PACKAGING RELATED PROCESS, SYSTEM & APPARATUS
A method for compacting a slug of product and apparatus for accomplishing the same. The invention describes collecting weighed product in an intermediate settling device to form a compact slug of product. The device can comprise a single settling chamber or can comprise multiple settling chambers which are axially rotatable. The slug can be compacting by jostling and/or vibrating the settling device. Thereafter, the product is discharged to a packaging apparatus. Because the product in the final package is denser, a smaller package can be utilized reducing manufacturing and shipping costs.
This is a continuation-in-part (CIP) application filed under 35 USC §111(a) and pursuant to 37 CFR §1.53(b) (1) claiming priority under 35 USC §120, of/to Patent Cooperation Treaty (PCT) Appl. Ser. No. PCT/US2010/053960, having a filing date of Oct. 25, 2010 and entitled PACKAGING RELATED PROCESS, SYSTEM & APPARATUS, the disclosure of which is hereby incorporated by reference in its entirety.
TECHNICAL FIELDThe present invention generally relates to the field of packaging, more particularly, to any or all of processes, systems and apparatuses to aid product packaging and/or for combined package manufacturing and product packaging, and more particularly still, but not exclusively, to processes, systems and apparatuses for at least settling a metered charge of a settleable product in advance of packaging/bagging in furtherance of achieving a volumetric reduction of the metered charge of settleable product.
BACKGROUND OF THE INVENTIONProcesses for packaging, for instance, bagging, settleable products are well known and numerous. One illustrative, non-limiting class of commonly bagged settleable products is comprised of foodstuffs, more particularly, snack foods.
Arguably, the most well-known member of the snack food family are those foodstuffs characterized as “chips,” e.g., potato, corn, tortilla, etc., salty, savory, or otherwise. With documented sales of packaged snacks at $68 billion in 2008 (reportlinker.com), Packaged Facts of Rockville, Md. (U.S.A.) projects sales to approach $82 billion by 2013, a total market increase of about 20%. By all accounts, despite the recent/current economic downturn and its impact on household budgets and the like, consumers are snacking more than ever. In as much as a variety of plausible rationales are generally provided for the increased and increasing sales of such foodstuffs, the fact remains that there exists ample opportunity for increased revenues for the manufacturers of such foodstuffs, and, it is hoped, increased profits.
Beyond the introduction of new snack foods (e.g., 350+ new salty snack launches in the U.S. in 2009 as per Mintel's (NY, U.S.A.) Global New Products Database), one of several focus areas believed advantageous with regard to hoped for rising revenues and profit is product packaging. For example, among other things, the sale of a fixed quantity, i.e., mass, in an otherwise smaller bag, sack, etc. (i.e., bag of smaller volume) reduces product packaging material costs via reduced material/resource consumption, thereby positively contributing to a profit and loss statement.
As depicted herewith,
Generally, a metered charge (i.e., a select mass of product for packaging) exits a metering station (
Needless to say, a variety of real challenges were no doubt confronted, and to at least some extent overcome, in the course of developing the processes, systems and apparatuses of
Apparatuses to facilitate packaging of a settleable product, as well as systems incorporating same, and attendant processes are provided. An advantageous apparatus includes an actuatable assembly, an assembly base, and an assembly actuator operatively linked to the assembly for selectively actuating the assembly relative to the assembly base. The actuatable assembly is characterized by at least a single product settling bin, and advantageously, at least two product settling bins. In the context of having two plus bins or chambers, each product settling bin of the product settling bins is positionable, via actuation of the actuatable assembly, for receipt of a metered charge of settleable product. Successive actuation of the actuatable assembly settles the metered charge of settleable product in furtherance of a discharge of a settled metered charge of settleable product from the apparatus to a packaging station.
The actuatable assembly, or the product settling bins thereof, is advantageously, but not necessarily, of a modular design, being readily “changed-out,” or in the case of the bins, changed-out or physically altered via adaptation, so as to more efficiently handle the processing of a variety of settleable products, or a packaging objective of a select settleable product. The assembly is generally actuated, e.g., via, among other alternatives, an indexed rotation, so as to compact or settle the settleable product retained by a bin of the plurality of product settling bins. Actuation is advantageously, but not necessarily, accomplished by a selectively controlled mechanical system, more particularly, via a servo-drive.
The bins of the product settling bins may be fairly characterized as tubes or sleeves, having “open” opposing ends. Generally, the bins include a metered charge ingress portion and a settled metered charge egress portion, with the ingress portion characterized by a sectional area exceeding a sectional area of the egress portion. In the context of a rotary compaction, the bins are circumferentially arranged within the assembly or assembly body, and may be positioned in an offset condition to minimize product “mounding.” A bin of particular utility is configured so as to include an ingress portion characterized by a funneled free end which delimits a metered charge reservoir which “feeds” the remainder of the bin with successive actuations of the actuatable assembly.
The assembly base is generally adapted to selectively permit passage of a settled metered charge of settleable product from a select bin, at, for example, a bin emptying site. More particularly, passage of the settled metered charge of settleable product from the bin positioned at the emptying site is achieved via a selective actuation of a settled metered charge discharge port, e.g., gate assembly, over which filled product settling bins are positionable in furtherance of a discharge of a settled metered charge of settleable product from the apparatus to a packaging station, advantageously, to a bag forming mandrel having at least a segment comprising air passage vents.
Functionally, the actuatable assembly, via selective actuation, moves in relation to the assembly base and the metering station overhead. More particularly, the actuation, in the form of an indexed rotation, proceeds in relation to a fill station/locus delimited by the metering station, and an emptying station/locus delimited by the assembly base, namely, the discharge port thereof. Preferably, metered product will be received at the loading station and released at the discharge station at approximately the same time.
As bin “x” of “N” total bins of the actuatable assembly is positioned for emptying at the emptying station, bin “x+1” is advantageously positioned for initial filing at the fill station proximal to the emptying station, while bin “x+2” has undergone an initial settling/compaction iteration, and bin “x−1” proceeds to an “on-deck” position for emptying (i.e., next in queue for emptying). Indexing occurs every time a settled and formed metered product charge is discharged from the assembly to or into the bag maker funnel/former, advantageously the lumen of a vented tube, with several charges of metered product introduced to the assembly throughout an actuation cycle. Via such operation, a settled and formed charge of a metered mass of settleable product, namely, a reduced volume product mass, is ready for packaging.
