U.S. patent application number 13/503568 was filed with the patent office on 2012-11-29 for packaging related process, system & apparatus.
This patent application is currently assigned to Douglas Machine Inc.. Invention is credited to Ronald M. Gust, Leon J. Krause.
Application Number | 20120297738 13/503568 |
Document ID | / |
Family ID | 43897193 |
Filed Date | 2012-11-29 |
United States Patent
Application |
20120297738 |
Kind Code |
A1 |
Krause; Leon J. ; et
al. |
November 29, 2012 |
PACKAGING RELATED PROCESS, SYSTEM & APPARATUS
Abstract
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.
Inventors: |
Krause; Leon J.; (Miltona,
MN) ; Gust; Ronald M.; (Miltona, MN) |
Assignee: |
Douglas Machine Inc.
|
Family ID: |
43897193 |
Appl. No.: |
13/503568 |
Filed: |
October 25, 2010 |
PCT Filed: |
October 25, 2010 |
PCT NO: |
PCT/US10/53960 |
371 Date: |
July 6, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12604748 |
Oct 23, 2009 |
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13503568 |
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12701762 |
Feb 8, 2010 |
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12604748 |
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12909306 |
Oct 21, 2010 |
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12701762 |
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Current U.S.
Class: |
53/523 |
Current CPC
Class: |
B65B 9/20 20130101; B65B
1/22 20130101; B65B 37/00 20130101; B65B 37/18 20130101; B65B 1/32
20130101 |
Class at
Publication: |
53/523 |
International
Class: |
B65B 1/20 20060101
B65B001/20 |
Claims
1. Apparatus to facilitate packaging of a settleable product
comprising an actuatable assembly, an assembly base, and an
assembly actuator operatively linked to said actuatable assembly
for selectively actuating said actuatable assembly relative to said
assembly base, said actuatable assembly comprising product settling
bins, each product settling bin of said product settling bins
positionable, via actuation of said actuatable assembly, for
receipt of a metered charge of settleable product, successive
actuation of said actuatable assembly settling the metered charge
of settleable product in furtherance of a discharge of a settled
metered charge of settleable product from the apparatus.
2. The apparatus of claim 1 wherein said actuatable assembly is
indexed via said assembly actuator.
3. The apparatus of claim 1 wherein said actuatable assembly is
reversibly indexed via said assembly actuator.
4. The apparatus of claim 1 wherein said actuatable assembly is
periodically actuated via said assembly actuator.
5. The apparatus of claim 1 wherein said actuatable assembly
comprises a first actuatable assembly readily exchangeable for a
second actuatable assembly, said second actuatable assembly
comprising product settling bins having an alternate configuration
compared to a configuration of those of said first actuatable
assembly.
6. The apparatus of claim 1 wherein said assembly actuator
comprises a mechanical system.
7. The apparatus of claim 1 wherein said assembly actuator
comprises a pneumatic system.
8. The apparatus of claim 1 wherein said assembly actuator
comprises a hydraulic system.
9. The apparatus of claim 1 wherein said assembly actuator
comprises a selectively controlled motor.
10. The apparatus of claim 1 wherein said assembly actuator
comprises a servo-drive.
11. The apparatus of claim 1 wherein said assembly actuator
comprises a selectively driven motor.
12. The apparatus of claim 1 wherein said product settling bins of
said actuatable assembly are readily exchangeable with alternately
configured settling bins.
13. The apparatus of claim 1 wherein said product settling bins of
said actuatable assembly comprise a first set of product settling
bins readily exchangeable for a second set of product settling
bins, said second set of product settling bins having an alternate
configuration compared to a configuration of those of said first
set of product settling bins.
14. The apparatus of claim 1 wherein said product settling bins of
said actuatable assembly comprise alternately configurable settling
bins.
15. The apparatus of claim 1 wherein said product settling bins of
said actuatable assembly include a metered charge ingress portion
and a settled metered charge egress portion, said ingress portion
characterized by a sectional area which exceeds a sectional area of
said egress portion.
16. The apparatus of claim 1 wherein said product settling bins of
said actuatable assembly include a metered charge ingress portion
and a settled metered charge egress portion, a transverse dimension
of said bin generally decreasing toward said egress portion from
said ingress portion.
17. The apparatus of claim 1 wherein said product settling bins of
said actuatable assembly include a funnel-like metered charge
ingress portion.
18. The apparatus of claim 1 wherein said product settling bins of
said actuatable assembly include a metered charge ingress portion
comprising a metered charge reservoir.
19. The apparatus of claim 1 wherein said product settling bins of
said actuatable assembly include a metered charge ingress portion
and a settled metered charge egress portion, said ingress portion
comprising metered charge reservoir characterized by a sectional
area of about 1.25-2.5 times greater than a sectional area of said
egress portion.
20. The apparatus of claim 1 wherein said assembly base is adapted
to selectively permit passage of a settled metered charge of
settleable product to a bag forming mandrel in furtherance of bag
formation.
