Combination Case Packing And Bundling Packaging System

Abstract

A packaging system includes a loading area configured to receive a product and a pusher assembly including a pusher arm and a support. The pusher assembly is switchable between a bundling orientation and a case packing orientation. In the bundling orientation, the support is disposed at a first end of the pusher arm. In the case packing orientation, the support is disposed at a second end of the pusher aim. The pusher assembly moves the product in a first direction from the loading area, along a bundling path, and to a bundler when in the bundling orientation. Conversely, the pusher assembly moves the product in a second direction from the loading area, along a case packing path, and into a case when in the case packing orientation.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to packaging systems and methods, and, more particularly, to a packaging system and/or method configured to send products in one direction when in a case packing orientation and in another direction when in a bundling orientation.

2. Discussion of the Related Art

Product packaging systems, conventionally referred to as, e.g., automatic case packers, bundlers, or automatic stack and package systems, are generally known in various packaging industries including, e.g., the packaging of paper products including paper roll products such as tissue paper and paper towel. The automatic case packers commonly include a feed assembly in which products are arranged in a layer and fed to the case packer assembly in order to package the products within a preformed case. Similarly, the automatic bundlers commonly include a feed assembly in which products are arranged in a layer and fed to the bundler assembly in order to bundle the products.

Modular packaging systems are known that allow for attachment of a case packer assembly to the infeed assembly when the products are to be packaged in cases. The modular packaging systems also allows for attachment of a bundler assembly to the infeed assembly when the products are to be bundled. In turn, the case packer assembly may be removed from the infeed assembly in order to attach the bundler assembly to the infeed assembly and vice versa. The changeover operation to remove one of the case packer assembly and the bundler assembly from the infeed assembly and replace it with the other of the case packer assembly and the bundler assembly can take over 12 hours to complete. As a result, long periods of downtime are needed during changeover of the packaging system.

Accordingly, it would be desirable to provide a packaging system that has case packing and bundling capabilities and that allows for quick and easy conversion between a case packing orientation and a bundling orientation to reduce downtime of the packaging system.

It would further be desirable to provide a packaging system that does not require removal of a bundling module in order to case pack the product being run through the case packing module of the packaging system.

SUMMARY OF THE INVENTION

The present invention is directed to a packaging system easily changeable between a case packing configuration and a bundling configuration to resolve one or more of the drawbacks discussed above.

According to one aspect of the invention, a packaging system includes a loading area, such as a platform or a plate, configured to receive a product and a pusher assembly including a pusher arm and a support coupled together. The pusher assembly is switchable between a first orientation and a second orientation. In the first orientation, the pusher assembly moves the product from the loading area in the first direction, along a bundling path, and to a bundler. In the second orientation, the pusher assembly moves the product from the loading area in the second direction, along a case packing path, and into a case.

In accordance with another aspect of the invention, the support is disposed at a first end of the pusher arm in the first orientation. Conversely, the support is disposed at a second end of the pusher arm in the second orientation. Further, the pusher assembly may include a push plate coupled to the pusher arm. In the first orientation, the push plate is coupled to the second end of the pusher arm. In the second orientation, the push plate is coupled to the first end of the pusher arm in the second orientation.

In accordance with yet another aspect of the invention, the pusher assembly is movably connected to a guide shaft along a top of the packaging system. In the first orientation, the pusher assembly moves in the first direction from a retracted position to an extended position. In this instance, the retracted position is located at a first end of the guide shaft. In the second orientation, the pusher assembly moves in the second direction from a retracted position to an extended position. In this instance, the retracted position of the pusher assembly locates the pusher arm from 1 to 24 inches from the product.

According to another aspect of the invention, a product pusher assembly includes a pusher arm, a support, and a push plate. The support is disposed at either a first end of the pusher arm in a first orientation or at a second end of the pusher arm in a second orientation. Similarly, the push plate is disposed at either the second end of the pusher arm in the first orientation or the first end of the pusher arm in the second orientation.

