in FIG. 9, wherein the sidewall of a feeder, such as a product transfer chute and a funnel, itself, acts as the footpad, and wherein the feeder comprises the articulating structure, and wherein the articulating structure is disposed at the periphery of the footpad, shown with the relative positions of the actuator arm and the footpad on the downstroke, without a mounting bracket, and without the support frame for clarity only, in accordance with the fourth embodiment of the present invention.

FIG. 12 is a front view of an automated packing system, comprising at least one automated packing apparatus, being serially disposed in an assembly line, wherein the second apparatus acts as a secondary set of plungers, in accordance with a fifth embodiment of the present invention.

FIG. 13 is a side view of an automated packing system, comprising two automated packing apparatuses, an upper distribution bucket, and a lower distribution bucket, wherein the lower distribution bucket acts in at least one capacity, such as a primary plunger and a secondary plunger, in accordance with a sixth embodiment of the present invention.

FIG. 14 is a flowchart of an automated method M for packing leafy produce into a tray, in accordance with the present invention.

MODES FOR CARRYING OUT THE INVENTION

FIG. 1 illustrates, in a perspective view, an automated packing system 1000, comprising an automated packing apparatus 100, in accordance with the present invention. The automated apparatus 100 for packing leafy produce 10 into a tray 20, comprises at least one plunger 30, each at least one plunger 30 having at least one actuator arm 40 and at least one footpad 50, the at least one footpad 50 having an upper surface 50a and a lower surface 50b, being in moveable relation to the at least one respective actuator arm 40, for contacting the leafy produce 10. The moveable relation comprises a structure 40a (not shown) for articulating the at least one footpad 50 about each respective at least one actuator arm 40. The articulating structure 40a is disposed at a location selected from a group consisting essentially of a periphery of the footpad 50 at the upper surface 50a, a centerline of the footpad 50 at the upper surface 50a, and a location between a centerline of the footpad 50 and a periphery of the footpad 50. The system 1000 is shown in FIG. 1 with a set of plungers 30, e.g., primary plungers, with a support frame 1001, with a hopper 80, comprising a primary chute 1002 and a secondary chute (pant-leg chute) 1003 for facilitating filling of two trays at a given filling interval, and a feeder 90, comprising a feature such as a product transfer (funnel) 120, for clarity and by example only. The primary chute 1002 comprises a flop gate 1002a and a flop gate actuator 1002b, as shown in FIG. 12 which is described, infra, and a flop gate control device 1002c, such as a solenoid switch, for controlling the flop gate actuator 1002b.

By example only, the articulating structure 40a comprises a feature selected from a group consisting essentially of a hinge, a pin, and a ball and socket combination. The at least one footpad 50 comprises a corrugated surface 50c at the lower surface 50b for minimizing surface tension of the leafy produce 10 which facilitates release of the leafy produce 10 from the footpad 50 when the plunger 30 retracts. The corrugated surface 50c comprises a configuration such as a sinusoidal profile and a square wave profile, the sinusoidal profile being preferred. The at least one actuator arm 40 comprises a structure for adjusting stroke (not shown), wherein the stroke is effected by programmable logic control (PLC), such as a magnetic read switch disposed on the actuator arm 40 and a PLC-defined dwell time. The actuator arm 40 comprises an actuator arm housing 40b such as a hollow tube. The at least one footpad 50 comprises a structure for adjusting size (not shown), especially the planform size. The footpad size adjusting structure comprises a feature such as at least one retractable footpad portion and a set of interchangeable footpads 50 which are interchangeable by loosening a fitting 41a at a proximal end of a guide-rod 41 and a fitting 50d at the upper surface 50a of the footpad 50, wherein each footpad 50 of the set comprises a distinct size.