A further contemplated settling assembly or station is characterized by translation of a product slug apparatus along a path characterized by a product slug transfer station and a product slug dwell station. Advantageously, but not necessarily, a pair of product slug apparatuses are provided, each separately cycled for translation to a common product slug transfer station from either a first product slug dwell station or a second product slug dwell station. Both ingress of a product slug and egress of a settled, settled/compacted product slug is contemplated at the transfer station, with settling manipulations being advantageously undertaken at the dwell station.
A method attendant to the settling assembly characterized by a translatable product slug apparatus contemplates introducing a product slug to an upper portion of a product slug chamber of a product slug settling device at a first processing station; transferring the product slug from the upper portion of the product slug chamber to a lower portion of the product slug chamber of the product settling device during travel of the product settling device to a second processing station; and, releasing a settled product slug from the lower portion of the product slug chamber upon return of the product settling device to the first processing station from the second processing station.
While a variety of adaptations to disclosed/depicted apparatuses, systems, stations, devices, elements etc. will be apparent in connection stated and implied objectives for such packaging related processes, systems and apparatuses, a knife or knife blade assembly and a vanned settling chamber are further features of note. As to the former, a station characterized by a blade or platen, e.g., a projecting blade, is provided, advantageously in the context of a rotary settling device. When positioned at a product slug transfer location, the blade facilitates egress of a settled, settled/compacted product slug from a lower chamber while a product slug is introduced to an upper chamber by preventing a transfer/unintended transfer of upper chamber contents to the lower chamber. Moreover, when positioned upstream from the product slug transfer station, the blade minimizes or eliminates bridging of the slug between the ingress and egress portions of a chamber, or between an upper and lower chamber as the case may be. As to the latter, at least partial rotation for a vanned settling chamber is contemplated, advantageously in the context of a rotary settling device, such that the integrity of a settled, settled/compacted product slug is maintained during transfer of the chamber contents in furtherance of packaging.
More specific features and advantages obtained in view of those features will become apparent with reference to the drawing figures and DETAILED DESCRIPTION OF THE INVENTION.
Generally, this invention relates to a method and apparatus for compacting a slug of product and increasing compaction of product within a package. Compaction refers to the density of product within a package. A goal is to form and compact an intermediate slug of product which is subsequently discharged into a packaging apparatus and eventually into a package. An additional goal in one embodiment is to ensure the increased compaction remains throughout the packaging operation. Applicants have found forming and compacting an intermediate slug and then discharging said slug for packaging results in increased product compaction. A slug of product refers to a collected charge of product.
Because of the resulting increased compaction of the product at the bagmaker, less settling occurs during the subsequent, shipping, handling, and displaying of the package. Thus, the apparatus and method of this invention ensures that the package displayed on the shelf will more resemble the package as seen at the bagmaker. As used herein, a bagmaker refers to any packaging apparatus. The method and apparatus can be utilized on a wide variety of bagmakers including but not limited to a vertical form, fill, and seal machine and horizontal form, fill, and seal machines, bag in a box apparatus, as well as boxing machines. Likewise, a packaging apparatus referred to as a fill seal bagmaker, whereby premade bags are opened, filled, and sealed, can also be utilized. The final packages described herein can comprise traditional flex packages associated with snack product, vertical packages, box packaging, bag in a box packaging, and other products containing product which is subject to settling.
The apparatus and method can be utilized to increase compaction of a variety of products including food products such as chips, pretzels, cookies, noodles, nuts, cereal, and seeds. Likewise, this invention also applies to individually wrapped products such as individually wrapped mints or other candies which are susceptible to settling. The apparatus and method also works for other various dry products including dog food, cat food, etc.
The description next immediately proceeds with general reference to
First, in as much as the subject packaging/packaging process improvements have origins in foodstuffs, more particularly, snack foods, and more particularly still, those fairly characterized as “chips,” the subsequently disclosed process, system, and apparatus need not be limited to such “product.” Settleable solid or semi-solid product, food stuff or otherwise, intended for metering and subsequent packaging, especially bagging, is contemplated for, among other things, an advantageous volume reduction via settling or compaction in advance of packaging. Notionally, a product charge (i.e., a predetermined weight (i.e., mass) of product sought for packaging) is to be volumetrically reduced without any departure in the quality or character of the product (e.g., in the case of chips or the like, appreciable breakage thereof). Volume reductions within a range of about 15-20% have been achieved, and, as should be readily appreciated, are a function of, among other things, the character and quality of the “product.”
Second, in as much as the following description proceeds with regard to heretofore know processes and systems, it is not necessarily so limited. Commercially, it is believed advantageous and/or desirable, and arguable a necessity in relation to current “in-plant” operations, to provide a settling or settling/product charge forming station within the frame or frame work of an existing bag manufacturing and packaging station. A retrofit settling system (i.e., a modular or turnkey station, which in turn may be adapted so as to have a modular character) is intended to fit above or into an existing bag maker frame in the area above an existing product funnel/former, with minimal bag maker modifications. Moreover, it is believed advantageous that the station itself be amenable to adaptation so as to accommodate the processing of a variety of products, products styles, and/or products charges (i.e., metered product quantities as manifest in a “small” or “large” package (e.g., bag) volume).
Third, in connection to a desire to produce a variety of different product “sizes,” and again, as noted above, process a variety of products or product styles, product loss is to be minimized (i.e., the entirety of the product charge is to be packaged or bagged). For example, and without limitation, processing chips for the production of single serving bags presents greater loss potential than processing chips for the production of “family size” bags. In as much as it has proven advantageous to form a settled metered product charge, it has been especially advantageous to produce and maintain a settled metered charge, namely, produce a settled and formed metered charge that is packaged or bagged. More particularly still, via the following processing steps, systems and apparatus, a settled metered charge is advantageously formed into the shape of the bag (i.e., the settled and formed metered charge is generally configured so as to mimic a configuration of the bag within which it is to reside, advantageously, but not exclusively or even necessarily, a section of the settled and formed metered charge dimensionally mimics the section of a bag former or bag forming mandrel). Thus, in light of the foregoing, a more consistent and thorough bagging operation is realized.