21. The apparatus of claim 1 wherein said assembly base is adapted
to selectively permit passage of a settled metered charge of
settleable product to a bag forming mandrel having at least a lower
segment comprising air passage apertures.
22. The apparatus of claim 1 wherein said assembly base includes a
settled metered charge discharge port.
23. The apparatus of claim 1 wherein said assembly base includes a
selectively actuatable settled metered charge discharge port 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.
24. A system for volumetrically reducing a settleable product in
advance of packaging same, said system comprising an actuatable
carrier and an actuator operatively linked to said actuatable
carrier for selectively actuating said actuatable carrier, said
actuatable carrier comprising a plurality of compacting chambers,
each settling chamber characterized by a ingress portion, and an
egress portion opposite said ingress portion.
25. The system of claim 24 wherein said ingress portion of said
compacting chamber is characterized by a reducing sectional area in
a direction toward said egress portion of said compacting
chamber.
26. The system of claim 24 wherein said ingress portion of said
compacting chamber tapers toward said egress portion of said
compacting chamber.
27. The system of claim 24 wherein said ingress portion of said
compacting chamber is characterized by a cross sectional area which
exceeds a cross sectional area of said egress portion of said
compacting chamber.
28. The system of claim 24 wherein said ingress portion of said
compacting chamber comprises a funneled free end.
29. The system of claim 24 in combination with a transfer mechanism
for selectively passing settled settleable product from a select
compacting chamber in furtherance of packaging.
30. The system of claim 29 wherein said transfer mechanism
comprises a bag forming mandrel, characterized by a vented lower
segment, through which settled settleable product passes.
31. The system of claim 24 in combination with a bag manufacturing
and packaging station characterized by a bag forming mandrel
comprising a tube through which settled settleable product passes,
said tube comprising an apertured segment below a forming shoulder
thereof.
32. A packaging related process comprising: a. providing a product
settling station comprising an actuatable assembly characterized by
a plurality of settling chambers; b. delivering a metered mass of
settleable product to a select settling chamber of said plurality
of settling chambers of said actuatable assembly; and, c. imparting
an inertial change upon said actuatable assembly in furtherance of
settling the metered mass of settleable product delivered to said
select settling chamber.
33. The packaging related process of claim 32 wherein said inertial
change comprises a velocity change.
34. The packaging related process of claim 32 wherein said inertial
change comprises an acceleration change.
35. The packaging related process of claim 32 wherein said inertial
change comprises a stoppage of motion associated with an actuation
of said actuatable assembly.
36. The packaging related process of claim 32 wherein said inertial
change comprises a periodic actuation of said actuatable
assembly.
37. The packaging related process of claim 32 wherein said inertial
change comprises a periodic actuation of said actuatable assembly
so to indexingly advance said select solid settling chamber.
38. The packaging related process of claim 32 wherein said solid
settling chambers are arranged so as to produce a settled charge of
a metered mass of settleable product having a substantially uniform
height.
39. The packaging related process of claim 32 further comprising
establishing a settled and formed charge of a metered mass of
settleable product by the settling of the metered mass of
non-uniform consumable solids via said settling chambers of said
plurality of settling chambers for release to a bagging
station.
40. The packaging related process of claim 32 further comprising
transferring a settled and formed charge of a metered mass of
settleable product by the settling of the metered mass of
non-uniform consumable solids via said settling chambers of said
plurality of settling chambers to a bagging station via a conduit
through which the settled and formed charge passes, said conduit
having a lower apertured portion.
41. The packaging related process of claim 32 wherein either said
actuatable assembly or said plurality of settling chambers thereof
are readily exchangeable with either an alternately configured
actuatable assembly or an alternately configured plurality of
settling chambers respectively.
Description
[0001] This is an international application filed under 35 USC
.sctn.363 claiming priority under 35 USC .sctn.120, of/to U.S.
patent application Ser. Nos. 12/604,748, 12/701,762 &
12/909,306, having filing dates of Oct. 23, 2009, Feb. 8, 2010
& Oct. 21, 2010 respectively, and entitled METHOD AND APPARATUS
FOR COMPACTING PRODUCT, PACKAGING RELATED PROCESS, SYSTEM &
APPARATUS, & METHOD AND APPARATUS FOR COMPACTING PRODUCT
respectively, the disclosures of which are hereby incorporated by
reference in their entireties.
TECHNICAL FIELD
[0002] The 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 INVENTION
[0003] Processes 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.
[0004] 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.
[0005] 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.
[0006] As depicted herewith, FIG. 1, bag manufacturing and packing
processes are generally characterized by a metering station 20, a
bag manufacturing and packaging station 22, and a bag transfer or
conveyance station 24. Such heretofore known bag manufacturing and
packing systems are depicted herewith, FIGS. 2 & 3 (U.S. Pat.
