HORIZONTAL FORM-FILL-SEAL PACKAGING SYSTEM
A machine including a first film dispenser which dispenses a first film, a second film dispenser which dispenses a second film, a first form system configured to form a first shape in the first film, a second form system configured to form a second shape in the second film, and a seal system configured to join the first film to the second film after the first shape is formed in the first film and the second shape is formed in the second film, wherein the first form system includes a bucket configured to hold a forming plate and a form head configured to form a cavity between the form head and the bucket that receives the first film.
The present application claims priority to U.S. Provisional Application No. 62/491,585, filed on Apr. 28, 2017, the contents of which are incorporated herein by reference in their entirety.
BACKGROUND Technical FieldEmbodiments relate to a system and method for forming a form-fill-seal package which can be filled with a product and then sealed.
Description of Related ArtA form-fill-seal packaging system of embodiments of this disclosure may be applicable to horizontal form-fill-seal machines used in the food processing industry for packaging a product, or for packaging medical supplies, and the like.
In a conventional horizontal form fill seal machine, a pouch is formed for packaging a product which consists of a top (lid) and a formable bottom. In such a conventional machine, a product is placed in the formable bottom, the product is covered with a flat top (lid), and then the pouch is sealed to close the package. The packaging acts as a moisture barrier to keep the contents of the package fresh and sterile. In some configurations, a vacuum may be drawn to vacuum-package the product. The package may be sealed by heat or by adhesive.
The materials forming the packaging may be a plastic film. For example in the case of ground beef, a deformable plastic film is used as the formable bottom so that the packaging conforms to the shape of the product. In some configurations, instead of a formable bottom, a tray having rigidity may be used, for example in the case of cheese slices. Still further, a paper film may be used as the lid while a plastic film is used for the bottom, as in the case of syringes for medical use.
Typical form-fill-seal packaging machines operate in a horizontal direction for maximal speed and reliability of packaging. For example, a formable bottom which forms a pouch advances along a horizontal direction with respect to a gravitational direction so that products can be dropped into the pouches and filled easily.
However, a limitation of conventional horizontal form-fill-seal packaging machines is that, among other things, a product must completely reside in the pouch formed by the bottom before the flat top can be applied to cover and close the package. That is, a product may not protrude above a web line of the pouch or else the machine cannot properly seal the package with the flat top. Furthermore, a seal formed by a conventional system is typically at least 0.25 inches wide and protrudes around the perimeter of the packaged product at the top edge. Such a seal is considered unsightly and contributes to an increased overall form factor. It is desired to improve upon these shortcomings and provide various other improvements in horizontal form-fill-seal packaging systems.
SUMMARYThe present disclosure addresses several matters such as those described above, and other matters not described above.
According to an aspect of an embodiment, a machine may comprise a first film dispenser which dispenses a first film; a second film dispenser which dispenses a second film; a first form system configured to form a first shape in the first film, a second form system configured to form a second shape in the second film; and a seal system configured to form a package by joining the first film to the second film after the first shape is formed in the first film and the second shape is formed in the second film. The first form system may comprise a bucket configured to hold a form plate, and a form head configured to form a cavity between the form head and the bucket, the cavity configured to receive the first film.
According to an aspect of an embodiment, the first form system may press the first film in a first direction, the second form system may press the second film in a second direction, and the first direction may be perpendicular to the second direction. Also, the first film may advance in the machine along a direction perpendicular to the first direction, and the second film may advance in the machine along a direction perpendicular to the second direction.
According to an aspect of an embodiment, the first form system may further comprise an air port configured to supply positive air pressure and to draw a vacuum within the cavity and a form bar configured to heat a portion of the first film inside the cavity when the air port supplies the positive air pressure within the cavity. Also, the first form system may be configured to form the first shape in the first film with the form plate when the air port draws a vacuum within the cavity after the form bar heats the portion of the first film. The second form system may function similar to the first form system to form the second shape in the second film.
According to an aspect of an embodiment, the machine may further comprise a gripper chain system configured to draw the first film to the seal system, wherein the seal system is configured to join the first film to the second film such that the second film advances through the machine by being pulled by the first film.