Also disclosed is a method of changing over a machine from a case packer configuration to a bundler configuration. In accordance with this aspect of the invention, the changeover of the pusher assembly from the case packer configuration to the bundler configuration includes removing a push plate of the pusher assembly from a first end of the pusher arm. In turn, the same push plate or a new push plate is attached to the second end of the pusher arm. The changeover also includes removing a support from the second end of the pusher arm and attaching the same support or a new support to the first end of the pusher arm.

Further yet, the support may be unlocked from the second end of the pusher arm by removing a locking pin from the opening of the support and a set of notches adjacent the second end of the pusher aim. The support may then be locked at the first end of the pusher arm by extending the same locking pin or a different locking pin through a set of notches adjacent the first end of the pusher arm and the opening in the support.

Also disclosed is a method of operating a combined case packer and bundling system. In accordance with this aspect of the invention, a product delivered to a loading area from an infeed conveyor is pushed by the pusher assembly from the loading area, along a case packing path, and to a case packer. Meanwhile, an additional product delivered to the loading area from the infeed conveyor may be pushed by the pusher assembly from the loading area, along a bundler path, and to a bundler.

The pusher assembly is configured to changeover between first and second orientations. In the first orientation, the pusher assembly pushes the product along the case packing path. In the second orientation, the pusher assembly pushes the additional product along the bundling path.

Other features and advantages of the present invention will become apparent to those skilled in the art from the following detailed description and the accompanying drawings. It should be understood, however, that the detailed description and specific examples, while indicating preferred embodiments of the present invention, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the present invention without departing from the spirit thereof, and the invention includes all such modifications.

BRIEF DESCRIPTION OF THE DRAWINGS

A preferred exemplary embodiment of the invention is illustrated in the accompanying drawings in which like reference characters represent like parts throughout.

FIG. 1 is a perspective view of a packaging system including a case packing module and a bundling module, according to an embodiment of the invention;

FIG. 2 is a side elevation view of the packaging system in a bundling orientation, the packaging system having a pusher assembly in a retracted position;

FIG. 3 is a side elevation view of the packaging system of FIG. 2 with the pusher assembly in an extended position;

FIG. 4 is a side elevation view of the packaging system in a case packing orientation with the pusher assembly in a retracted position;

FIG. 5 is a side elevation view of the packaging system of FIG. 4 with the pusher assembly in an extended position;

FIG. 6 is a perspective view of the pusher assembly in the bundling orientation;

FIG. 7 is an exploded perspective view of the pusher assembly of FIG. 6;

FIG. 8 is a perspective view of the pusher assembly in the case packing orientation; and

FIG. 9 is an exploded perspective view of the pusher assembly of FIG. 8.

DETAILED DESCRIPTION

A preferred exemplary embodiment of a combination case packing and bundling packaging system according to the present invention is illustrated in the accompanying drawings in which like reference numerals represent like parts throughout.

Referring first to FIGS. 1-5, a packaging system 10 is shown according to the preferred embodiment of the present invention. The packaging system 10 includes a case packing module 12 and a bundling module 14 configured to fill either boxes or bundles, respectively, with a variety of products, such as, but not limited to, bathroom tissue rolls, bathroom tissue packages, household paper towel rolls, household towel packages, packages of napkins (both consumer and industrial), jumbo tissue rolls, center pull towels, hard wound hand towels, plus many other types of products that can be in boxes or bundled. FIGS. 2-3 depict the packaging system 10 oriented in a first, bundling orientation 16, while FIGS. 4-5 depict the packaging system 10 oriented in a second, case packing orientation 18.

As shown in FIGS. 1-5, the packaging system 10 includes an infeed conveyor system 20, such as a conveyor belt, that directs product from a first end 22 of the packaging system 10 to an elevator 24. As best shown in FIGS. 2 and 3, the packaging system 10 may include an up-ender assembly 26 that assists in transferring the product from the infeed conveyor 20 to the elevator 24. Products may be loaded onto the infeed conveyor 20 in either a horizontal position or a vertical position. When the packaging system is oriented in the bundling orientation 16, products that are conveyed in the horizontal position on the infeed conveyor 20 are upended and collated by the up-ender assembly 26 onto a loading area, which in this example is a loading plate 28, of the elevator 24 so that the product is oriented in the vertical position on the loading plate 28. It is also contemplated that, when the packaging system 10 is oriented in the case packing orientation 18 as shown in FIGS. 4 and 5, the up-ender assembly 26 may be removed from the packaging system 10 so that product in the horizontal position on the infeed conveyor 20 remains in the horizontal position when it is loaded onto the loading plate 28.