No. 7,328,544 (Yokota et al.), FIGS. 1 & 2 thereof), with a
less "busy" depiction of a bag manufacturing and packaging station
depicted herewith FIG. 4 (U.S. Pat. No. 5,732,532 (Fujisaki et
al.), FIG. 1 thereof), each teaching incorporated herein by
reference in their entireties.
[0007] Generally, a metered charge (i.e., a select mass of product
for packaging) exits a metering station (FIGS. 2 & 3), or a
hopper (FIG. 4). The metered charge is directed to a tube, or chute
(e.g., a mandrel of a former (FIG. 3)) for passage therethrough.
Roll fed film is directed toward and upon the mandrel, and
ultimately thereabout, whereupon it is longitudinally sealed to
form a film sleeve (FIG. 4). Thereafter, the sleeve so formed is
transversely sealed via a sealer underlaying the tube, so as to
thusly receive and retain the metered charge of product, the
transverse seal portion likewise cut, and a packaged/bagged product
charge thereby formed and transferred from the station, via a chute
conveyor or the like, for subsequent post packaging processing.
[0008] 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 FIGS. 1-4 and
the like. While Yokota et al. appear to have focused upon clinging
bags exiting the bag manufacturing and packaging station (1:49-67),
and Fujisaki et al. upon blockages of the filing passage of the
tubular mandrel (2:7-35), little if anything has been done in
connection to pre-packaging preparation of the product, aside from
establishing a metered feed of the product, to enhance the bag
manufacturing and product packaging operations, and the quality
and/or character of the packaged product. Thus, in light of at
least the forgoing, it is believed that bag manufacturing and
product packaging related challenges remain, with real and
perceived benefits believed obtainable. In furtherance of, among
other things, packaging materials reduction, the delivery of a
metered charge of improved character and/or quality, and the
production of a bagged snack food or the like possessing a real
and/or perceived improved character (e.g., an increased mass to
volume ratio for the packaged product, a reduction in the amount of
product fines or the like accompanying the packaged product, etc.),
it remains advantageous and desirable to provide new and/or
improved pre-packaging prepatory steps, and attendant
apparatus/systems, and thus an improved packaging related process,
system and apparatus for a settleable product.
SUMMARY OF THE INVENTION
[0009] An apparatus to facilitate packaging of a settleable
product, as well as a system incorporating same, and an attendant
process is provided. The 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 product
settling bins. 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.
[0010] 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.
[0011] 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.
[0012] 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.
[0013] 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.
[0014] 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. 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 depicts common processing steps of known bag
manufacturing and packaging process;
[0016] FIGS. 2 & 3 depict a known packaging/bagging system of
Ishida Co., Ltd. (e.g., U.S. Pat. No. 7,328,544), not inconsistent
with the process of FIG. 1;
[0017] FIG. 4 depicts a known packaging/bag forming system of House
Foods Corp. (e.g., U.S. Pat. No. 5,732,532), not inconsistent with
the process of FIG. 1;
[0018] FIG. 5 depicts an improved bag manufacturing and packaging
process;
[0019] FIG. 6 is a perspective view of a filling apparatus
employing one embodiment of the invention comprising a settling
chamber;
[0020] FIG. 7 depicts a preferred, not limiting settling assembly,
above isometric view, associated with the settling or
settling/forming station of the improved bag manufacturing and
packaging process of FIG. 5;
[0021] FIG. 8 is a plan view of the settling assembly of FIG.
7;
[0022] FIG. 9 is a below isometric view of the settling assembly of
FIG. 7;
[0023] FIG. 10 is a top profile view of a rotary settling device
comprising multiple settling chambers in their discharging and
receiving positions;
[0024] FIG. 11 is a perspective view of a rotary settling device
comprising multiple settling chambers in a mid-rotation
position;
[0025] FIG. 12 is a below perspective view of a subassembly of the
settling assembly of FIG. 7, see especially FIG. 9, namely, a gate
assembly;
[0026] FIG. 13 is an exploded view of the subassembly of FIG.
12;
[0027] FIG. 14 is an above isometric view of the turret assembly of
the settling assembly of FIG. 7;
[0028] FIG. 15 is an above isometric view of an alternate turret
assembly, with FIG. 15A directed to an alternate sleeve or
container configuration;
[0029] FIG. 16 is an above isometric view of the settling assembly
of FIG. 7 in combination with an improved tube/mandrel of a bag
manufacturing station; and,
[0030] FIG. 17 is an above isometric view of the settling assembly
of FIG. 7, with substituted turret assembly, in combination with an
improved tube/mandrel of a bag manufacturing station;
[0031] FIG. 18 is a perspective view of a filling apparatus similar
to that of FIG. 6 comprising a settling chamber and vacuum relief
holes;
[0032] FIG. 19 depicts, in above isometric, cooperative elements of
a combined settling, settling/forming station and bag manufacturing
and packaging station, parts removed;
[0033] FIG. 20 depicts, in below isometric, the combination of FIG.