According to an aspect of an embodiment, the first shape of the first film may be a first pocket and the second shape of the second film may be a second pocket. Also, the seal system may comprise seal head that is configured to form the package by joining the first film to the second film such that the first pocket and the second pocket are directly opposing, the package comprising the first pocket and the second pocket with a cavity formed therebetween.
According to an aspect of an embodiment, the first pocket of the first film may have a same shape of the second pocket of the second film, and the seal system may be configured to form a seam along a longitudinal axis of the package, the first pocket and the second pocket being symmetrical to each around the longitudinal axis.
According to an aspect of an embodiment, the first film may be welded to the second film to form the package.
According to an aspect of an embodiment, product may be inserted into the first pocket before forming the package such that a portion of the product rests above a top edge of the first pocket, and the package may be formed such that the portion of the product rests within the second pocket.
A brief description of some representative drawings is provided as follows.
Embodiments may provide an apparatus and a method to form a package. In particular, the embodiments may comprise a machine having a first form system, a second form system, and a seal system. Each of the first form system and the second form system may be configured to form a pouch out of a respective film. The two pouches are brought together in the seal system to form a package. A product may be inserted into the package at a loading system prior to sealing.
According to embodiments, it becomes possible to form a package having a narrow-width sealing seam which is centrally located around a loaded product. For example, a product may be inserted at the loading section into a first pouch formed by the first forming system. The product may protrude above the top edge of the pouch, which may be the web line. A second pouch formed by the second forming system is brought together with the first pouch and joined. At the seal system, the package is closed around the product, resulting in the first pouch and the second pouch, which each comprise a respective half of the package, being sealed around the product. The sealed package may thus be top-to-bottom symmetrical relative to the web line. The embodiments may generate a unique presentation of a sealed package which is, for example, clean and sleek. Additionally, embodiments may achieve greater uniformity.
In one embodiment, a process description is outlined as follows with reference to
With reference to
The film 2 may advance along the horizontal direction, for example, along the web line of the machine 100. The film 2 may advance intermittently, such that the sheet of film 2 is held stationary for a predetermined length of time while certain processing occurs at a particular system. Forming the first pouch 3 by the lower forming system 80 may occur simultaneously with forming the second pouch 7 by the upper forming system 140. Further, sealing by the seal system 160 may also occur simultaneously, so that the machine 100 operates on an indexed basis.
The film 2 used to form the first pouch 3 and the film 6 used to form the second pouch 7 may be the same type of material. The films 2, 6 may be a shrinkable film that is sensitive to heat, humidity, stress, strain, and the like, such that the films 2, 6 exhibit formability. Using such a shrinkable film presents a challenge in that once the film is formed into a particular shape, such as that of a pouch, the film tends to shrink back to its original state. Therefore, the conditions of forming the first pouch 3 at the lower forming system 80 and the second pouch 7 of the upper forming system 140 may be controlled, as discussed later.
Furthermore, although one type of die is shown in the lower forming system 80 and the upper forming system 140, various dies may be used to form a desired shape of a pouch.
At a loading area 60, as shown in
Loading of the product 10 may be accomplished by hand or by dropping the product 10 into the pouch 3 formed by the bottom film 2. For example, a conveying machine may transport pre-formed products and guide them over an edge so that they fall into respective pouches by gravity. Also, the loading area 60 may be, for example, long enough so that three advances are present before the film 2 is pulled under the seal head 170 of the sealing system 160.
When the formed pockets 3 filled with the product 10 are advanced into the sealing system 160 of the machine 100, the top film 6 may also be pulled under the seal head 170 along with the product 10, so that the product 10 has a layer of formed film 2 below and a layer of formed film 6 above. At this time, the machine 100 may begin a sealing process. At the seal system 160, as shown in
After the sealing process, where the first pouch 3 of the film 2 and the second pouch 7 of the film 6 have been sealed together, the sealed films with the product 10 in between, as a package 300, may then be pulled into a cutting area (not shown) of the machine 100. It is in the cutting area that a portion of the films 2,6 may be, for example, cut crosswise by guillotine knife system and during final discharge, cut lengthwise by a rotary knife system such that the package 300 is separated from the remainder of the films 2, 6 or other packages 300 formed and sealed by the machine 100. After both directions of the film are cut, the package 300 may be free from the machine 100 and may be grabbed by a retrieval system (not shown). Further post-processing steps may include adding a label, etc.