Preferably, the plunger 30 is angularly disposed in relation to the tray 10. The plunger 30 is activated, i.e., deployed by a feedback and control unit comprising sensor 110 (discussed, infra), upon sensing the presence of a tray 20 and retracted upon packing the tray 20 with the leafy produce 10. The apparatus 100 comprises a primary plunging mechanism 31, as shown and described, infra, with respect to FIG. 12. The footpad 50 is preferably selected to fit the size of the opening of the tray 20. In particular, as the footpad 50 reaches the bottom of the stroke, a puff of gas, such as air and nitrogen (N₂), as well as an inert gas, such as helium (He) and argon (Ar), is administered through a manifold disposed at the periphery of the upper surface 50a of the footpad 50. After the dwell period has lapsed, the plunger 30 retracts; and the filled tray 20 is stepped forward by the conveyer 60 for applying the lid 130.

By example only, the present system 1000 further comprises a tray denester 140 (not shown) which removes two trays 20 from two magazines 150 (not shown) using a vacuum technique, such as air suction. The tray denester 140 receives a signal for supplying the trays 20 to a conveyor 60 having a stepper 70 (not shown). The vacuum technique involves a vacuum device (not shown) such as a cam and cylinder apparatus which travels upward to the waiting trays 20, contacts the bottom of the trays 20, pulls two trays 20 on a downstroke, releases those two trays 20 on the conveyor 60. The gas puff facilitates alignment of the trays 20 on the conveyor 60. The conveyor 60 runs the length of a processing line which may be twenty-five feet, for example, and is operated by a control panel (not shown) that imparts a signal which indicates the stepping distance for the conveyor 60, as shown and described with respect to FIG. 12, infra.

FIG. 2 illustrates, in a downward perspective view, the automated packing system 1000, as shown in FIG. 1, comprising the automated packing apparatus 100, in accordance with the present invention.

FIG. 3 illustrates, in an upward perspective view, an automated packing system 1000, comprising an automated packing apparatus 100, shown without the support frame 1001 for clarity only, in accordance with the present invention.

FIG. 4 illustrates, in an downward perspective view, an automated packing apparatus 100, shown in relation to a feeder 90, such as a product transfer chute 120 and a funnel, with a mounting bracket 32, and without the support frame 1001 for clarity only, in accordance with the present invention. A set of plungers 30 are lowered into the product transfer chute 120 by the primary plunging mechanism 31.

FIG. 5 illustrates, in a downward perspective view, an automated packing apparatus 100, shown without a mounting bracket 32 and without the support frame 1001 for clarity only, in accordance with the present invention.

FIG. 6 illustrates, in a side view, an automated packing apparatus 100, wherein at least one plunger 30 is disposed outside a feeder 90, such as a product transfer chute 120 and a funnel, shown without a mounting bracket 32 and without the support frame 1001 for clarity only, in accordance with a first embodiment of the present invention.

FIG. 7 illustrates, in a side view, an automated packing apparatus 100, wherein at least one plunger 30 is disposed a feeder 90, such as a product transfer chute 120 and a funnel, shown without a mounting bracket 32 and without the support frame 1001 for clarity only, in accordance with a second embodiment of the present invention.

FIG. 8 illustrates, in a side view, an automated packing apparatus 100, wherein a plunger 30 is disposed inside a feeder 90, such as a product transfer chute 120 and a funnel, wherein the actuator arm 40 includes an actuating structure 50e and an articulating arm 42, wherein the articulating arm 42 includes an articulating structure 42a, and wherein the articulating structure 42a is disposed at a periphery of a footpad 50 at an upper surface 50a, shown with the relative positions of the plunger 30 and the footpad 50 on a downstroke, without a mounting bracket 32, and without the support frame 1001 for clarity only, in accordance with a third embodiment of the present invention.

FIG. 9 illustrates, in a side view, an automated packing apparatus 100, wherein at least one sidewall of a feeder 90, such as a product transfer chute 120 and a funnel, itself, acts as a footpad 50, and wherein the feeder 90, such as the product transfer chute 120, comprises an articulating arm 42 which includes an articulating structure 42a, and wherein the articulating structure 42a is disposed at a periphery of the footpad 50, with the relative positions of the footpad 50 on a downstroke, without a mounting bracket 32, and without the support frame 1001 for clarity only, in accordance with a fourth embodiment of the present invention.