In addition to the loading plate 28, the elevator 24 also includes a linear shaft 30 coupled to an assembly frame 32 of the packaging system 10. The loading plate 28 is configured to travel along the linear shaft 30 in order to adjust the vertical placement of the loading plate 28 and the product disposed thereon. For example, the loading plate 28 may be attached to one or more guide wheels 34 that travel along the linear shaft 30 to raise and lower the loading plate 28. A backstop 36 may be aligned perpendicular to the loading plate 28 in order to interact with the product when the product is moved from the infeed conveyor 20 to the elevator 24. The backstop 36 acts as a consistent surface to which the product is pressed against while multiple layers of product are stacked on the loading plate 28. As a result, all of the product is properly collated and aligned on the loading plate 28. Additionally, the backstop 36 helps prevent the layers of product from tipping over.

Once the product has been loaded on the elevator 24, the loading plate 28 is raised to an unloading position. In the unloading position, the product is oriented to interact with a product pusher assembly 38. The pusher assembly 38 is movably coupled to a guide shaft 40 oriented horizontally and extending across the assembly frame 32 at the top of the packaging system 10. In turn, the pusher assembly 38 is configured to move laterally in either a first direction 42 or a second direction 44.

When the packaging system 10 is in the bundling orientation 16, the pusher assembly 38 is configured to move the product in the first direction 42 toward the bundling module 14 disposed at a second end 46 of the packaging system 10. In FIGS. 2 and 3, this is illustrated as moving the product to the right by moving between a retracted position (FIG. 2) and an extended position (FIG. 3). FIGS. 6 and 7 depict the pusher assembly 38 in the bundling orientation 16. As shown, the pusher assembly 38 includes a pusher arm 48 attached to a vertical support 50. The pusher arm 48 and vertical support 50 are shown in further detail in FIG. 7, at which point their attachment will be described in further detail.

While the representative embodiment of the invention illustrates the vertical support 50 as extending vertically from the pusher arm 48, other embodiments of the invention may include a support 50 that is not vertically oriented. That is, the support 50 according to other embodiments of the invention may be any shape and oriented in any direction.

FIGS. 6 and 7 further illustrate the orientation and configuration of the pusher assembly 38 when in the bundling orientation 16. In the bundling orientation 16, the support 50 is located at or adjacent to a first end 52 of the pusher arm 48. The pusher assembly 38 also includes a first attachment plate 54 disposed at the first end 52 of the pusher arm 48 and a second attachment plate 56 disposed at a second end 58 of the pusher arm 48. A push plate 60a is coupled to the second end 48 of the pusher arm 48. In the representative embodiment of the invention, the push plate 60a is coupled to the second attachment plate 56. The push plate 60a includes an outer surface 62a that interacts with the product to move the product from the elevator 24, along a bundling path 64 disposed adjacent the elevator 24, and to the bundling module 14.

In the retracted position shown in FIG. 2, the pusher assembly 38 is positioned on the left side of the product. More specifically, the pusher assembly 38 is positioned on the first side of the product so that the pusher assembly 38 is disposed at a first end 39 of the guide shaft 40 so that the outer surface 62a of the push plate 60a is spaced apart from the left side of the product. In the extended position shown in FIG. 3, the pusher assembly 38 has been moved along the guide shaft 40 to push the product in the first direction 42 and off the loading plate 28.

When the packaging system 10 is in the case packing orientation 18, the pusher assembly 38 is configured to move the product in the second direction 44 within the case packing module 12 and toward the first end 22 of the packaging system 10. In FIGS. 4 and 5, this is illustrated as moving the product to the left by moving between a retracted position (FIG. 4) and an extended position (FIG. 5). FIGS. 8 and 9 depict the pusher assembly 38 in the case packing orientation 18.