With reference now to
As depicted the settling device 30 comprises a single settling chamber 40, a vibrator 31, and a gate 72 of a gate assembly 38. A settling device, as used herein, refers to a device which receives and captures an amount of product in order to form an intermediate slug of compacted product. A settling chamber 40 is a distinct chamber which receives and retains product. In one embodiment the settling chamber 40 has four vertical walls and an open top and bottom.
Applicants have found that collecting product discharged from the weigher 23 and holding product, for a period of time, in the settling chamber 40 facilitates settling of the product and increases compaction of the product. Increasing the settling of the product during packaging results in a decrease of post manufacturing settling. The settling chamber 40 can be jostled or vibrated via a vibrator 31 to facilitate and speed up the settling of the product. The time necessary and the amount of external energy, such as vibrations, required to facilitate settling is dependent upon many factors including but not limited to the geometry of the product, the size and geometry of the settling chamber, the size of the slug, and the level of compaction desired. Those skilled in the art will be able to determine the amount of time and energy required to yield a desired level of compaction. Other movements such as vertical, horizontal, rotational, vibrational, and mixtures thereof can also be imparted to the settling chamber to facilitate settling of the product which results in increased compaction. The vibrator 31, which is optional, can comprise any device which vibrates the settling chamber 40. The vibrator 31 can be located in various places throughout the settling device 30.
Applicants have found that the geometry of the settling chamber 40 has an effect on the shape of the packaged slug as well as the shape of the final package, especially if the final package is a traditional flex bag. In one embodiment the cross-sectional shape of the settling chamber 40 is substantially similar to the desired shape of the slug. For example, in one embodiment the settling chamber 40 has a substantially oval cross-section to mimic the substantially oval cross-section of a traditional flex bag. Other cross-sections may be utilized including but not limited to a circular and square cross-section.
The height of the settling chamber 40 can be varied according to the desired size and shape of the intermediate slug which ultimately dictates the size and shape of the finished product. In one embodiment the size of the settling chamber 40 is approximately 0.5 to 2.5 times the height of the final package, and in one embodiment the settling chamber 40 is approximately 1.25 times the height of the final package. The size of the chamber is dependent upon a variety of factors including the amount of settling required. In one embodiment, the height of the settling chamber 40 is chosen so as to properly fit between the weigher and the packing apparatus without raising the weigher.
In one embodiment, the bottom of the settling chamber 40 has a larger opening than the top of the settling chamber. For some products susceptible to bridging, having a larger exit diameter minimizes bridging. This helps the product maintain its desired compact shape and results in faster and more efficient discharges.
At the bottom of the settling chamber 40 is gate 72. The gate 72 can comprise many types of gates including sliding and swinging gates. In one embodiment the gate 72 is a sliding gate which allows for quick and efficient discharge of the product from the settling chamber 40.
Downstream of the gate 72 is the product delivery cylinder 60. In some embodiments there is an intermediate funnel 99 which directs product discharged from the gate 72 to the product delivery cylinder 60. The intermediate funnel 99 can comprise one or more funnels which can comprise straight or slanted walls. Further, the intermediate funnel 99 can comprise a variety of shapes. In one embodiment, the intermediate funnel 99 has a shape similar to the shape of the settling chamber 40.
In some embodiments, as the process moves downstream from the receiving funnel 25 to the product delivery cylinder 60, each subsequent downstream transition point has a larger diameter than the upstream transition point. Thus, in such an embodiment, the intermediate funnel 99 has a larger diameter than the settling chamber 40 but a smaller diameter than the product delivery cylinder 60. Such an arrangement minimizes bridging and any other disruption to the united slug.
Thus, the method for compacting a slug of product begins by weighing an amount of product in a weigher. Then, the product is directed and received into a settling device. Once the product is in the settling device, the product is compacted to form a slug of product. As discussed, this can be accomplished by storing the product for a time, or by jostling, rotating, and/or vibrating the settling device. After compacting the product, the product is discharged to a product delivery cylinder. It should be noted that the product can be directly discharged into the product delivery cylinder or it can be discharged into an intermediate funnel or chute before reaching the product delivery cylinder. Thereafter the slug is deposited from the product delivery cylinder into a package. As discussed above, the settling device is located downstream from a weigher and upstream from the product delivery cylinder. Further, the settling device can comprise only a single settling chamber, or the device can comprise more than one settling chamber.
In one embodiment the settling device 30 comprises only a single settling chamber 40. However, in other embodiments the settling device 30 comprises more than one settling chamber 40. In one embodiment, two or more settling chambers 40 act in parallel, each discharging its slug to the downstream product delivery cylinder 60. In other embodiments at least two chambers act in series whereby a first chamber is located below a second chamber and product is partially settled in a first chamber before being deposited for further settling in a second chamber. In one embodiment, one or more settling chambers 40 are located on a rotary settling device. In one embodiment each subsequent chamber results in increased settling.
With reference now to
Generally, the apparatus 30 includes an actuatable assembly, e.g., actuatable turret assembly 32, a turret assembly base 34, a turret assembly actuator 36 operatively linked to the actuatable turret assembly 32 for selectively actuating the actuatable turret assembly 32 relative to the turret base 34. Moreover, a gate subassembly 38 (reference also
The actuatable turret assembly 32 generally comprises product settling bins or containers 40, advantageously, open ended bins (i.e., sleeves or tubes) which will be subsequently detailed, and an assembly body 42, e.g., mounting plates or spacers, upper 44 and lower 46 as shown, for retaining the product settling bins and thereby define the assembly. Each product settling bin 40 of the product settling bins is selectively positionable, via select actuation of the actuatable turret assembly 32 (e.g., as by a mechanical, hydraulic or pneumatic drive, and advantageously, as shown, via a servo-drive 48), for receipt of a metered charge of settleable product. Via an actuation, reversible or otherwise, of the actuatable turret assembly 32, e.g., indexed rotation, or more generally, a successive or sequential agitating actuation, settling of the metered product charge of settleable product in furtherance of a discharge of a settled, settled and formed metered charge of settleable product from the apparatus to a packaging station is achieved.