FIG. 10 illustrates, in a side view, an automated packing apparatus 100, as shown in FIG. 8, wherein a plunger 30 is disposed inside a feeder 90, such as a product transfer chute 120 and a funnel, wherein the actuator arm 40 includes an actuating structure 50e and an articulating arm 42, wherein the articulating arm 42 includes an articulating structure 42a, and wherein the articulating structure 42a is disposed at a periphery of a footpad 50 at an upper surface 50a, shown with the relative positions of the plunger 30 and the footpad 50 on a downstroke, without a mounting bracket 32, and without the support frame 1001 for clarity only, in accordance with a third embodiment of the present invention.

FIG. 11 illustrates, in a side view, an automated packing apparatus, as shown in FIG. 9, wherein at least one sidewall of a feeder 90, such as a product transfer chute 120 and a funnel, itself, acts as a footpad 50, and wherein the product transfer chute 120 comprises an articulating arm 42 which includes an articulating structure 42a, and wherein the articulating structure 42a is disposed at a periphery of the footpad 50, with the relative positions of the footpad 50 on a downstroke, without a mounting bracket 32, and without the support frame 1001 for clarity only, in accordance with a fourth embodiment of the present invention.

FIG. 12 illustrates, in a front view, an automated packing system 1000, comprising two automated packing apparatuses 100, 100′, being serially disposed in an assembly line, wherein the second apparatus 100′ acts as a secondary set of plungers, in accordance with a fifth embodiment of the present invention. The primary chute 1002 comprises a flop gate 1002a, a flop gate actuator 1002b, and a flop gate control device 1002c, such as a solenoid switch, for controlling the flop gate actuator 1002b. The flop gate 1002a limits the amount of leafy produce 10 which is packed at a given packing interval.

FIG. 13 illustrates, in a side view, an automated packing system 1000, comprising an automated packing apparatus 100, an upper distribution bucket 1004, and a lower distribution bucket 1005, wherein the lower distribution bucket 1005 acts in at least one capacity, such as a primary plunger 100 and a secondary plunger 100′, being deployed by a lower distribution bucket mechanism (not shown), in accordance with a sixth embodiment of the present invention. The lower bucket 1005 may be used to supplement the packing capability of the plunger 30 or be used in its stead.

Referring to both FIGS. 1 and 12, the automated system 1000 for packing leafy produce 10 into a tray 20, comprises a conveyor 60 having a stepper 70 for accommodating and moving at least one tray 20, a tray filler generally comprising a hopper 80 for channeling the leafy produce 10 and a feeder 90 for receiving the channeled leafy produce 10 and for filling the leafy produce 10 into the at least one tray 20, and an automated packing apparatus 100 for packing the leafy produce 10 into a tray 20, the apparatus 100 comprising at least one plunger 30, each at least one plunger 30 having at least one actuator arm 40 and at least footpad 50, the at least one footpad 50 having an upper surface 50a and a lower surface 50b, being in moveable relation to the at least one respective actuator arm 40, for contacting the leafy produce 10.

The system 1000 further comprises a sensor 110 for detecting the presence of the at least one tray 20 and for supplying an electronic signal to the feeder 90 to effect its opening for filling the at least one tray 20 with the leafy produce 10 (a designated amount thereof). The feeder 90 includes a product transfer chute 120 or a funnel being disposed into the at least one tray 20 upon receipt of the electronic signal from the sensor 110. In the alternative, the plunger 30 is disposed within the product transfer chute 120. The system 1000 further comprises the following features: a structure (not shown) for applying at least one lid 130 to each respective at least one tray 20, a structure (not shown) for labeling an upper surface of the at least one lid 130 and a lower surface of each respective at least one tray 20, and a structure (not shown) for vibrating the at least one tray 20 to assist settling and packing of the leafy produce 10. The structure for applying the lid 130 comprises a lid denester 145 (not shown) which operates in a manner similar to that of the lid denester 140, i.e., using a vacuum technique involving a cam and cylinder combination. Finally, the system 1000 further comprises a security banding device for applying a polymeric band to the rim of the lidded tray (not shown).