19; and,
[0034] FIG. 21 is a view as FIG. 20, with bag manufacturing and
packaging station elements removed to show underlaying details.
DETAILED DESCRIPTION OF THE INVENTION
[0035] 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.
[0036] 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.
[0037] 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.
[0038] The description next immediately proceeds with general
reference to FIG. 5, and FIGS. 6-11 of FIGS. 5-21. Processing steps
of an improved bag manufacturing and packaging process are
generally depicted in FIG. 5, namely, the addition of a product
settling station, more particularly, a metered product settling and
metered product charge forming station, to the process of FIG. 1.
Preferred, non-limiting apparatuses to facilitate packaging (i.e.,
improved packaging) of settleable solids are generally depicted in
FIG. 6 and the several views of FIGS. 7-11. Particulars with regard
to subassemblies thereof, namely, a gate assembly, as
advantageously but not necessarily depicted in the views of FIGS.
12 & 13, and turret assemblies, as advantageously but not
necessarily depicted in FIGS. 14 & 15, are likewise provided.
Finally, contemplated apparatuses, equipped with the alternate
turret assemblies of FIGS. 14 & 15, are depicted in combination
with an improved tube/bag forming mandrel in FIGS. 16 & 17
respectively, as well as the major process elements of FIG. 6
likewise equipped in FIG. 18. Prior to proceeding with the detailed
description, several preliminary matters warrant mention.
[0039] 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."
[0040] 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 turn key 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).
[0041] 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 IS 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.
[0042] With reference now to FIG. 5, an improved bag manufacturing
and packing process is disclosed, namely, a process characterized
by a settling or settling/forming step, more particularly, a
metered product charge settling or settling/forming step 21. In
lieu of a metered product charge passing directly to a bag
manufacturing and packing station, e.g., introduction of the
metered product charge for passage through a bag former (i.e.,
through a lumen of a bag forming mandrel or tube (FIG. 4)), the
instant process advantageously includes an intervening step,
namely, that of compacting, settling, and/or forming a settled
preselect arrangement of the metered product charge. As will be
subsequently detailed in connection to a presentation of system and
apparatus particulars, an improved, non-limiting bag manufacturing
and packing process may be fairly characterized by the step of
agitating a metered product charge, as by one or more inertial
changes imparted in respect of an actuatable assembly which
retains, via at least a single settling or settling/forming
chamber, the metered product charge. As should be readily
appreciated, for product or products amenable or prone to settling,
e.g., chips, as opposed to, for example, shelled nuts, a volumetric
reduction of a given product mass (i.e., metered product charge) is
achieved, and results in, among other things, a commensurate
reduction in packaging (e.g., bag forming) materials.
[0043] FIG. 6 provides a perspective view of a filling apparatus
employing one embodiment of the invention comprising a settling
chamber. In FIG. 6, a settling device 30 is located between a
metering station 20, characterized by a weigher 23 and a receiving
funnel 25, and the product delivery cylinder 60 of a vertical form,
fill, and seal machine. The weigher 23 can comprise virtually any
weigher known in the art. In one embodiment, the weigher 23 is a
statistical weigher. As depicted, downstream of the weigher 23 is a
receiving funnel 25. A receiving funnel 25, or a series of funnels,
receives and guides product to the downstream bagmaker. As used
herein a receiving funnel 25 refers to any device downstream of a
weigher but upstream from a settling device which collects and
directs product. The receiving funnel 25 can be attached and part
of the weigher 23 and can comprise vertical or slanted walls. In
one embodiment, there is a metal detector located between the
weigher 23 and the receiving funnel 25 to monitor foreign debris.
Those skilled in the art will appreciate that a receiving funnel 25
is not necessary in all embodiments. Downstream of the receiving
funnel 25 and the weigher 23 is the settling device 30.
[0044] 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.
[0045] 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.
[0046] 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.
[0047] 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.
[0048] 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.
[0049] 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.
[0050] 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.
[0051] 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.
[0052] 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.
[0053] 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 40 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.
[0054] With reference now to FIGS. 7-11, there is generally shown
an apparatus 30 to facilitate the packaging, i.e., improved
packaging, of settleable product by rotary charge compaction. The
apparatus, alone or in select combination with further process
related components, may be fairly characterized as a product
settling or product settling/forming system or station.
Advantageously, but not necessarily, as previously noted, the
general apparatus or assembly of FIGS. 7-11 is configured,
dimensioned and/or readily adapted or adaptable for inclusion or
incorporation, as by a retrofit, in or into known bag manufacturing
and packaging systems, e.g., and without limitation, those of
Ishida Co., Ltd. (Japan).
[0055] Generally, the apparatus 30 includes an actuatable assembly,
e.g., actuatable turret assembly 32 (reference also FIGS. 11 &
12), 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
FIGS. 9 & 10) is advantageously provided, namely, a selectively
operable gate assembly for permitting egress of a settled and
formed metered product charge from the actuatable turret assembly
32, via the turret assembly base 34.
