U.S. patent application number 14/903127 was filed with the patent office on 2016-12-29 for system and method for the folding, filling and sealing of carton sleeves.
The applicant listed for this patent is SIG TECHNOLOGY AG. Invention is credited to Werner Seiche.
Application Number | 20160376045 14/903127 |
Document ID | / |
Family ID | 50877315 |
Filed Date | 2016-12-29 |
United States Patent
Application |
20160376045 |
Kind Code |
A1 |
Seiche; Werner |
December 29, 2016 |
System and Method for the Folding, Filling and Sealing of Carton
Sleeves
Abstract
A system for the folding, aseptic filling, and aseptic sealing
of packaging agents including a transporting device including a
conveyor belt and cells connected to the conveyor belt for the
transportation of the carton sleeves, a device for folding and
conveying the carton sleeves to the cells of the transporting
device, a device for sterilizing the carton sleeves, a device for
folding and sealing bottom surfaces of the carton sleeves, a device
for filling the carton sleeves with contents, a device for folding
and sealing the gable surfaces of the carton sleeves, and an
aseptic chamber. The cells at least in a partial region of the
system are arranged within the aseptic chamber, while the conveyor
belt is arranged outside the aseptic chamber. A corresponding
method is also illustrated and described.
Inventors: |
Seiche; Werner; (Bergheim,
DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SIG TECHNOLOGY AG |
Neuhausen am Rheinfall |
|
CH |
|
|
Family ID: |
50877315 |
Appl. No.: |
14/903127 |
Filed: |
June 3, 2014 |
PCT Filed: |
June 3, 2014 |
PCT NO: |
PCT/EP2014/061439 |
371 Date: |
January 6, 2016 |
Current U.S.
Class: |
53/426 |
Current CPC
Class: |
B65B 5/065 20130101;
B65B 55/04 20130101; B65B 7/20 20130101; B65B 55/027 20130101; B65B
55/025 20130101; B65B 43/50 20130101; B65B 43/10 20130101; B65B
3/025 20130101 |
International
Class: |
B65B 55/02 20060101
B65B055/02; B65B 43/50 20060101 B65B043/50; B65B 55/04 20060101
B65B055/04; B65B 43/10 20060101 B65B043/10; B65B 7/20 20060101
B65B007/20 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 9, 2013 |
DE |
10 2013 107 223.2 |
Claims
1. A system for folding, aseptic filling, and aseptic sealing of
carton sleeves comprising: a transporting device comprising a
conveyor belt and cells connected to the conveyor belt for
transporting the carton sleeves, a device for folding and conveying
the carton sleeves to the cells of the transporting device, a
device for sterilising the carton sleeves, a device for folding and
sealing the bottom surfaces of the carton sleeves, a device for
filling the carton sleeves with contents, a device for folding and
sealing gable surfaces of the carton sleeves, and an aseptic
chamber, wherein the cells at least in a partial region of the
system are arranged within the aseptic chamber, while the conveyor
belt is arranged outside the aseptic chamber.
2. The system according to claim 1, wherein the aseptic chamber has
a wall with a slit running in a transporting direction.
3. The system according to claim 1, wherein the cells at least in a
region of the device for sterilising the carton sleeves, device for
folding and sealing the bottom surfaces of the carton sleeves,
device for filling the carton sleeves with contents, and the device
for folding and sealing the gable surfaces of the carton sleeves,
are arranged within the aseptic chamber.
4. The system according to claim 1, wherein the system further
comprises a device for removing filled and sealed carton sleeves
from the cells of the transporting device.
5. The system according to claim 1, wherein the conveyor belt and
the cells are arranged in a horizontal plane.
6. The system according to claim 1, wherein the system comprises
devices for pre-folding the bottom surfaces and the gable surfaces
of the carton sleeves.
7. The system according to claim 1, wherein the system further
comprises at least one device for ejecting defective carton sleeves
from the aseptic chamber.
8. The system according to claim 1, wherein the system further
comprises a device for the final fabrication of the carton sleeves,
for attaching flaps of the carton sleeves.
9. The system according to claim 1, wherein the system further
comprises a device for conditioning the cells, for cleaning,
disinfecting and/or drying the cells.