FIG. 14 illustrates, in a flowchart, an automated method M for packing leafy produce 10 into a tray 20 which comprises the steps of conveying and stepping at least one tray (as indicated by block 2000), channeling the leafy produce 10 through a hopper 80 (as indicated by block 2000), feeding the channeled leafy produce 10 into the at least one tray 20, thereby filling the at least one tray 20 (as indicated by block 3000), providing an automated packing apparatus 100 for packing the leafy produce 10 into the at least one tray 20, the apparatus 100 providing step comprising providing at least one plunger 30, the plunger 30 providing step comprising providing each at least one plunger 30 with at least one actuator arm 40 and at least one footpad 50, the at least one footpad 50 having an upper surface 50a and a lower surface 50b, being in moveable relation to the at least one respective actuator arm 40, for contacting the leafy produce 10 (as indicated by block 4000), providing a sensor for detecting the presence of the at least one tray and for supplying an electronic signal to the feeder to effect its opening for filling the at least one tray with the leafy produce (as indicated by block 5000), packing the at leafy produce into the at least one tray using the automated packing apparatus (as indicated by block 6000), and applying at least one lid to each respective at least one tray (as indicated by block 7000). Finally, the method M further comprises the step security banding the rim of the lidded tray (as indicated by block 8000).

The method M includes a method of fabricating an automated packing apparatus 100 for packing leafy produce 10 into a tray 20, comprising: providing at least one plunger 30, the plunger 30 providing step comprising providing each at least one plunger 30 with at least one actuator arm 40 and at least footpad 50, the at least one footpad 50 having an upper surface 50a and a lower surface 50b, being in moveable relation to the at least one respective actuator arm 40, for contacting the leafy produce 10. The method M further comprises the following steps (not shown): labeling an upper surface of the at least one lid 130 and a lower surface of each respective at least one tray 20, vibrating the at least one tray 20 to assist settling and packing of the leafy produce 10, labeling an upper surface of the at least one lid 130 and a lower surface of each respective at least one tray 20; and vibrating the at least one tray 20 to assist settling and packing of the leafy produce 10.

Information as herein shown and described in detail is fully capable of attaining the above-described object of the invention, the presently preferred embodiment of the invention, and is, thus, representative of the subject matter which is broadly contemplated by the present invention. The scope of the present invention fully encompasses other embodiments which may become obvious to those skilled in the art, and is to be limited, accordingly, by nothing other than the appended claims, wherein reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” All structural and functional equivalents to the elements of the above-described preferred embodiment and additional embodiments that are known to those of ordinary skill in the art are hereby expressly incorporated by reference and are intended to be encompassed by the present claims.

Moreover, no requirement exists for a device or method to address each and every problem sought to be resolved by the present invention, for such to be encompassed by the present claims. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. However, various changes and modifications in form, material, and fabrication material detail maybe made without departing from the spirit and scope of the inventions as set forth in the appended claims should be readily apparent to those of ordinary skill in the art. No claim herein is to be construed under the provisions of 35 U.S.C. 112, sixth paragraph, unless the element is expressly recited using the phrase “means for.”

INDUSTRIAL APPLICABILITY

The present invention industrially relates to agricultural apparatuses, systems, and methods. More particularly, the present invention industrially relates to agricultural apparatuses, systems, and methods for processing produce. Even more particularly, the present invention industrially relates to agricultural apparatuses, systems, and methods for packing processed produce.

Claims

1. An automated apparatus for packing leafy produce into a tray, comprising:

at least one plunger, each at least one plunger having at least one actuator arm and at least one footpad, the at least one footpad having an upper surface and a lower surface, being in moveable relation to the at least one respective actuator arm, for contacting the leafy produce.