[0056] 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.
[0057] 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 t.sub.0 is thereafter relocated,
via turret assembly actuation, so as to underlay a discharge of the
metering station, and is there filled at time t.sub.1. A "filling"
bin (FB) is preferably, but not necessarily immediately adjacent
(i.e., "down stream" of) an "emptying" bin (EB), see e.g., FIG. 9
(i.e., bin emptying and filling operations are advantageously, but
not necessarily adjacent one another). As the next earliest filled
bin, essentially retaining the settled and formed metered charge,
is positioned relative to the turret assembly base for content
discharge, the initially "filled" bin commensurately proceeds in
relation to the turret assembly base, and via an inertial change,
may be fairly characterized as having transitioned from an
initially filled state or condition to an initially settled,
settled and formed state or condition.
[0058] 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.
[0059] 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 FIG. 9, the turret base 34 includes an egress
port, e.g., a cut out or aperture 58 as shown, which is (see e.g.,
FIG. 16) or may be (FIG. 9) operatively linked to a bag
former/mandrel 60, and a slotted peripheral edge 61 (i.e., a slot
62) which permits and/or accommodates reversible translation or
reciprocation of the gate subassembly 38 of FIG. 12. Further
non-limiting advantageous features of the turret assembly base 34
include, but need not be limited to, the inclusion of an elongate
through hole, e.g., a slot 64, extending adjacent and parallel to
the egress port 58, an upper surface recess, more particularly, a
channeled recess 66 as shown, and the addition of a track or track
segment 68 depending or otherwise extending from a lower surface 70
of the turret base 34 so as to be adjacent and parallel to the slot
62 of the slotted peripheral edge 61. As should be appreciated with
reference to FIGS. 8 & 9, the interior turret base slot 64 is
positioned "downstream" of egress port 58, and is generally
dimensioned and configured so as to selectively receive and pass
product fines, crumbs, etc.
[0060] With reference now to FIG. 10, a rotary settling device 30
is depicted comprising eight settling chambers 40a-h located above
the stationary turret table 34, a gate 72, and a vibrator 31. While
the figure illustrates eight settling chambers 40a-h, other numbers
of settling chambers may also be utilized. Those skilled in the art
will understand that the number of required settling chambers is
dependent upon a variety of factors including but not limited to
the geometry of the product, the desired size and weight of each
slug, and the desired throughput in bags per minute, amount of
settling time required, etc.
[0061] 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.
[0062] 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.
[0063] 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.
[0064] 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.
[0065] FIGS. 10 and 11, however, depict an embodiment in which the
receiving and discharging does not take place in the same chamber.
As depicted in FIG. 10, the discharging chamber 40a discharges
product and a different chamber, the receiving chamber 40c receives
product from the receiving funnel 25. In one embodiment, the
discharging and the receiving takes place simultaneously. Thus,
after the discharge chamber 40a discharges its product, it rotates
two positions to become the receiving chamber 40c at which time it
receives product. In other embodiments the discharge chamber 40a
will only rotate one spot before becoming the receiving chamber
whereas in other embodiments the discharge chamber will rotate
multiple positions before becoming the receiving chamber. The
location of the receiving and discharging positions depends on a
variety of factors including but not limited to the location of the
receiving funnel 25 and the product delivery cylinder 60 and the
required amount of settling.
[0066] 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.
[0067] 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.
[0068] As shown in FIGS. 10 & 11, the receiving funnel 25 is
located atop the rotary settling device 30. The receiving funnel 25
directs product to the receiving chamber. As noted above, the
receiving funnel 25 may be directly below the weigher 23 or it may
be below another funnel or series of funnels.
[0069] FIG. 11 is a perspective view of a rotary settling device
comprising multiple settling chambers in a mid-rotation position,
the opening 92 located on the stationary table 44 likewise visible.
As depicted, the chambers are in mid-rotation so the chambers are
not receiving or discharging product. In other embodiments,
however, product is received and/or discharged during rotation. In
some embodiments, however, it is desired that the compact slug is
maintained in its compact state after the slug has been formed.
[0070] In FIG. 11, a stationary top 35 is depicted. The top 35 acts
to ensure that the product within the settling chambers 40 does not
escape the settling chambers 40. Further, the top 35 acts to keep
external items from entering the settling device and subsequently
becoming packaged. The top 35 is not necessary in all embodiments,
and those skilled in the art will understand which processing
conditions will warrant such a top.
[0071] As depicted, the intermediate funnel 99 and the product
receiving cylinder 60 are depicted downstream of the opening 92. In
FIG. 11, the product receiving cylinder 60 is part of the bag
former in a vertical form, fill, and seal, machine. In one
embodiment, the product receiving cylinder 60 is directly connected
to the rotary device 30. In other embodiments the product receiving
cylinder 60 is not directly attached to the rotary device 30. The
product receiving cylinder 60 may be separated from the rotary
device 30 by a gap or it may be connected via other equipment such
as the intermediate funnel 99.