Notionally, with respect to the metered product settling and forming bins, a preselect equilibrium or pseudo-equilibrium state for ingress and egress of product to and from the turret assembly is preferable but not necessary. As will be later detailed in connection to a discussion of a preferred sequence of operation, a content discharging bin at time t0 is thereafter relocated, via turret assembly actuation, so as to underlay a discharge of the metering station, and is there filled at time t1. A “filling” bin (FB) is preferably, but not necessarily immediately adjacent (i.e., “downstream” of) an “emptying” bin (EB), see e.g.,
The actuatable turret assembly 32 is generally supported, more particularly and advantageously, rotatingly supported, with respect to the turret assembly base or base plate 34. A servo motor 50 of the servo-drive 48 is operatively linked, via a shaft, 52 a shaft hub 54, and a shaft bushing 56 as indicated, to or with the assembly, namely, the assembly body 42, so as to selectively impart motion thereupon.
The turret assembly base 34 is generally adapted to permit selective passage of processed metered product charges from the bins 40 of the turret assembly 32. Toward that end, and with specific reference to
With reference now to
In a rotary settling device 30, the settling chambers 40a-h can be arranged in a variety of positions. In one embodiment, the centers of each settling chamber are evenly spaced along the turret table 34. In one embodiment the chambers are evenly spaced and oriented like a wagon spoke. As depicted, the settling chambers 40 are angled relative to the turret table 34 to maximize the number of chambers which will fit on the turret table 34.
In the embodiment depicted, the settling chambers 40 have an open top and bottom so the product is maintained within the settling chambers 40 by the presence of the stationary turret table 34. In such an embodiment the settling chambers 40 glide and rotate over the turret table 34. There is an opening 92 in the turret table 34 located above the gate 72. In one embodiment, the shape of the opening corresponds to the shape of the settling chamber 40. The chamber located in the position above the gate 72, and aligned with the opening 92, is referred to as the discharge chamber 40a. The product in the discharge chamber 40a is maintained by the gate 72. Accordingly, when the gate 72 is opened, via sliding or otherwise, the product falls through the opening 92 in the turret table 34 and passes the open gate 72. Those skilled in the art will understand that there are other ways of maintaining product within each settling chamber such as having a separate gate for each settling chamber.
In one embodiment, downstream and below the gate 72 is the product delivery cylinder 60. In such an embodiment, the compacted slug is discharged from the discharge chamber and into the product delivery cylinder 60 where it is subsequently packaged in a bagmaker.
The settling chambers 40 can be filled in a variety of locations. In one embodiment, the discharge chamber 40a is also the same settling chamber which receives product, called the receiving chamber. In such an embodiment, after discharging product in the discharge chamber 40a the gate 72 will close. Thereafter, the discharge chamber 40a will then receive product. All of the settling chambers 40 in turn will then move one spot in the progression, during which time the product in the settling chamber settles and becomes more compact. Thus, in some embodiments the receiving and discharging do not take place simultaneously.
After the receiving chamber 40c has received its product, it rotates clockwise throughout the positions until it again becomes the discharge chamber 40a. While the example has been described as rotating clockwise, this should not be deemed limiting as the device can also rotate counterclockwise.
While the settling chambers 40 are rotating, the product becomes more compact. In one embodiment, a vibrator 31 vibrates the product within the settling chambers 40 to facilitate settling of the product. The vibrator 31 can be placed on a variety of places, including but not limited to, on the stationary turret table 44, attached to the chambers 40, or otherwise attached to the rotary settling device 30 or other supporting structure.
As shown in
In
As depicted, the intermediate funnel 99 and the product receiving cylinder 60 are depicted downstream of the opening 92. In
In one embodiment, the product in the package comprises product from only a single settling chamber. In such an embodiment, the amount of product received in the receiving chamber is equal to the amount of product in the final package. In still other embodiments, the final package comprises two slugs of product. In one embodiment the package comprises product from at least two different settling chambers. In other embodiments the package comprises two slugs of product from the same chamber. In such an embodiment a first slug is first formed and discharged and then subsequently a second slug is formed in the same chamber and then discharged.
Applicants have found that in some products the compaction is further increased when two or more smaller slugs are compacted separately and then added into a single package. For example, if the final product is to comprise two slugs of product, then the slugs formed from two different chambers will both be deposited to a single package. Referring back to
In one embodiment, the height of each chamber is selected so that existing apparatuses can be retrofitted with charge compaction without, for example, raising the weigher. As an example, in one embodiment, due to the multi-charge method, the settling chambers can be made shorter in height, due to the height being spread amongst multiple chambers, and as a result the weigher does not have to be moved. This results in decreased capital costs to retrofit an existing apparatus.
Applicants have found that after inducing settling the slug maintains its shape and compaction as it is packaged. This results in less settling after packaging giving the consumer a fuller package which more resembles the fuller look of a bag at the bagmaker. As previously discussed, increasing settling during packaging reduces post package settling which results in several benefits. One such benefit is the ability to use a comparatively smaller package for the same product weight. This results in decreased production costs as less material is required to manufacture the package. Additionally this results in decreased shipping costs as more packages can fit in a given volume. Further, this allows more packages to be displayed on the retail shelf as smaller packages occupy less space. Likewise, a smaller package allows a consumer to store the same amount of product in a smaller space, thus freeing valuable pantry space.
As discussed, this apparatus and method provide the opportunity to package the same quantity of product in a comparatively smaller package. The smaller package can have a decreased height, width, or combinations thereof compared to the previous package. In one embodiment the width of the package is not altered and only the height dimension is changed. Such an embodiment minimizes the modifications required to the bagmaker. The following examples demonstrate the effectiveness of one embodiment of the instant invention and are for illustrative purposes only. Accordingly, the following examples should not be deemed limiting.