10. The system according to claim 1, wherein the device for filling
the carton sleeves with contents is a carousel.
11. A method for the folding, aseptic filling, and aseptic sealing
of carton sleeves, comprising the following steps: a) folding and
conveying the carton sleeves to cells fastened to a conveyor belt,
b) sterilising the carton sleeves, c) folding and sealing the
bottom surfaces of the carton sleeves, d) filling the carton
sleeves with contents, and e) folding and sealing gable surfaces of
the carton sleeve, wherein the cells at least in a partial region
of the method are guided through an aseptic chamber, while the
conveyor belt is guided outside the aseptic chamber.
12. The method according to claim 11, wherein the cells are guided
through the aseptic chamber at least during the steps b), c), d)
and e).
13. The method according to claim 11, wherein step aa) pre-folding
of the bottom surfaces and/or gable surfaces of the carton sleeves
is carried out after step a) and before step b).
14. The method according to claim 13, wherein step ab) ejection of
defective carton sleeves from the cells of the transporting device
is carried out after step aa) and before step b).
15. The method according to claim 11, wherein step ca) ejection of
defective carton sleeves from the cells of the transporting device
and from the aseptic chamber is carried out after step c) and
before step d).
16. The method according to claim 11, wherein the carton sleeves
are guided during step d) along a circular path.
17. The method according to claim 11, wherein step f) removal of
the filled and sealed carton sleeves from the cells of the
transporting device is carried out after step e).
18. The method according to claim 17, wherein step g) final
fabrication of the carton sleeves and attachment of the flaps of
the carton sleeves is carried out after step f).
19. The method according to claim 17, wherein step h) conditioning
of the cells of the transporting device and cleaning, disinfection
and/or drying of the cells of the transporting device is carried
out after step f).
20. The method according to claim 11, wherein the conveyor belt and
the cells have a constant speed.
21. The method according to claim 11, wherein the conveyor belt and
the cells are guided in a horizontal plane.
22. The method according to claim 11, wherein a continuous inflow
of sterile air takes place within the aseptic chamber.
Description
[0001] The invention relates to a system for the folding, aseptic
filling and aseptic sealing of carton sleeves with: a transporting
device comprising a conveyor belt and with cells connected to the
conveyor belt for transporting the carton sleeves, a device for
folding and conveying the carton sleeves to the cells of the
transporting device, a device for sterilising the carton sleeves, a
device for folding and sealing the bottom surfaces of the carton
sleeves, a device for filling the carton sleeves with contents, a
device for folding and sealing the gable surfaces of the packing
casings, and with an aseptic chamber.
[0002] The invention also relates to a method for the folding,
aseptic filling and aseptic sealing of carton sleeves comprising
the following steps: a) folding and conveying the carton sleeves to
cells fastened to a conveyor belt, b) sterilising the carton
sleeves, c) folding and sealing the bottom surfaces of the carton
sleeves, d) filling the carton sleeves with contents, and e)
folding and sealing the gable surfaces of the carton sleeves.
[0003] In the context of the invention illustrated and described
hereinafter the term "aseptic" is understood to mean in conformity
with the following publications of the VDMA (Verband Deutscher
Maschinen-und Anlagenbau e.V.--German Engineering Federation):
[0004] "Aseptische Verpackungsmaschinen fur die
Nahrungsmittelindustrie: Mindestanforderungen und Rahmenbedingungen
fur einen bestimmungsgema.beta.en Betrieb" (No. 11/2006; February
2006), and [0005] Worksheet "Hygienische Abfullmaschinen der Klasse
V nach VDMA: Prufung von Packmittelentkeimungsvorrichtungen auf
deren Wirkungsgrad" (No. 6/July 2002; revised version July
2008).
[0006] According to the aforementioned publications the term
"aseptic" presupposes in particular a microorganism reduction rate
of the filling and packaging plant of at least four powers of 10
(at least four "log steps"; this corresponds to a reduction of at
least 99.99%). The microorganism reduction rate is determined on
the basis of defined test methods using suitable test
microorganisms. Not every plant with aseptic or sterile properties
known from the prior art can therefore be regarded as "aseptic" in
the meaning of the present invention.