[0072] 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.
[0073] 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.
[0074] 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 FIG. 10, in such an embodiment
a single package will comprise product discharged from the
discharge chamber 40a as well as product from the chamber 40h
located one spot behind the discharge chamber 40a. Thus, product
from both chambers 40a/40h is deposited to a vertical form, fill,
and seal machine to be packaged in a single package.
[0075] 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.
[0076] 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.
[0077] 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.
[0078] 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.
[0079] Control
[0080] 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.
[0081] Single Charge
[0082] In the next trial, a non-rotary settling apparatus
comprising a single settling chamber, similar to that of FIG. 2 in
operation, was utilized using the single charge method whereby each
package comprised a single slug of product. The settling device had
settling chambers comprising a substantially oval cross section and
a width of 12 inches. Because of the settling of the product, a
smaller bag was utilized. The smaller bag had a width of 12 inches
and a height of 16.75 inches with about 15.75 inches of useable
space. At the bagmaker the packages were approximately 86% full and
had a product level of about 13.55 inches. Thus, the settling
device decreased the same quantity of product in a bag with the
same width from a product level of 15.25 inches to a product level
of 13.55 inches at the bagmaker. After the shelf simulation, the
packages were approximately 82% full and had a product level of
about 12.85 inches. Thus, the fullness of the package decreased by
only about 4% and resulted in a fuller bag compared to the control.
Further, the product level dropped only about 0.7 inches which is
about half of the drop experienced in the control.
[0083] Multi-Charge
[0084] 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.
[0085] 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.
[0086] With renewed general reference to FIGS. 7-11, and particular
reference to FIGS. 12 & 13, there is depicted an advantageous,
non-limiting gate subassembly, more particularly, a selectively
actuatable gate subassembly 38. The selectively actuatable gate
subassembly 38 generally includes a gate 72, and a gate base 74
operatively supporting the gate 72. The gate base 74 in turn
generally, but not necessarily, includes a upper gate guide or tray
76, united with the gate 72, for reversible sliding retention
within the gate path 66 (FIG. 9), and a lower gate guide, namely, a
track guide 78 for travel upon the track or track segment 68 in
furtherance of operatively supporting the upper gate guide 76/gate
72. While a non-limiting gate "sliding" is indicated, alternate
gating or regulating solutions (i.e., actions) may be suitable
provided.
[0087] 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., FIG. 7, one or more structural
elements, or a support assembly 86 as depicted, retain the
servo-drive 48' in operative proximity to the turret assembly base
34.
[0088] Operatively, and with reference to FIG. 9, as the free end
of the pivot segment 82 is drawn distally from the turret assembly
base 34, clockwise rotation of the servo drive shaft 53 in the
figure as indicated, the link 84 likewise responds so as to result
in a pull (i.e., retraction or gate "opening") motion or action
being imparted to the gate subassembly 38. Contrariwise, subsequent
to product release/egress, the free end of the pivot segment 82 is
drawn proximally towards the turret assembly base 84,
counterclockwise rotation of the servo drive shaft 53 in the
figure, the link 84 likewise responds so as to result in a push
(i.e., gate "closing") motion or action being imparted to the gate
subassembly. It is to be noted that extremely fast gate actuation
is advantageous, as it avoids disturbance of the settled and formed
metered product charge and allows the contents of the discharging
bin to maintain its status or condition as it passes from the bin
to/into the lumen of the bag former/bag forming mandrel.
[0089] 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
before the opening 92 is opened. 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.
[0090] With particular reference now to FIGS. 14 & 15, two
advantageous, non-limiting actuatable turret assemblies 32, 132 are
shown, namely, assemblies intended to produce a "large" (FIG. 14),
and "small" (FIG. 15) settled and formed metered charges. As was
previously referenced, it is not uncommon during product processing
to alter the mass of the metered charge for packaging. As evident
by perusal of the grocer shelves, a variety of package sizes are
available, ranging from single serve multi-packs to "family" or
"party" size bags. Via a modular approach, one actuatable turret
assembly may be readily exchanged for another actuatable turret
assembly, or alternately, an exchange or retrofit of the bins of
given assembly to accommodate variable production objectives is
contemplated. Prior to a presentation of the particulars of the
actuatable turret assemblies of FIGS. 14 & 15, namely,
characteristic details with regard to the product settling/product
settling and forming bins thereof, some general observations are
warranted.
[0091] 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 52
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.