In the case packing orientation 18 of FIGS. 8 and 9, the support 50 is located at or adjacent to the second end 58 of the pusher arm 48. A push plate 60b is coupled to the first end 48 of the pusher arm 48. In particular, the push plate 60b is coupled to the first attachment plate 54 disposed at the first end 48 of the pusher arm 48. The push plate 60b includes an outer surface 62b that interacts with the product to move the product from the elevator, along a case packing path 66 disposed adjacent the elevator and within the case packing module 12.

In the retracted position shown in FIG. 4, the pusher assembly 38 is positioned on the right side of the product. More specifically, the pusher assembly 38 is positioned on the right side of the product so that the outer surface 62b of the push plate 60b is spaced apart from the right side of the product by 1 to 24 inches. As a result, the pusher assembly 38 may disposed at a or spaced apart from a second end 41 of the guide shaft 40. In the extended position shown in FIG. 5, the pusher assembly 38 has been moved along the guide shaft 40 to push the product in the second direction 44 and off the loading plate 28.

Each push plates 60a, 60b may be changed out for alternative push plates. In turn, the push plates 60a, 60b may be customized for the specific product being moved from the elevator 24.

While the above describes left and right sides of the product, this is merely for directional interpretation of the figures and in no way intended to limit the scope of the invention. It is only to emphasize that the pusher assembly 38 is disposed on different sides of the product in the bundling and case packing orientations 16, 18.

The pusher assembly 38 also includes a plurality of guide wheels 68 coupled to the support 50. The guide wheels 68 are configured to interact with the guide shaft 40 in order to movably couple the pusher assembly 38 to the guide shaft 40. In turn, the guide wheels 68 interact with the guide shaft 40 to allow the pusher assembly 38 to move between the retracted and extended positions. In the representative embodiment of the invention, the guide wheels 68 include a first set of guide wheels 68a configured to be disposed above the guide shaft 40 (see FIGS. 1-5) and a second set of guide wheels 68b configured to be disposed below the guide shaft 40 (see FIGS. 1-5).

Referring again to FIGS. 1-5, the above discussed bundling path 64 and case packing path 66 are shown in detail. The bundling path 64 is disposed adjacent a first side 70 of the elevator 24, while the case packing path 66 is disposed adjacent a second side 72 of the elevator 24. In the representative embodiment of the invention, the bundling path 64 and the case packing path 66 are disposed on opposite sides of the elevator 24. As discussed above, the bundling path 64 is configured to receive product from the elevator 24 when the pusher assembly 38 is in the bundling orientation 16 and moving from the retracted position to the extended position in the first direction 42. Conversely, the case packing path 66 is configured to receive product from the elevator 24 when the pusher assembly 38 is in the case packing orientation 18 and moving from the retracted position to the extended position in the second direction 44.

Referring to FIGS. 7 and 9, the pusher arm 48 of the pusher assembly 38 is shown in greater detail. The pusher arm 48 includes a first sidewall 74 and a second sidewall 76 oriented parallel to each other. In varying embodiments of the invention, the pusher arm 48 can include more or less than the two (2) sidewalls 74, 76 shown in FIGS. 7 and 9. In embodiments of the invention having multiple sidewalls, the pusher arm 48 may also include a plate 78 extending horizontally between the sidewalls 74, 76 for either partially or entirely along the length of the sidewalls 74, 76. In the representative embodiments of the invention, the sidewalls 74, 76 and plate 78 may include a combination of orifices or recesses formed therein to reduce the weight of the pusher arm 48.

The first sidewall 74 includes a first notch 80 and a second notch formed in the top surface 84 thereof As shown in FIGS. 7 and 9, the first notch 80 is disposed nearer the first end 52, while the second notch 82 is disposed nearer the second end 58. Each notch 80, 82 is preferably spaced apart from its respective end 52, 58. Similarly, the second sidewall 76 includes a first notch 86 and a second notch 88 formed in the top surface 90 of the sidewall 76. The first and second notches 86, 88 of the second sidewall 76 are aligned with the first and second notches 80, 82 of the first sidewall 74. In the preferred embodiment of the invention, the notches 80, 82 of the first sidewall 74 extend from a first side 92 of the sidewall 74 to a second side 94 of the sidewall 74. Likewise, the notches 86, 88 of the second sidewall 76 extend from a first side 96 of the sidewall 76 to a second side 98 of the sidewall 76. The purpose of the notches 80, 82, 86, 88 described above will be discussed in further detail below after description of the support 50.