2. An apparatus, as recited in claim 1, wherein the moveable relation comprises means for articulating the at least one footpad about each respective at least one actuator arm.

3. An apparatus, as recited in claim 2, wherein the articulating means is disposed at a location selected from a group consisting essentially of a periphery of the footpad at the upper surface, a centerline of the footpad at the upper surface, a location between a centerline and a periphery of the footpad.

4. An apparatus, as recited in claim 2, wherein the articulating means comprises a feature selected from a group consisting essentially of a hinge, a pin, and a ball and socket combination.

5. An apparatus, as recited in claim 1, wherein the at least one footpad comprises a corrugated surface at the lower surface for minimizing surface tension of the leafy produce.

6. An apparatus, as recited in claim 5, wherein the corrugated surface comprises a configuration selected from a group consisting essentially of a sinusoidal profile and a square wave profile.

7. An apparatus, as recited in claim 1, wherein the at least one actuator arm comprises means for adjusting stroke.

8. An apparatus, as recited in claim 1, wherein the at least one footpad comprises means for adjusting size.

9. An apparatus, as recited in claim 1, wherein the plunger is angularly disposed in relation to the tray.

10. An apparatus, as recited in claim 9, comprising two opposing plungers being angularly disposed in relation to the tray, wherein the first opposing plunger conducts a first stroke, and wherein the second opposing plunger conducts a second stroke.

11. An apparatus, as recited in claim 9, comprising two serial plungers being angularly disposed in relation to the tray, wherein the first serial plunger conducts a first stroke, and wherein the second serial plunger conducts a second stroke.

12. An apparatus, as recited in claim 1,

wherein the moveable relation comprises means for articulating the at least one footpad about each respective at least one actuator arm,

wherein the articulating means is disposed at a location selected from a group consisting essentially of at a periphery of the footpad at the upper surface and at a centerline of the footpad at the upper surface,

wherein the articulating means comprises a feature selected from a group consisting essentially of a hinge, a pin, and a ball and socket combination,

wherein the at least one footpad comprises a corrugated surface at the lower surface for minimizing surface tension of the leafy produce,

wherein the at least one actuator arm comprises means for adjusting stroke, and

wherein the at least one footpad comprises means for adjusting size.

13. An automated system for packing leafy produce into a tray, comprising:

a conveyor having a stepper for accommodating and moving at least one tray;

a hopper for channeling the leafy produce;

a feeder for receiving the channeled leafy produce and for filling the leafy produce into the at least one tray; and

at least one automated packing apparatus for packing the leafy produce into a tray, each at least one automated packing apparatus comprising at least one plunger, each at least one plunger having at least one actuator arm and at least footpad, the at least one footpad having an upper surface and a lower surface, being in moveable relation to the at least one respective actuator arm, for contacting the leafy produce.

14. A system, as recited in claim 13, further comprising a sensor for detecting the presence of the at least one tray and for supplying an electronic signal to the feeder to effect its opening for filling the at least one tray with the leafy produce.

15. A system, as recited in claim 14, wherein the feeder includes a funnel being disposed into the at least one tray upon receipt of the electronic signal from the sensor.

16. A system, as recited in claim 15, wherein the plunger is disposed within the funnel.

17. A system, as recited in claim 13, further comprising means for applying at least one lid to each respective at least one tray.

18. A system, as recited in claim 13, further comprising means for labeling an upper surface of the at least one lid and a lower surface of each respective at least one tray.

19. A system, as recited in claim 13, further comprising means for vibrating the at least one tray to assist settling and packing of the leafy produce.

20. A system, as recited in claim 13, further comprising means for security banding the at least one lid to each respective at least one tray.