[0007] Packagings can be produced in various ways and from a very
wide range of materials. One widely employed method is to produce a
blank from the packaging material, from which first of all a carton
sleeve is formed by folding and further steps, and finally a
finished packaging is formed. This variant has inter alia the
advantage that the blanks are very flat and can therefore be
stacked in a space-saving manner. In this way the blanks and carton
sleeves can be produced at a site other than that in which the
folding and filling of the carton sleeves takes place. As material
composites are often used, for example a composite consisting of
several thin layers of paper, cardboard, plastic or metal. Such
packagings are widely used in particular in the foodstuffs
industry.
[0008] In the field of packaging technology numerous systems and
methods are known, with which carton sleeves collapsed flat are
folded, sealed on one side, filled with contents, and can then be
completely sealed.
[0009] Conventional non-aseptic systems and methods for the
folding, filling and sealing of composite packagings are known for
example from EP 0 112 605 A2 or from U.S. Pat. No. 3,060,654. In
these systems the carton sleeves are typically transported by
conveyor belts or other transporting means from one station to the
further stations.
[0010] The systems known from EP 0 112 605 A2 or from U.S. Pat. No.
3,060,654 have the disadvantage however that the carton sleeves are
at no point protected against microorganisms. Neither is an active
disinfection or sterilisation provided, nor are provisions made for
maintaining the state achieved by the sterilisation. With these
systems and methods therefore only foodstuffs can be packaged,
which in any case have to be consumed within a short period or in
which a thorough cooling ("cooling chain") has to be ensured, for
example fruit juices. For the filling and packaging of foodstuffs
that have themselves been sterilised in order to increase their
longer shelf life, the procedures known from EP 0 112 605 A2 or
from U.S. Pat. No. 3,060,654 are therefore not suitable.
[0011] An improvement of the shelf life can be achieved by
arrangements in which a sterilisation of the packagings takes place
before the filling operation. In addition the state achieved by the
sterilisation should be maintained. For this purpose the
transporting means with which the packagings are transported--for
example conveyor belts or mandrel wheels--are often completely
enclosed by a chamber. This has the aim of protecting the
packagings from renewed contamination following their
sterilisation. Such a system is known for example from U.S. Pat.
No. 4,590,734, U.S. Pat. No. 5,534,222 or U.S. Pat. No. 4,375,145.
Arranging the transporting means completely within a chamber has
the disadvantage however that such chambers must occupy a very
large volume that has to be completely sterilised or in any case
has to be maintained sterile. A further disadvantage of a complete
enclosing of the transporting means by a chamber is the fact that
the components disposed within the chamber are very difficult to
access for cleaning, maintenance or repair work. In addition it has
also proved disadvantageous that the transporting means cannot be
lubricated in a conventional manner, since conventional lubricants,
e.g. oil or grease, generally do not meet the hygiene requirements
that have to be maintained in the chamber.
[0012] The volume to be sterilised can be reduced if the
transporting means is not enclosed by a chamber along its whole
path. Instead the packagings to be filled can be introduced
together with the transporting means into an aseptic chamber and
after the filling and possibly further steps can be removed again
from this chamber. Such arrangements are therefore an aseptic
"tunnel" rather than an aseptic chamber. Airtight locks are
provided at the inlet and outlet of the tunnel, which are intended
to ensure a sealing of the tunnel--for example by a "curtain" of
sterile air. Such systems and methods are known for example from WO
2011/002383 A1. A problem remains however due to the fact that also
the transporting means--at least in a partial region of the
arrangement--are guided through the aseptic tunnel and in this way
contaminants, for example in the form of lubricants or dust, could
be introduced into the tunnel.
[0013] Against this background the object of the invention is to
elaborate and develop the system mentioned in the introduction and
described in more detail hereinbefore as well as the method
mentioned in the introduction and described in more detail
hereinbefore in such a way that, despite the most economical use of
sterilising agents, an improved hygiene in the filling of composite
packagings is achieved.