FIGS. 7 and 9 also show the support 50 of the pusher assembly 38 in greater detail. The support 50 includes a first sidewall 100 and a second sidewall 102. In other embodiments of the invention, it is contemplated that the support 50 may include any number of sidewalls more or less than the two (2) sidewalls 100, 102 shown. The sidewalls 100, 102 are spaced apart from each other by connector pins 104 that extend between inner surfaces 106, 108 of the respective sidewalls 100, 102. In addition, each connector pin 104 may extend through a respective orifice 110 formed in the first sidewall 100 and a respective orifice 112 formed in the second sidewall 102. As a result, the connector pins 104 also couple the first and second sidewalls 100, 102 to each other. While the representative embodiment of the invention depicts the use of four (4) connector pins 104, it is contemplated that any number of connector pins 104 may be used.

As described earlier, guide wheels 68 are coupled to the support 50 with the first set of guide wheels 68a being disposed adjacent a top edge 114 of the support 50 and the second set of guide wheels 68b being disposed below the first set of guide wheels 68a. Further yet, the first and second sets of guide wheels 68a, 68b are spaced apart from each other in order to receive the guide shaft 40 between the two sets of guide wheels 68a, 68b. The first sidewall 100 includes a number of orifices 116 formed through the sidewall 100 so that the guide wheels 68 may be attached to the support 50. Similarly, the second sidewall 102 includes a number of orifices 118 formed through the sidewall 102 in order to assist with attaching the guide wheels 68 to the support 50.

As shown in FIGS. 6-9, the first set of guide wheels 68a includes wheels 120 disposed outside the sidewalls 100, 102 of the support 50. Similarly, the second set of guide wheels 68b includes wheels 122 disposed outside the sidewalls 100, 102 of the support 50. Each wheel 120, 122 outside the first sidewall 100 has a corresponding wheel 120, 122 outside the second sidewall 102. Each set of guide wheels 68a, 68b includes a connector or axle 124, 126, respectively, that extends laterally between the corresponding wheels 120, 122, respectively. Further, the axles 124, 126 extend between the sidewalls 100, 102 and through the above described orifices 116, 118 of the first and second sidewalls 100, 102, respectively.

The orifices 116 of the first sidewall 102 can be classified as either orifices 116a corresponding to the first guide wheel set 68a or orifices 116b corresponding to the second guide wheel set 68b. Likewise, the orifices 118 of the second sidewall can be classified as either orifices 118a corresponding to the first guide wheel set 68a or orifices corresponding to the second guide wheel set 68b. The first orifices 116a of the first sidewall 100 are formed adjacent to the top edge 114 of the support 50 and aligned with respective first orifices 118a of the second sidewall 102 also formed adjacent to the top edge 114 of the support 50. A respective axle 124 is then disposed between the sidewalls 100, 102 and through the respective orifices 116a, 118a to assist in coupling the guide wheels 68a to the support 50, coupling together the sidewalls 100, 102 of the support 50, and properly spacing the sidewalls 100, 102 apart from each other.

The second orifices 116b of the first sidewall 100 spaced apart from and disposed below the first orifices 116a of the first sidewall 100. The second orifices 116b of the first sidewall 100 are aligned with second orifices 118b of the second sidewall 102 spaced apart from and disposed below the first orifices 118a of the second sidewall 102. A respective axle 126 is then disposed between the sidewalls 100, 102 and through the respective orifices 116b, 118b in order to couple the guide wheels 68b to the support 50. In addition, the axles 126 assist in coupling together the sidewalls 100, 102 of the support 50 and properly spacing the sidewalls 100, 102 apart from each other.

FIGS. 7 and 9 further illustrate a keyed opening 128 formed through the first sidewall 100 and a location adjacent a bottom edge 130 of the support 50. A matching keyed opening (not shown) is formed through the second sidewall 102 at a location adjacent the bottom edge 130 of the support 50 in order to be aligned with the keyed opening 128 of the first sidewall 100. The keyed opening 128 is shaped to having a larger diameter at an upper portion 132 of the keyed opening 128 than at a lower portion 134 of the keyed opening 128. In varying embodiments of the invention, the sidewalls 100, 102 may include any number of orifices and recessed formed therein in addition to the orifices and openings 110, 112, 116, 118, 128 described above so as to reduce the weight of the support 50.