Explanation will now be given in greater detail to a form-fill-seal packaging system embodiment. Referring to
[Gripper Chain System 20]
With reference to
The gripper chain 22 may be pulled through the machine 600 via a drive motor (not shown) that may be, for example, a servo motor with a speed reducer that rotates a drive shaft with two drive sprockets, one sprocket 24 on each side of the machine 600. The drive sprockets may directly engage the gripper chain 22. The gripper chain 22 may be guided through the machine 600 along plastic guide blocks. The drive motor may be powered via a drive amplifier that is controlled by the programmable logic controller 180 (PLC).
[Lower Unwind System 40]
With reference to
The lower unwind system 40 may function such that, when the machine 600 advances the gripper chain 22, the gripper chain 22 pulls along the film 2 through the machine 600, thereby moving the traversing roller 42 in a direction such as a vertical direction. The movement of the traversing roller 42 may activate a switch that sends a signal to the PLC 180. The PLC 180 may activate a drive amplifier, which turns on the motor 43 to rotate the spindle 44 and unroll the film 2. The unrolled portion of film 2 may then be pulled into the machine's gripper chains 22. When the film 2 is pulled along the machine 600 by the gripper chains 22, a portion of the film 6 within the lower unwind system 40 moves to the lower forming system 80. As the spindle 44 rotates and the film 2 unwinds from the core 45, the traversing roller 42 may return to a neutral position, and the switch may disengage. This may stop the spindle 44 from unrolling any more film.
[Lower Forming System 80]
With reference to
The form bar 93 may be, for example, an aluminum bar with a machined cavity into which a heating element and thermocouple are inserted. The heating element may be electrically connected to a solid state relay which is controlled by the PLC 180 and powered from the main cabinet's electric panel. The heating element may be controlled in such a way that a set value is entered on the touch screen display 220 and the heating element heats the bar until reaching the set value. After the set value is reached, the heating element may be powered on or off, or otherwise controlled, to maintain a constant set temperature.
The lower forming system 80 may function by, for example, “air over vacuum forming.” That is, with reference to
After positive air pressure is applied to heat the film 2, with reference to
Water may then be run through the form bucket 95 by, for example, water porting section 99 so that the forms onto which the film 2 is pushed or pulled are chilled, which causes the film 2 to undergo a thermal shock from a formable heated state to a hardened cooled state so that the film 2 maintains the shape of the form. Accordingly, a first pouch 3 is formed in the film 2.
Following, neutral air pressure may be reintroduced back between the form head 90 and the form bucket 95 for ventilation and the form head 90 and the form bucket 95 may be separated. For example, the forming electrical actuator 82 may lift the form head 90, and the form bucket lifting system may lower the form bucket 95. When the machine 600 advances, the first pouch 3 of the film 2 may be moved to the load area 40 by the gripper chain system 20 to be supplied with product 10.
[Upper Unwind System 120]
With reference to
The upper unwind system 120 may function in a substantially similar manner as described with respect to the lower unwind system 40. Yet, The top film 6 may be pulled along without the use of a gripper chain. For example, the top film 6 may be welded, either in conduction with sealing by the sealing system 160 or in an independent step, to the lower film 2 so that the lower film 2 pulls the top film 6 with it when the machine 600 advances one index. When the top film 6 is pulled along the machine 600, a portion of the film 6 within the upper unwind system 120 moves to the upper forming system 140. Further, the upper unwind system 120 may also comprise the guide rollers 127 for supporting the film 6 and guiding the film 6 from a horizontal direction to a vertical direction on the way of the film 6 to the upper forming system 140.
[Upper Forming System 140]
With reference to
The upper forming system 140 may function with an internal process substantially similar to the internal process described with respect to the lower forming system 80. That is, both the upper forming system 140 and the lower forming system 80 may use the “air over vacuum forming” process. In other words, the internal structure of the form head 150 and the form bucket 155 may be substantially similar to the internal structure of the form head 90 and the form bucket 95, respectively.