Control
A trial was conducted using chips with a product weight of 21.5 ounces. The wheat chips were thin wafers having ridges. A settling device was not used on the control. The bags had a width of 12 inches, a total height of 18.75 inches and a usable height of 17.75 inches after deducting one inch for the top and bottom seals. The void space in each package was measured and the fullness level of each bag calculated. The void space was measured by measuring the average level of product in the package. The packages removed from the bagmaker, which was a vertical form, fill, and seal machine, were approximately 86% full on average and had an average product level of 15.25 inches. Thereafter to determine the conditions of the packages after sitting on the shelf, the packages were subjected to a simulated retail process which included simulating the transporting, handling, and shelf time of a typical package. After simulation, the void space was measured and the fullness of each bag was calculated to be approximately 78% on average with a product level of 13.85 inches. Thus, the fullness of the packages decreased by about 8% on average after the shelf simulation, and the product level decreased by an average of 1.4 inches.
Single Charge
In the next trial, a non-rotary settling apparatus comprising a single settling chamber, similar to that of
Multi-Charge
In the next trial, the same apparatus was utilized using the multi-charge method wherein the final package comprised two slugs of product. Thus, in this embodiment, the settling chamber formed and discharged a slug, and then the same settling chamber subsequently formed and discharged a second slug into the same package as the first discharged slug. The same size bag as the single charge was also used in the multi-charge trial. At the bagmaker the packages were approximately 87% full and had product levels of about 13.65 inches. After the shelf simulation, the packages were approximately 83% full and had a product level of about 13.15 inches. Thus, compared to the single-charge method, the multi-charge method resulted in a fuller bag both at the bagmaker and after shelf-simulations.
In both the single-charge and the double-charge, a smaller package was produced which held the same quantity of product as the larger bag in the control, but which required less material to manufacture. Accordingly, compacting the product results in decreased manufacturing costs, decreased shipping costs, an increased number of packages available for a given amount of retail space, a package which required less pantry space, and a package which appeared fuller to the retail consumer.
With renewed general reference to
As shown, the selectively actuatable gate subassembly 38 is advantageously actuated by a further servo-drive 48′, namely, a servo motor 50′ and linkage arm 80 which converts rotational motion to translation or reciprocation so as to provide, among other things, a swift and certain reversible gate motion. The linkage arm 80 generally includes a pivot segment or element 82, united with the servo drive shaft 53 so as to extend therefrom, and a link 84, a first end portion thereof secured to a free end of the pivot segment, and a second end portion thereof anchored upon a portion of the lower gate guide 78. As should be readily appreciated, and apparent via reference to e.g.,
Operatively, and with reference to
Applicants have found that a slow moving gate 72 decreases the compaction of the slug whereas a fast acting gate 72 allows the slug to remain compact. As used herein a fast acting gate is a gate which is completely open in less than about 50 milliseconds. There are a variety of ways to minimize the effect that the gate 72 has on the compaction of the slug. In one embodiment the speed of the gate 72 is increased. In another embodiment, the gate 72 is completely open in as little as about 40 milliseconds. As discussed, this fact acting gate 72 acts to minimize the decrease in compaction. In one embodiment the length of the gate 72 is increased. This allows the velocity of the gate 72 to increase as the opening 92 is revealed. Further, as depicted the gate 72 and the opening 92 are positioned so that the shortest distance in the opening 92 is in the same direction that the gate 72 is opened. The fast acting gate 72 can be implemented in any device described herein.
With particular reference now to
A plurality of settling/product settling and forming bins 40, 140 are generally shown circumscribing an axis of rotation, namely, an axis corresponding to an axial centerline 88 of shaft of the turret assembly driver 48. The product settling/product settling and forming bins of the preferred apparatus may be fairly characterized as vertical tubes or vertically oriented sleeves (i.e., a structure having an “open” top and bottom). Each bin or tube is characterized by a metered product charge ingress portion 90, 190, and a settled metered product charge egress portion 92, 192 opposite thereof, and may be fairly characterized as having an axially extending centerline 94, 194. Preferably, but not necessarily, the sectional area of the bin generally increases toward the egress portion from the ingress portion (e.g., the ingress portion of the settling/settling and forming chamber tapers toward the egress portion thereof). Likewise, a maximum dimension of or for the bin generally increases toward the egress portion from the ingress portion. Moreover, the bins are advantageously configured so as to be fairly characterized by a cross section selected from the group consisting of circular, oblong or oval, however, other cross sections may prove beneficial.
With continued and general reference to
With reference again and specifically to
With reference now to
With reference now to
With regard to the bag forming mandrel 60, 160 it is fairly characterized as a sleeve which defines a lumen 63, 163 for the receipt and passage of, in the instant description, a settled and formed metered product charge. Although not shown, it is contemplated that the mandrel support or be equipped with a gas charging tube(s) or the like so as to facilitate the introduction of a gas charge, e.g., nitrogen, to the product package in advance of closure. The mandrel 60, 160, more particularly, the sleeve as shown, advantageously includes at least a longitudinal segment with passages there through. In as much as perforations or apertures 65, 165 are shown, the passages need not be so limited. As part of film processing in furtherance of forming a film/bag sleeve about the mandrel, bag forming operations, namely, transverse sealing/sealing cutting in furtherance of forming closed top and bottom bag sleeve portions so as to thusly define a bag top/bottom, result in air displacement within the lumen of the mandrel in an upward direction (i.e., toward the metered charge forming operations). A mandrel comprising an apertured or otherwise vented tube or sleeve/sleeve segment allows for the inevitable countercurrent “updraft” to short circuit in advance of encountering the falling charged of settled and formed metered product so that the compacted charge remains substantially compact.
Now referring to
In one embodiment the holes do not begin in the first three inches of the product delivery cylinder 60. Applicants have found that some product comprising edges or corners can catch on the holes 65, and thus disrupt the flow of the product. To overcome this problem, in one embodiment the product is allowed to build momentum in a section of the product delivery cylinder 60 which does not comprise holes before introducing the product into a section of the product delivery cylinder 60 comprising holes 65. In another embodiment the holes 65 are sized so as to minimize product catching on the holes 65. As depicted
The vacuum holes 65 can be implemented in any bagmaker comprising a product delivery cylinder 60 which comprises a collar 27. In one embodiment, the bagmaker comprises a vertical form, fill, and seal bagmaker comprising a weigher and product delivery cylinder.