Referring again to FIGS. 6-9, the support 50 is attached to the pusher arm 48 by placing the bottom edge 130 of the support 50 in contact with a top surface 136 of the plate 78 of the pusher arm 48. In the representative embodiment of the invention, the support 50 is sized so that the sidewalls 100, 102 of the support 50 are disposed within the perimeter established by the sidewalls 74, 76 of the pusher arm 48. In the bundling orientation 16 of FIGS. 6 and 7, the support 50 is disposed adjacent the first edge 52 of the pusher arm 48 in a position where the first notches 80, 86 of the first and second sidewalls 74, 76, respectively, of the pusher arm 48 are aligned with the keyed openings 128 of the support 50. More specifically, the first notches 80, 86 are aligned with the lower portions 134 of the keyed openings 128.

In the case packing orientation 18 of FIGS. 8 and 9, the support 50 disposed adjacent the second edge 58 of the pusher arm 48. In particular, the support 50 is disposed in a position so that the second notches 82, 88 of the first and second sidewalls 74, 76, respectively, of the pusher arm 48 are aligned with the keyed openings 128 of the support 50. In the representative embodiment of the invention, it is the lower portions 134 of the keyed openings 128 that is aligned with the second notches 82, 88.

The above described the first notches 80, 86 and the openings 128 of the support 50 act as an indexing feature or referencing structure to ensure that the support 50 is properly located in the bunding orientation 16. Similarly, the second notches 82, 88 and the openings 128 of the support 50 act as an indexing feature or referencing structure to ensure that the support 50 is properly located in the case packing orientation 18. In other embodiments of the invention, it is contemplated that other indexing features or referencing structures may be used to ensure proper alignment of the support 50 in either the bundling orientation 16 or the case packing orientation 18.

As described above, in the bundling orientation 16 and the case packing orientation 18, the keyed openings 128 of the support 50 are aligned with either the first notches 80, 86 or the second notches 82, 88 of the pusher arm 48, respectively. In the representative embodiment of the invention, alignment of the keyed openings 128 with either the first notches 80, 86 or the second notches 82, 88 allows for insertion of a securing device in the form of at least one locking pin 138. In the representative embodiment of the invention, the locking pin 138 may be inserted through the upper portions 132 of the keyed openings 128 and then lowered to a locked position in which the locking pin 138 extends through the lower portions of the keyed openings 128 and either the first notches 80, 86 or the second notches 82, 88, depending on the orientation of the pusher assembly 38. In other embodiments of the invention, other securing devices 138 may be used to secure the support 50 and the pusher arm 48 in either the bundling orientation 16 or the case packing orientation 18.

The locking pin 138 may further include a locking handle 140, the rotation of which secures the locking pin 138 in the locked position. A locking plate 142 may also be disposed above one or both sidewalls 74, 76 of the pusher aim 38 and secured to one or both sidewalls 100, 102 of the support 50 directly above the in-use notches. The locking plate 142 may include a slot opening 144 formed therein and sized to not allow the locking pin 138 to move from its position within the lower portion 134 of the keyed opening 128 and the in-use notches.

The above described configuration makes transitioning the pusher assembly 38 between the bundling orientation 16 and the case packing orientation 18 a quick and easy process that can be completed in typically less than 15 minutes. To transition the pusher assembly 38 from the bundling orientation 16 to the case packing orientation 18, a user need only manipulate the locking pin 138—and locking plate 142, if present—to move the locking pin 138 from the locked position within the lower portions 134 of the keyed openings 128 and notches 80, 86 to an unlocked position within the upper portions 132 of the keyed openings 128. The locking pin 138 may either be completely removed from the keyed openings 128 or remain in the upper portions 132 of the keyed openings 128 for the next steps. The support 50 may then be moved from adjacent the first end 52 of the pusher arm 38 to adjacent the second end 58 of the pusher arm 38. In other embodiments of the invention, the support 50 may be removed from the first end 52 of the pusher arm 38 and a new support or the same support 50 may be coupled to the second end 58 of the pusher arm 38. The locking pin 138 may then be moved from the unlocked position within the upper portions 132 of the keyed openings 128 to the locked position within the lower portions 134 of the keyed openings and the notches 82, 88 of the pusher arm 38. The user may then manipulate the locking pin 138—and locking plate 142, if present—to secure the locking pin 138 in the locked position.