However, the upper forming system 140 may be horizontally mounted, as opposed to being vertically mounted like the lower forming system 80. When the upper form system 140 is mounted horizontally, as shown in
Further, the upper form system 140 may comprise the film guide roller 144 to guide the second pouches 7 of the film 6 from between the form head 150 and the form bucket 155 to the sealing system 160. The film guide roller 144 may also guide the second pouches 7 of the film 6 to be each placed on top of a respective first pouch 3 of the film 2.
[Sealing System 160]
With reference to
The seal head 170 may lower down to the film line where second pouches 7 of the film 6 are located on top of the first pouches 3 of the film 2, and the seal bucket 175 may lift up to the seal head 170, creating a sealed cavity with both a second pouch 7 of the film 6 and a first pouch 3 of the film 2 sandwiched in the middle. Sealing System 160 may then begin a seal process. That is, for example, a vacuum may introduced to both the seal head 170 and the seal bucket 175 for a determined amount of time based on a value set on the touch-screen display 220. After that set time and/or a vacuum level is reached, a heated seal bar (not shown) of the sealing system 160 may be energized (fired) for a predetermined amount of time. During this time both the second pouches 7 of the film 6 and the first pouch 3 of the film 2 are sealed together, only around the product placed within the first pouch 3 and the second pouch 7. This area in which the may be referred to as a seal area. Typical seal widths range between 3 mm wide up to 15 mm wide.
After both the second pouch 7 of the film 6 and the first pouch 3 of the film 2 are sealed, the vacuum may be turned off and neutral air pressure may be reintroduced back between the seal head 170 and the seal bucket 175 for ventilation and the seal head 170 and the seal bucket 175 may be separated. Accordingly, a package 300 may be formed.
[Programmable Logic Controller & Input Device]
With reference to
The PLC 180 may control the machine 600 and comprise at least one processor and memory. For example, the PLC 180 may control all air manifolds, servo amplifiers, relays, and contactors of the machine 600. The air manifolds of the machine 600 may comprise valves that control air supplies to lifting systems, cutting systems, unwind systems of the machine 600. Accordingly, the PLC 180 may control air supply to the systems.
In the above embodiment, the seal head 170 may join the first pouch 3 of the film 2 and the second pouch 7 of the film 6 by heat, such that the shrinkable films are attached to each other. However, another means, such as an adhesive, may be used to join the films 2, 7. Because the films 2, 7 may be joined together at a later stage of the production line, only one of the films 2,7 may require driving in order to convey the films 2,7. For example, in the above embodiment, the film 2 may be pulled off the core 10 by the motor 43. The core 125 may not be driven, yet the film 6 may still be pulled off the core 125 by being pulled by the film 2 because the film 2 and the film 6 become joined. Nevertheless, one or more motors may be provided to drive both cores 45, 125 and either, or both could be operated.
Furthermore, the sealing occurring at the sealing system 160 may serve to join the films 2, 6 together. However, a separate joining step may be provided before the sealing system 160 to independently join the films 2, 6 together. For example, a step of tacking the films 2, 6 together by welding may be performed prior to the sealing step in order to maintain proper timing between the top and bottom forming steps. Such tacking may occur at a location in the films 2, 6 spaced apart from the forming systems 80, 140 where the pouches 3, 7 are formed.
The package 300 may be sealed such that it can be opened by peeling. Therefore, a cutting step may be employed where peel tabs are formed at appropriate locations around the sealed package 300. Furthermore, additional sealing techniques may be added, such as using re-sealable adhesive, adding a zipper, and double sealing, for example.
It should be noted that although a few embodiments have been described, those skilled in the art will readily appreciate that many modifications are possible to the embodiments without materially departing from the novel teachings and advantages of the embodiments. For example, heat may be applied to the film in the form process by directly contacting the film with a heating element, or may be applied by injecting heated air or steam into the form bucket. Accordingly, all such modifications are intended to be included within the scope of the embodiments as discussed herein.