21. An automated system, as recited in claim 13, further comprising:

a sensor for detecting the presence of the at least one tray and for supplying an electronic signal to the feeder to effect its opening for filling the at least one tray with the leafy produce;

means for vibrating the at least one tray to assist settling and packing of the leafy produce;

means for applying at least one lid to each respective at least one tray;

means for security banding the at least one lid to each respective at least one tray; and

means for labeling an upper surface of the at least one lid and a lower surface of each respective at least one tray,

wherein the feeder includes a funnel being disposed into the at least one tray upon receipt of the electronic signal from the sensor, and

wherein the plunger is disposed within the funnel.

22. An automated system, as recited in claim 13, wherein the at least one plunger is disposed outside the feeder.

23. An automated system, as recited in claim 13, wherein the at least one plunger is disposed inside the feeder.

24. An automated system, as recited in claim 13,

wherein the actuator arm comprises:

an actuating structure; and

an articulating arm,

wherein the articulating arm includes an articulating structure, and

wherein the articulating structure is disposed at a periphery of the footpad for facilitating pivoting of the footpad onto the leafy produce.

25. An automated system, as recited in claim 13,

wherein at least one sidewall of the feeder, itself, acts as a footpad, and

wherein feeder comprises an articulating arm,

wherein the articulating arm includes an articulating structure, and

wherein the articulating structure is disposed at a periphery of the footpad for facilitating pivoting of the footpad onto the leafy produce.

26. An automated system, as recited in claim 13,

wherein the at least one automated packing apparatus comprises a first automated packing apparatus and a second automated packing apparatus,

wherein the first automated packing apparatus and a second automated packing apparatus are serially disposed in an assembly line, and

wherein the second automated packing apparatus acts as a secondary set of plungers by plunging the leafy produce a second time.

27. An automated system, as recited in claim 13,

wherein the hopper comprises: a primary chute; and a secondary chute,

wherein the primary chute comprises; a flop gate for limiting the amount of leafy produce to be filled in two trays; a flop gate actuator; and a flop gate control device for controlling the flop gate actuator, and

wherein the secondary chute comprises two chute branches for facilitating filling of two trays simultaneously,

28. An automated system, as recited in claim 13, further comprising:

an upper distribution bucket; and

a lower distribution bucket,

wherein the lower distribution bucket acts in at least one capacity selected from a group consisting essentially of a primary plunger and a secondary plunger, and

wherein the lower distribution bucket is deployed by a lower distribution bucket mechanism.

29. A method of fabricating an automated packing apparatus for packing leafy produce into a tray, comprising: providing at least one plunger, the plunger providing step comprising providing each at least one plunger with at least one actuator arm and at least footpad, the at least one footpad having an upper surface and a lower surface, being in moveable relation to the at least one respective actuator arm, for contacting the leafy produce.

30. An automated method for packing leafy produce into a tray, comprising the steps of:

conveying and stepping at least one tray;

channeling the leafy produce through a hopper;

feeding the channeled leafy produce into the at least one tray, thereby filling the at least one tray;

providing an automated packing apparatus for packing the leafy produce into the at least one tray, the apparatus providing step comprising providing at least one plunger, the plunger providing step comprising providing each at least one plunger with at least one actuator arm and at least footpad, the at least one footpad having an upper surface and a lower surface, being in moveable relation to the at least one respective actuator arm, for contacting the leafy produce;

providing a sensor for detecting the presence of the at least one tray and for supplying an electronic signal to the feeder to effect its opening for filling the at least one tray with the leafy produce;

packing the at leafy produce into the at least one tray using the automated packing apparatus; and

applying at least one lid to each respective at least one tray.

31. A method, as recited in claim 30, further comprising the step of security banding the at least one lid to each respective at least one tray.

32. A method, as recited in claim 30, further comprising the step of vibrating the at least one tray to assist settling and packing of the leafy produce.

33. A method, as recited in claim 30, further comprising the step of labeling an upper surface of the at least one lid and a lower surface of each respective at least one tray.

34. A method, as recited in claim 30, further comprising the steps of:

vibrating the at least one tray to assist settling and packing of the leafy produce;

labeling an upper surface of the at least one lid and a lower surface of each respective at least one tray; and

security banding the at least one lid to each respective at least one tray.