Referring back generally to, for example
The poker can be located at the discharge chamber 40a, or it can be located adjacent to the discharge chamber 40. Moreover, in connection to settling containers or chambers characterized by a reservoir, it is believed advantageous to provide agitation directed to both the reservoir and the settled charge portion thereof (see e.g., the chambers of FIG. 15/15A. In one embodiment the poker is located above the discharge chamber 40a and may be configured and/or actuated to “nudge” the chambered product or chamber, or the poker may be configured and/or actuated so as to travel, top to bottom if you will, through at least an upper portion of the chamber. In one embodiment the poker is actively coupled to the sensor. As used herein actively coupled refers to a device which receives a signal from another device. Thus, the poker receives a signal, either directly or indirectly, from the sensor. Finally, in as much as sensing or an on demand functionality is contemplated, poker actuation may likewise be a coincident with the noted discharge cycle, i.e. a given rather than a select operation.
With reference now to
In the instant embodiment, assembly body 42 comprises selectively configured assembly body plates, more particularly, stylized upper 44′ and lower 46′ assembly plates which might be fairly characterized or colloquially referred to as “starwheels.” Generally, the plates include U-shaped peripheral “cutouts” 45, the “legs” thereof in outward extension, i.e., away from axial centerline 88. While a hub and spoke or wagon wheel arrangement is depicted, an arrangement commensurate with the off-set container arrangement of either
hile the peripheral profile of the plate depicted is amenable to direct receipt of a companion settling container within the U-shaped recesses, indirect receipt of a variety of alternately dimensioned and/or configured settling containers is contemplated. Towards that end, one or more “sets” of alternative configured sleeves, such as sleeve 47 of a “first” sleeve set is provided so as to enable quick, ready receipt and retention of a variety of diverse settling container configurations by the assembly plates. In the as shown sleeve, an aperture 101 is positioned adjacent a trailing end or edge 103 of sleeve 47 so as to receive and retain a portion of settling container 40, e.g., as shown, container segment 191, while a funneled end or reservoir 189 is, via such sleeve configuration, selectively spaced from axial centerline 88. The sleeves, an “upper” and “lower” for each container as shown, in turn are readily received and reliable retained with the assembly body plates, more particularly, by each of the U-shaped peripheral cutouts. In as much as wholesale change-out or change-over of a turret assembly is contemplated, via the noted adaptation of the assembly body plates, alternately equipping the turret assembly with one or more select settling containers is hereby realized.
In furtherance of reducing processing or line down time, additional features are to be noted. Namely, a quick and sure reversible release assembly, characterized by clamps 105 (e.g.,
As should be appreciated in connection to a contrasting of the views of
Adjacent the gate from above and the apertured plate from below, and thusly essentially delimited thereby (
As to a preferred sequence of operation, the actuatable turret assembly selectively rotates in relation to the turret base and the metering station overhead. More particularly, the actuation, in the form of an indexed rotation, proceeds in relation to a fill station/locus delimited by the metering station, and an emptying station/locus delimited by the turret base. Preferably, metered product will be received at the loading station and released at the discharge station at approximately the same time.
As tube of “x” of “N” total tubes of the assembly is positioned for emptying at the emptying station, tube “x+1” is advantageously positioned for initial filling at the fill station proximal to the emptying station while tube “x+2” has undergone an initial settling/compaction iteration, and tube “x−1” proceeds to an “on-deck” position for emptying (i.e., next in queue for emptying). Indexing occurs every time a settled and formed metered product charge is discharged from the turret assembly to or into the bag maker funnel/former, advantageously the lumen of a vented tube as per
For the larger/largest bag size(s) there are preferably seven or eight bins/tubes retained in the turret assembly body which receive metered product charges, one at a time/sequentially, from the metering station. The number of sleeves or tubes is variable, a function of, among other things, the type of product for processing and the processing objectives for the product, e.g., the quantity or number could possibly double when smaller bags are contemplated. Insert or change out bins, via a mix and match approach, may be used to satisfy one or more alternate product processing objectives.
As the turret rotates it settles the product in the turret by a quick cessation and restart of a unidirectional motion. In as much as the contemplated motion is “start/stop,” and the motion is unidirectional rotation, it need not be so limited. For instance, inertial changes generally are believed satisfactory for aiding and/or performing settling operation, e.g., changes in turret assembly velocity or acceleration, and, a back and forth cycling of the turret assembly, whether via forward and rearward rotation of the assembly depicted herein, or, via a bi-directional motion via a modified or alternately configured turret assembly, is likewise a contemplated option.
With reference now to
The knife blade is a static or stationary element in the context of provisions of a rotary turret or otherwise indexing assembly (e.g., the settling assembly of
Referring now to
The apparatus 200 for settling or settling/compacting a product slug generally includes a chamber 202 for receipt of a product slug, and an assembly 204 operatively linked to the chamber 202 for at least selective partial rotation of the chamber about an axis of rotation 206 associated therewith. The chamber has an egress portion 208 opposite an ingress portion 210, and includes a sidewall 212 having a product slug surface 214 characterized by a vane 216.
While the vanned settling chamber 202 may be configured as heretofore described and depicted settling chambers 40 (see e.g., see
Preferably, but not necessarily or exclusively, the vane(s) extend in a non-linear fashion from an upper periphery 201 to a lower periphery 203 of the chamber 202, and in connection to the configuration of
The adapted product slug chamber of
Functionally, a product slug introduced so as to reside or dwell within the vanned settling chamber is advantageously at least partially rotated during indexing of the turret/turret assembly so as to be operated upon by the vane or vanes of the chamber surface. More particularly, preferably and without limitation, with each indexed rotation of the turret assembly of the rotary settling device of
With reference now to
Referring to
The product slug apparatuses, as shown, are not inconsistent with the product settling and forming bins/settling chambers of
Individual translation assemblies, or a shared/common translation assembly, are generally characterized by a carriage, for instant a first carriage 373 for the first settling apparatus 341 and a second carriage 375 for the second settling apparatus 343 as shown, and a track or track assembly 377 upon which the carriages are selectively and individually translatable. One or more chamber supports, e.g., upper 367 and lower 369 chamber supports as shown, extend from the carriage or carriages, directly or indirectly, via a yoke or some such structure, so as to maintain a select spaced apart distance for a supported settling apparatus in relation to the carriage. Moreover, the carriage may advantageously include bumpers 379 as shown, namely, bumpers extending from opposing free lateral surfaces of the carriage.