[0092] With continued and general reference to FIG. 14, and
particular reference to FIG. 8, it is to be noted that the
circumferentially arranged bins 40 would appear askew within the
turret assembly body 42. The solid settling and forming bins 40 are
circumferentially arranged within the turret assembly body 42 such
that an offset angle .theta. is defined by an intersection of an
axis of elongation 96 for each solid settling and forming bin 40
and a ray 98 linking an axial centerline of the actuatable turret
assembly (i.e., axial centerline 88 of shaft 52) and a mid-point of
the axis of elongation 96 (i.e., the previously noted axially
extending centerline 94 of the bin 40). Via such arrangement or
configuration, a level or substantially uniform filling/filled
height of metered product charge is generally maintained within the
sleeve as the turret assembly is periodically and/or selectively
actuated (e.g., stopped or abruptly stopped) while rotating from a
metered product filling locus to a settled and formed metered
product discharge locus (i.e., product "mounding," owing to
centrifugal forces/inertial changes, is, if not eliminated, greatly
and advantageously reduced). As should be appreciated in light of
the foregoing, the particulars of the FIG. 14 turret assembly, more
particularly the bins and their arrangement within the assembly,
facilitate the formation of a settled and formed metered product
for subsequent packaging. While it is believed that an offset angle
.theta. of up to about 45.degree. might be sufficient in
furtherance of the stated objective, it is believed that an offset
angle .theta. within the range of about 20-40.degree. is
advantageous.
[0093] With reference again and specifically to FIG. 15, a
plurality of settling/settling forming sleeves 140, characterized
by a substantially circular cross section, are shown
circumferentially arranged about the axis 88 of turret assembly
rotation. The sleeves 140, as shown, generally include an upper
portion or segment characterized by a pronounced reducing sectional
area, more particularly, and advantageously, the ingress portion
190 of the settling/settling forming sleeves 140 includes a
funneled free end, e.g., a metered charge reservoir 189, which
receives at least an initial metered product charge. Subsequent
actuation of the turret assembly 132, e,g., indexed rotation
resulting in successive or sequential travel and stopping of the
initially charged sleeve, transfers at least a portion of the
initial metered charge from the reservoir 189 to a sleeve segment
191 of reduced and generally reducing sectional area which includes
the egress portion 192. Via select actuation of the actuatable
turret assembly 132, and in advance of contents discharge or egress
in furtherance of packaging, a settled and formed metered product
charge results in the reducing diameter portion of the sleeve.
Advantageously, but not necessarily, the sectional area of the
ingress portion (i.e., the metered charge reservoir 189) is within
a range of about 1.25-2.5 times greater than a sectional area of
the settled charge forming and/or egress portion 192.
[0094] With reference now to FIG. 15A, a portion of a further
alternate settling/settling forming sleeve is depicted, namely, a
metered charge reservoir 189'. The reservoir has ingress 190',
fairly characterized as a triangle with rounded apexes. In relation
to its arrangement within the turret assembly, a "nose" of the
reservoir is intended to be directed toward axial centerline 88. A
taper characterizes the transition from the reservoir 189' to the
settled charge portion of the sleeve which includes egress portion
(not shown). The lower sleeve portion of reservoir 189' may be
configured so as to have an oval cross section as should be
appreciated with reference to the lower portion thereof, however,
this portion is not intended to be so. limited.
[0095] With reference now to FIGS. 16 & 17, contemplated
metered product settling systems are depicted in combination with
product transfer means, namely, an improved bag former or bag
forming mandrel 60, 160 (reference also FIG. 18, and generally,
FIGS. 4 & 6). In keeping with the foregoing details, the
combination of FIG. 16 is characterized by the turret assembly of
FIG. 14, whereas the combination of FIG. 17 is characterized by the
turret assembly of FIG. 15, more particularly, the metered charge
receiving bins/sleeves of FIGS. 14 & 15 respectively. As
indicated, the bag forming mandrel cross section generally mimics
the cross section of the egress portion of the product settling
bins, e.g., oblong (FIG. 14), and circular (FIG. 15).
[0096] 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 therethrough. 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.
[0097] Now referring to FIG. 18, there is shown a perspective view
of a further filling apparatus employing a settling chamber and
vacuum relief holes. FIG. 18 is similar to FIG. 6 except that FIG.
18 also illustrates vacuum relief holes 65 in a portion of bag
forming mandrel 60. FIG. 18 illustrates the settling device located
downstream from a weigher 23 and upstream from a product delivery
cylinder 60, wherein the product delivery cylinder 60 comprises a
forming collar 27, and wherein the product delivery cylinder 60
comprises vacuum relief holes 65 located above the forming collar
27. As discussed, in one embodiment a compact slug of product is
formed prior to depositing said product in the product delivery
cylinder 60. As earlier noted, this compact slug creates a vacuum
in the product delivery cylinder 60 as it falls within the product
delivery cylinder 60. This did not occur in the prior art as the
product had sufficient spread to prevent the formation of a vacuum.