Claims
1. A machine comprising:
- a first film dispenser which dispenses a first film;
- a second film dispenser which dispenses a second film;
- a first form system configured to form a first shape in the first film, the first form system comprising: a bucket configured to hold a form plate, and a form head configured to form a cavity between the form head and the bucket, the cavity configured to receive the first film;
- a second form system configured to form a second shape in the second film; and
- a seal system configured to form a package by joining the first film to the second film after the first shape is formed in the first film and the second shape is formed in the second film.
2. The machine according to claim 1, wherein
- the first form system presses the first film in a first direction,
- the second form system presses the second film in a second direction, and
- the first direction is perpendicular to the second direction.
3. The machine according to claim 2, wherein
- the first film advances in the machine along a direction perpendicular to the first direction, and
- the second film advances in the machine along a direction perpendicular to the second direction.
4. The machine according to claim 1, wherein
- the first form system further comprises an air port configured to supply positive air pressure and to draw a vacuum within the cavity.
5. The machine according to claim 4, wherein
- the first form system further comprises a form bar configured to heat a portion of the first film inside the cavity when the air port supplies the positive air pressure within the cavity.
6. The machine according to claim 5, wherein the first form system is configured to form the first shape in the first film with the form plate when the air port draws a vacuum within the cavity after the form bar heats the portion of the first film.
7. The machine according to claim 1, further comprising
- a gripper chain system configured to draw the first film to the seal system, wherein the seal system is configured to join the first film to the second film such that the second film advances through the machine by being pulled by the first film.
8. The machine according to claim 1, wherein
- the first shape of the first film is a first pocket and the second shape of the second film is a second pocket, and
- the seal system comprises seal head that is configured to form the package by joining the first film to the second film such that the first pocket and the second pocket are directly opposing, the package comprising the first pocket and the second pocket with a cavity formed therebetween.
9. The machine according to claim 8, wherein
- the first pocket of the first film has a same shape of the second pocket of the second film, and
- the seal system is configured to form a seam along a longitudinal axis of the package, the first pocket and the second pocket being symmetrical to each other around the longitudinal axis.
10. A method of forming a package with a machine, the method comprising:
- dispensing a first film;
- dispensing a second film;
- forming a first pocket in the first film by pressing the first film with a first form head;
- forming a second pocket in the second film by pressing the second film with a second form head; and
- forming a package comprising the first pocket and the second pocket by joining the first film with the second film such that the first pocket aligns with the second pocket.
11. The method of claim 10, wherein
- the forming the first pocket includes pressing the first film with the first form head in a first direction,
- the forming the second pocket includes pressing the second film with the second form head in a second direction, and
- the first direction is perpendicular to the second direction.
12. The method of claim 11, further comprising:
- advancing the first film in the machine along a direction perpendicular to the first direction, and
- advancing the second film in the machine along a direction perpendicular to the second direction.
13. The method of claim 10, wherein
- the forming the first pocket includes performing an air-over-vacuum process comprising supplying positive air pressure and drawing a vacuum within a cavity that receives the first film, the cavity formed between the first form head and a first bucket.
14. The method of claim 13, wherein
- the air-over-vacuum process further comprises heating a portion of the first film inside the cavity when the positive air pressure is supplied within the cavity.
15. The method of claim 14, wherein
- the air-over-vacuum process further comprises forming the first shape in the first film with a form plate when drawing a vacuum within the cavity after heating the portion of the first film.
16. The method of claim 10, wherein
- the forming the package includes joining the first film with the second film such that first pocket and the second pocket are directly opposing.
17. The method of claim 16, wherein
- the forming the package includes forming a seam along a longitudinal axis of the package, the first pocket and the second pocket being symmetrical to each other around the longitudinal axis.
18. The method of claim 10, wherein
- the forming the package includes welding the first film to the second film.
19. The method of claim 10, further comprising
- inserting a product into the first pocket before forming the package.
20. The method of claim 10, further comprising
- inserting the product into the first pocket before forming the package such that a portion of the product rests above a top edge of the first pocket, wherein
- the forming the package includes forming such that the portion of the product rests within the second pocket.
Type: Application
Filed: Apr 26, 2018
Publication Date: Nov 1, 2018
Applicant: ROLLSTOCK INC. (Kansas City, MO)
Inventors: Todd PETERSON (Kansas City, MO), Mark TAYLOR (Kansas City, MO)
Application Number: 15/963,607