As is further contemplated and shown, the system is characterized by a structural element 381 for advantageous support of the track or track assembly 377 in relation to other system elements, a base or table 383, characterized by a settled product discharge aperture 385 over which the settling apparatuses 341, 343 are positionable, and a gate assembly 387 characterized by a gate or keeper 393 for select actuation in relation to the aperture of the base in furtherance of discharge of a settled product slug from the lower portion of the settling apparatus. Although not shown, a mechanism, mechanisms or an assembly/system for translating the carriage or carriages upon the track or track of the track assembly is contemplated, with effectuation of such function, e.g., select indexed translation of a carriage/carriages upon a track of guide, believed well within the skill of such artisans.
As heretofore discussed, the aim of the subject settling assembly is that of settling or settling/compacting a product slug in contemplation of select packaging operations. Notionally, a preferred non-limiting method of settling a product slug comprises the introduction of a product slug to an upper portion of a product slug chamber of a product slug settling device at a first processing station; transferring the product slug from the upper portion of the product slug chamber to a lower portion of the product slug chamber of the product settling device during travel of the product settling device to a second processing station; and, releasing a settled product slug from the lower portion of the product slug chamber upon return of the product settling device to the first processing station from the second processing station. Particulars of such approach, in the context of the settling assembly of
As was previously noted, the system is characterized by a product slug transfer station 351, generally corresponding to/correlating with a local of the settled product discharge aperture 385 of table 383, which is generally intermediate product slug dwell stations 353, 355 (see any of
The subject in line charge compact sequence of operation is not inconsistent with that previously described in connection to the rotary turret sequence of operation. Two product slug apparatuses enabled for linear motion, versus a pivot/rotation, are provided, more particularly, for indexing, and advantageously vibration, between two locals or stations so as to essentially yield the equivalent of three dwell vibration cycles and two index cycles. As processing circumstances warrant, for example, and without limitation, owing to the character of the product, a further gate or knife blade may be desirable to process larger charges or a packaging rate of greater than about 80 units per minute, i.e., 80 bags per minute. Moreover, dimensional changes for the depicted product slug apparatus (e.g., longer/wider product delivery cylinders or longer/wider slug reservoirs, or adaptations/provisions for alternately configured product slug apparatuses may prove advantageous in light of again other considerations, such as the nature of character of the product, or to accommodate timing considerations associated with slug transfers/indexing.
As to the process, discussion proceeds with the rightmost apparatus
With apparatus I at the transfer station and apparatus II at its dwell station, i.e., position one, each apparatus is advantageously vibrated in furtherance of enhancing gravitational settling of a product slug retained therein/by, more particularly, settling or settling/compaction of the product charge within the product slug dwell sleeve, e.g., the product delivery cylinder. While a variety of apparatus manipulations may be had in connection to vibration or the like (i.e., apparatus manipulations to effectuate settling), apparatus oscillations are contemplated as are vibrations imparted by carriage engagements, via the bumpers thereof, either with each other or with regard to structures of the track assembly. A metered product slug is introduced into the upper portion of the chamber of apparatus I, namely, the product slug reservoir thereof, while apparatus I is so positioned. Simultaneously, or via near synchronous or other select advantageous timing, the gate of the gated table aperture is actuated so as permit release of the settled, settled/compacted product slug for packaging, and thereafter is returned to its keeper position. With the cessation of ingress/egress operations, apparatus I travels to its dwell station, i.e., with reference to
With regard to position two, apparatus II is loaded with a metered charge with settled, settled/compacted product slug retained within the product slug dwell sleeve released, with both apparatuses advantageously manipulated in furtherance of gravitational settling of a retained product slug. Thereafter, apparatus II indexingly travels to its dwell station, with reference to
Thus, since the steps, assemblies, and/or structures of the packaging related process, system and apparatus disclosed herein may be embodied in other specific forms without departing from the spirit or general characteristics thereof, some of which forms have been indicated, the features described and depicted herein/with are to be considered in all respects illustrative and not restrictive. Accordingly, the scope of the disclosed invention is as defined in the language of the appended claims, and includes liberal, not insubstantial equivalents thereto.
Claims
1. Apparatus for settling a product slug, said system comprising:
- a product slug chamber; and,
- a translation assembly for operative translational support of said product slug chamber;
- said product slug chamber being indexably translated from a product slug transfer station to a product slug dwell station, product slug ingress and egress in relation to said product slug chamber being conducted at said product slug transfer station, product settling being conducted in relation to said product slug dwell station.
2. A system for settling a product slug, said system comprising:
- a first product slug apparatus;
- a second product slug apparatus; and,
- a translation assembly for operative translational support of said first product slug chamber and said second product slug apparatus;
- each of said first and said second product slug apparatuses being indexably translated from a product slug transfer station to either of a corresponding first product slug dwell station or second a product slug dwell station.
3. The system of claim 2 wherein said translation assembly comprises a single carriage, said first product slug apparatus and said second product slug apparatus being commonly supported thereby in furtherance of indexed translation.
4. The system of claim 2 wherein said translation assembly comprises a first carriage for translating said first product slug apparatus in furtherance of indexed translation of said first product slug apparatus.
5. The system of claim 2 wherein said translation assembly comprises a second carriage for translating said second product slug apparatus in furtherance of indexed translation of said second product slug apparatus.
6. The system of claim 2 wherein said translation assembly comprises a first carriage for translating said first product slug apparatus in furtherance of indexed translation of said first product slug apparatus, and a second carriage for translating said second product slug apparatus.
7. A system for settling a product slug, said system comprising:
- a first product slug apparatus;
- a first translation assembly operatively supporting said first product slug apparatus for translation;
- a second product slug apparatus;
- a second translation assembly operatively supporting said second product slug apparatus for translation; and,
- each of said first and said second product slug apparatuses being indexably translated from a product slug transfer station to either of a corresponding first product slug dwell station or second a product slug dwell station.