Additionally, there was no slide gate 72 to cut off the flow of air
and thus form a vacuum. However, the compact slug does create a
vacuum above the slug within the product delivery cylinder 60 when
the product delivery cylinder 60 is sealed. In one embodiment the
product delivery cylinder 60 is sealed when the upstream gate 72 is
closed. This vacuum decreases the speed with which the slug can
fall. To minimize the created vacuum, vacuum relief holes 65 are
positioned above the forming collar 27 which directs the packaging
material. The vacuum relief holes 65 allow air to be pulled within
the product delivery cylinder 60 and break the vacuum. The vacuum
relief holes 65 may comprise a single hole or may comprise two or
more holes. In one embodiment the holes are sized from about
1/8.sup.th of an inch to about 1/4.sup.th of an inch.
[0098] 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 FIG. 18 does not comprise an
intermediate funnel 99, however other embodiments comprise an
intermediate funnel 99. Such an intermediate piece allows product
to build momentum which can also reduce the likelihood of product
being snagged or caught on the holes 65.
[0099] 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.
[0100] Referring back generally to, for example FIGS. 6-11, another
embodiment of the invention is now discussed. In one embodiment the
discharge chamber 40a is monitored with a sensor. A sensor can
comprise any sensor known in the art. In one embodiment the sensor
comprises a digital or analog sensor. In another embodiment the
sensor comprises a photo eye. As an example, in one embodiment a
sensor is located above the discharge chamber 40a. The sensor can
determine the presence of product in the chamber which would
indicate that not all of the product has exited the discharge
chamber 40a. With such condition detected, a poker can assist in
clearing the remaining product from the discharge chamber 40a. A
poker can comprise any mechanical device which can forcibly remove
product from a chamber. In one embodiment the poker comprises a
mechanical rod which forces the product from the chamber. In
another embodiment the poker comprises a piston which forces the
product from the chamber. In another embodiment the poker comprises
a blast of air, nitrogen, etc. to force the remaining product to
discharge the discharge chamber 204a. It is to be further noted
that a sensing and agitation functionality may be readily
associated with a variety of the contemplated settling,
settling/forming approaches previously or subsequently discussed
and/or contemplated.
[0101] 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.
[0102] With reference now to FIGS. 19-21, attention is particularly
directed to structural departures of select subassemblies,
structures and/or elements of settling apparatus 30 (e.g., that of
FIG. 7). In advance of further particulars, it is to be noted that
a portion of base 34, see e.g., FIG. 7, is absent from the FIG. 19
depiction to facilitate a view of structures/features otherwise not
visible from "above." Moreover, in as much as FIG. 20 is an
underside view of the apparatus of FIG. 19 which, among other
things, illustrates operably positioned bag forming elements of the
bag forming/bag filling station, FIG. 21 depicts a detailed view as
FIG. 20 with the bag forming elements of the bag forming/bag
filling station absent to facilitate a view of structures/features
otherwise not visible.
[0103] 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 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 FIG.
8 or 10 is likewise contemplated.
[0104] While 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.
[0105] 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.,
FIG. 20) for reversibly retaining the bag forming mandrel (FIGS. 20
& 21), and a man way 107 to accommodate settling container
passage to and from the turret assembly body from below are
provided.
[0106] As should be appreciated in connection to a contrasting of
the views of FIGS. 20 & 21, the turret base 34 includes a
passage in the form of aperture or cutout 58, generally provided to
permit/facilitate egress of settled, settled and formed metered
product charge(s) from the settling, settling forming station to
the bag manufacturing and packaging station (see FIG. 5). As
illustrated, a portion of aperture 58 is traversed, traversable or
otherwise overlain in furtherance of a selective discharge of a
settled product charge from a settling container, as by gate 72
(FIG. 19) which, as previously described, is quickly cycled between
first and second operative positions in furtherance of permitting
passage of the settled product charge to, into and through the
underlying bag forming mandrel via the guarded/gated portion of the
aperture. In connection to the arrangement of FIG. 19, the gate is
in an egress blocking position in relation to an aperture 109 of
apertured plate 111 retained upon underside 70 of turret base 34
(FIG. 20, see especially FIG. 21) and is in general alignment with
the bag forming mandrel (FIG. 20).
[0107] Adjacent the gate from above and the apertured plate from
below, and thusly essentially delimited thereby (FIGS. 19 & 21
respectively), is the "remainder" of the aperture (i.e., the
aperture portion not overlain with the gate/apertured plate) which
serves as a man way or access point (FIG. 20 or 21) to facilitate
selective settling chamber change outs or change overs. More
particularly, as should be appreciated with inspection of either
FIG. 20 or 21, passage of a settling cannister through turret base
34, for securement within the assembly body plates is possible via
the man way.
[0108] 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.
[0109] As tube "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 FIG. 16 or 17, with several charges of metered product
introduced to the turret assembly throughout an actuation cycle. By
way of non-limiting example, with the filling and emptying stations
adjacent or neighboring, and no otherwise "empty" settling and
forming chambers, the number of travel "stops" for the turret
assembly will be equal to N-2, i.e., two less than the number of
bins.
[0110] 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.
[0111] 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.
[0112] 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.
* * * * *