Conversely, to transition the pusher assembly 38 from the case packing orientation 18 to the bundling orientation 16, the locking pin 138 is manipulated—and locking plate 142, if present—to move the locking pin 138 from the locked position within the lower portions 134 of the keyed openings 128 and the notches 82, 88 to an unlocked position within the upper portions 132 of the keyed openings 128. The support 50 is then moved from adjacent the second end 58 of the pusher arm 38 to adjacent the first end 52 of the pusher arm 38 in order to align the keyed openings 128 with the notches 80, 86. In other embodiments of the invention, the support 50 may be removed from the second end 58 of the pusher arm 38 and a new support or the same support 50 may be coupled to the first end 52 of the pusher arm 38. The locking pin 138 is then moved from the unlocked position within the upper portions 132 of the keyed openings 128 to the locked position within the lower portions 134 of the keyed openings 128 and the notches 80, 86. The locking pin 138—and locking plate 142, if present—is then manipulated to secure the locking pin 138 in the locked position.

As previously discussed above and shown in FIGS. 1-5, the packaging system 10 includes a case packing module 12 and a bundling module 14. The above described infeed conveyor 20 and elevator 24 are disposed within the case packing module 12 and coupled to the frame 146 of the case packing module 12 portion of the system 10. In addition, the case packing path 66 is also disposed within the case packing module 12 and, preferably, above the infeed conveyor 20 in order to optimize the footprint of the case packing module 12 and the packaging system 10. The bundling path 64 is also disposed within the case packing module 12. As discussed above, the bundling path 64 is disposed on the opposite side of the elevator 24 as the case packing path 66.

The case packing path 66 leads the product from the elevator 24 to a case (not shown) in order to load the product into the case. Meanwhile, the bundling path 64 leads the product from the elevator 24 to the bundling module 14 at the second end 46 of the system 10. The bundling module 14 includes a bundler 148 aligned with the bundling path 64 and coupled to the frame 150 of the bundling module 14. The bundler 148 may be in the form poly former for bundling the product into polyethylene wrapped bundles. Other embodiments of the invention may use other forms of bundlers 148 to bundle and wrap the product.

As shown in FIGS. 1-5, the bundling path 64 and the case packing path 66 may also include access doors 152 on either or both sides of the paths 64, 66. The access doors 152 are oriented perpendicular to and act as sidewalls for the paths 64, 66 when closed. When opened, the access doors 152 allow a user to access the bundling path 64 of case packing path 66 to assist in maintaining the system 10.

The bundling module 14 may be detached from the case packing module 12. The system may be operated to direct the product from the infeed conveyor 20, to the elevator 24, to the case packing path 66, and to a case with or without the bundling module 14 attached to the case packing module 12. That is, the bundling module 14 may remain attached to the case packing module 12 when the packaging system 10 is operating in the case packing orientation 18.

Other embodiments and uses of the invention will be apparent to those skilled in the art from consideration from the specification and practice of the invention disclosed herein. It is understood that the invention is not confined to the specific materials, methods, formulations, operating/assay conditions, etc., herein illustrated and described, but embraces such modified forms thereof as come within the scope of the following claims.

Claims

1. A packaging system comprising:

a loading area configured to receive a product; and

a pusher assembly switchable between a first orientation and a second orientation, the pusher assembly including a pusher arm;

wherein the pusher assembly is configured to move the product from the loading area in a first direction when in the first orientation, and

wherein the pusher assembly is configured to move the product from the loading area in a second direction when in the second orientation.

2. The packaging system of claim 1, wherein the pusher assembly is configured, when it is the first orientation thereof, to move the product from the loading area to a bundler.

3. The packaging system of claim 1, wherein the pusher assembly is configured, when it is the second orientation thereof, to move the product from the loading area to a case packer.