8. The system of claim 7 wherein each of said first and second product slug apparatuses is characterized by a product slug reservoir for receipt of a product slug.
9. The system of claim 7 wherein each of said first and second product slug apparatuses is characterized by a product slug reservoir for receipt of a product slug, said product slug reservoir having a reducing cross section in relation to an ingress portion thereof.
10. The system of claim 7 wherein each of said first and second product slug apparatuses is characterized by a product slug dwell sleeve for retention of a settled product slug.
11. The system of claim 7 wherein each of said first and second product slug apparatuses is characterized by a product slug dwell sleeve for retention of a settled product slug, said product slug dwell sleeve having a uniform cross section throughout a length thereof.
12. The system of claim 7 wherein each of said first and second product slug apparatuses is characterized by a product slug dwell sleeve for retention of a settled product slug, said product slug dwell sleeve having a reducing cross section in relation to an ingress portion thereof.
13. The system of claim 7 wherein each of said first and second product slug apparatuses is characterized by a product slug dwell sleeve for retention of a settled product slug, said product slug dwell sleeve having an increasing cross section in relation to an ingress portion thereof.
14. The system of claim 7 wherein each of said first and second product slug apparatuses is characterized by an upper a product slug reservoir for receipt of a product slug and a lower product slug dwell sleeve for retention of a settled product slug from said upper product slug reservoir.
15. A method of settling a product slug comprising:
- a. introducing a product slug to an upper portion of a product slug chamber of a product slug settling device at a first processing station;
- b. transferring the product slug from said upper portion of said product slug chamber to a lower portion of said product slug chamber of said product settling device during travel of said product settling device to a second processing station; and,
- c. releasing a settled product slug from said lower portion of said product slug chamber upon return of said product settling device to said first processing station from said second processing station.
16. Apparatus for settling a product slug, said apparatus comprising a chamber for receipt of a product slug and an assembly operatively linked to said chamber for at least selective partial rotation of said chamber about an axis of rotation associated therewith, said chamber having an egress portion opposite an ingress portion and comprising a sidewall, said sidewall having a product slug surface characterized by a vane.
17. The apparatus of claim 16 wherein said ingress portion of said chamber is dimensioned so as to be greater that said egress portion of said chamber.
18. The apparatus of claim 16 wherein said egress portion of said chamber is dimensioned so as to be substantially equivalent to a dimension of said ingress portion of said chamber.
19. The apparatus of claim 16 wherein said sidewall is of a cylindrical configuration.
20. The apparatus of claim 16 wherein said sidewall is of a frustoconical configuration.
21. The apparatus of claim 16 wherein said chamber is adapted for travel along a preselect travel path in furtherance of receipt of a product slug and/or discharge of a settled product slug.
22. The apparatus of claim 16 wherein said chamber is adapted for travel along a preselect travel path in furtherance of receipt of a product slug and/or discharge of a settled product slug, said chamber undergoing selective partial rotation during said travel.
23. The apparatus of claim 16 wherein said chamber is adapted for travel along a preselect travel path in furtherance of receipt of a product slug and/or discharge of a settled product slug, said chamber being rotated at travel position correlating to a discharge local for discharge of a settled product slug.
24. The apparatus of claim 16 wherein said chamber is adapted for travel along a preselect travel path in furtherance of receipt of a product slug and/or discharge of a settled product slug, said chamber undergoing at least 360 degree rotation at travel position correlating to a discharge local for discharge of a settled product slug.
25. The apparatus of claim 16 wherein said chamber is adapted for intermittent travel along a preselect travel path in furtherance of receipt of a product slug and/or discharge of a settled product slug.
26. The apparatus of claim 16 wherein said chamber is adapted for intermittent travel along a preselect travel path in furtherance of receipt of a product slug and/or discharge of a settled product slug, said chamber undergoing selective partial rotation during said intermittent travel.
27. The apparatus of claim 16 wherein said chamber is adapted for intermittent travel along a preselect travel path in furtherance of receipt of a product slug and/or discharge of a settled product slug, said chamber undergoing selective partial rotation during travel portions of said intermittent travel.
28. The apparatus of claim 16 wherein said chamber is adapted for intermittent travel along a preselect travel path in furtherance of receipt of a product slug and/or discharge of a settled product slug, said chamber undergoing selective partial rotation during non-travel portions of said intermittent travel.
29. The apparatus of claim 16 wherein said vane is spirally configured in relation to said product slug surface of said chamber.
30. The apparatus of claim 16 wherein said product slug surface of said chamber is characterized by vanes.
31. The apparatus of claim 16 wherein said product slug surface of said chamber is characterized by vanes, each vane having a non-linear configuration.
32. The apparatus of claim 16 wherein said product slug surface of said chamber is characterized by a plurality of vanes.
33. The apparatus of claim 16 wherein said product slug surface of said chamber is characterized by a plurality of vanes, each vane having a non-linear configuration.
34. The apparatus of claim 16 wherein said assembly comprises a diver and a driven element in operative combination, said driven element operatively united with said chamber.
35. The apparatus of claim 16 wherein said assembly comprises a diver and a driven element in operative combination, said driver being selectively operable.
36. A system for settling a product slug, said system comprising:
- a. a product slug receiving reservoir for receipt of an initial product slug charge;
- b. a settled product sleeve, spaced apart from said product slug receiving reservoir, for receipt of the initial product slug charge from said product slug receiving reservoir; and,
- c. a keeper, positioned to be interposed between said product slug receiving reservoir and said settled product sleeve so as to thereby prevent passage of the initial product slug charge from said product slug receiving reservoir to said settled product sleeve, said keeper, or a combination of said product slug receiving reservoir and said settled product sleeve, being selectively actuatable in furtherance of allowing passage of the initial product slug charge from said product slug receiving reservoir to said settled product sleeve.
Type: Application
Filed: Apr 23, 2012
Publication Date: May 2, 2013
Inventors: Ronald M. Gust (Miltona, MN), Jacob P. Hendrickx (Campbell, MN)
Application Number: 13/453,521
International Classification: B65B 5/00 (20060101);