4. The packaging system of claim 1, wherein the pusher assembly further comprises a support coupled to the pusher arm;

wherein the support is disposed at a first end of the pusher arm in the first orientation; and

wherein the support is disposed at a second end of the pusher arm in the second orientation.

5. The packaging system of claim 1, wherein the pusher assembly is movably connected to a guide shaft extending along a top of the packaging system;

wherein the pusher assembly is configured, in the first orientation thereof, to move in the first direction from a retracted position at a first end of the guide shaft to an extended position; and

wherein the pusher assembly is configured, in the second orientation thereof, to move in the second direction from a retracted position to an extended position.

6. The packaging system of claim 1, wherein a push plate is coupled to the second end of the pusher arm in the first orientation of the pusher assembly, and wherein the push plate or another push plate is coupled to the first end of the pusher arm in the second orientation of the pusher assembly.

7. The packaging system of claim 1, wherein the loading area is located on an elevator that is movable vertically to transfer the product from an infeed conveyor to an unloading position, and wherein the pusher assembly is configured to interact with the product when the product is in the unloading position.

8. A product pusher assembly comprising:

a pusher arm, wherein the pusher arm has first and second ends, each of the ends being configured to selectively support a support while the other ends remains free of a support;

a push plate disposed at the second end of the pusher arm in the first orientation and disposed at the first end of the pusher arm in the second orientation.

9. The product pusher assembly of claim 8, wherein the pusher arm includes a first sidewall, a second sidewall spaced apart from the first sidewall, and a plate disposed perpendicular to and extending between the first and second sidewalls;

wherein the support is disposed on an upper surface of the plate and between the first and second sidewalls.

10. The product pusher assembly of claim 9, wherein the support and the pusher arm include a first indexing feature disposed at or adjacent to the first end of the pusher arm; and

wherein the support and the pusher arm include a second indexing feature disposed at or adjacent to the second end of the pusher arm.

11. The product pusher assembly of claim 10, wherein the first indexing feature aligns the support and the pusher arm in the first orientation; and

wherein the second indexing feature align the support and the pusher arm in the second orientation.

12. The product pusher assembly of claim 11, further comprising a securing device that is configured to secure the product pusher assembly in the first orientation or the second orientation.

13. The product pusher assembly of claim 12, wherein the product pusher assembly is configured to move in a first direction when in the first orientation; and

wherein the product pusher assembly is configured to move in a second direction when in the second orientation.

14. The product pusher assembly of claim 12 wherein the product pusher assembly is configured to changeover from the first orientation and the second orientation by removing the push plate from the second end of the pusher arm and attaching the push plate or another push plate to the first end of the pusher arm;

wherein the product pusher assembly is configured to changeover from the first orientation and the second orientation by removing the support from the first end of the pusher arm and attaching the support or another support to the second end of the pusher arm.

15. A method of operating a packing system, comprising:

delivering product to a loading area from an infeed conveyor;

using a pusher assembly, pushing the product from the loading area and along a case packing path toward a case packer;

delivering additional product onto the loading area from the infeed conveyor; and

using the pusher assembly, pushing the additional product from the loading area and along a bundling path toward a bundler.

16. The method of claim 15, wherein pushing the product along the case packing path includes moving the pusher assembly along a guide shaft in a first direction, and wherein pushing the product along the bundling path comprises moving the pusher assembly along the guide shaft in a second direction.

17. The method of claim 15, further comprising changing over the pusher assembly between first and second orientations between pushing the product along the case packing path and pushing the additional product along the bundling path.

18. The method of claim 17, wherein the changing over includes removing a push plate of the pusher assembly from a first end of a pusher arm of the pusher assembly and attaching the push plate or another push plate to a second end of the pusher arm.

19. The method of claim 18, wherein the changing over further includes removing a support from the second end of the pusher arm and attaching the support or another support at the first end of the pusher arm.

20. The method of claim 19, wherein the changing over further comprises locking the support to the first end or the second end of the pusher arm by extending a pin through either a first set of notches of the pusher arm and an opening in the support or a second set of notches of the pusher arm and the opening in the support, respectively.