[0014] This object is achieved with a system according to the
preamble of Claim 1, in that the cells at least in a partial region
of the system are arranged within the aseptic chamber, while the
conveyor belt is arranged outside the aseptic chamber.
[0015] The invention is based on the idea that only the immediate
surroundings of the carton sleeves to be sterilised have to be
enclosed by the aseptic chamber. In particular only the cells that
carry and guide the carton sleeves should be arranged within the
aseptic chamber, while the conveyor belt, to which the cells are
connected, is arranged outside the aseptic chamber. Cells are
understood to mean any elements that are suitable for carrying
carton sleeves, for example clamping elements, frames, containers
or the like. A conveyor belt is understood to mean any means that
is suitable for moving the cells, for example belts, chains or the
like. Although the solution according to the invention is
structurally somewhat more complicated, it nevertheless has the
considerable advantage that the conveyor belt cannot introduce any
contaminants into the aseptic chamber. In addition the volume of
the aseptic chamber can be smaller if the conveyor belt runs
outside the aseptic chamber. The external arrangement of the
conveyor belt and the small chamber volume enable, despite a more
sparing use of sterilising agents (e.g. hydrogen peroxide), a very
high degree of cleanliness to be achieved within the aseptic
chamber. As a result the system is particularly suitable for the
filling of very sensitive contents such as foodstuffs. An aseptic
chamber is understood to mean a space that is suitable for
screening a specific volume, in particular aseptic air, against an
external environment, in particular non-aseptic air. Sterile, i.e.
largely microorganism-free conditions, can be achieved for example
by the system described in WO 2010/142278 A1 and also by the method
described therein.
[0016] According to one arrangement of the invention it is
envisaged that the aseptic chamber comprises a wall with a slit
running in the transportation direction. This arrangement provides
a structurally particularly simple possibility of enabling the
cells to run within the aseptic chamber even though the conveyor
belt runs outside the chamber. In fact, the cells can be guided for
example by a thin holding arm that extends outwardly from the
conveyor belt through the slit into the interior of the aseptic
chamber, where it is there connected to the cells. Preferably the
slit is closed tight with a seal.
[0017] In a further development of the invention it is envisaged
that the cells, at least in the region of the device for
sterilising the carton sleeves, the device for folding and sealing
the bottom surfaces of the carton sleeves, the device for filling
the carton sleeves with contents and the device for folding and
sealing the gable surfaces of the carton sleeves, are arranged
within the aseptic chamber. Preferably the cells during the
aforementioned steps and between the aforementioned steps are
arranged the whole time within the same aseptic chamber. Since the
cells are arranged within the aseptic chamber only in the
hygienically particularly critical steps of sterilisation, bottom
folding/sealing, filling and gable folding/sealing, the volume to
be maintained sterile can be further reduced. The cells are thus
introduced before or during the sterilisation into the aseptic
chamber, and during or after the gable folding/sealing are
withdrawn again from the aseptic chamber. This arrangement can also
be described as an aseptic "tunnel". The conveyor belt runs all the
time outside the aseptic chamber. Preferably the inlet and outlet
of the aseptic chamber are sealed. This can be achieved for example
by a "curtain" of sterile air.
[0018] A further arrangement of the invention envisages that the
system comprises a device for removing the filled and sealed carton
sleeves from the cells of the transporting device. The filled and
sealed carton sleeves have to be removed from the cells of the
transporting device so that the cells can receive new carton
sleeves that have not yet been filled. This can be effected for
example by gripping arms that grasp the carton sleeves at the seams
that are formed during the sealing of the gable surfaces and bottom
surfaces ("fin seams"). To this end the gripping arms preferably
follow for a short time the direction and speed of the conveyor
belt.
[0019] According to a further development of the invention it is
envisaged that the conveyor belt and the cells are arranged in a
horizontal plane. By means of this development it is ensured that
the carton sleeves are guided in a horizontal plane. This has the
advantage that the carton sleeves and where appropriate their
contents are not subjected to vertical accelerations. In addition
the arrangement in a horizontal plane has the advantage that all
regions of the unit are equally easily accessible in order to carry
out for example cleaning, maintenance or repair work.
[0020] In a further arrangement of the invention it is envisaged
that the system comprises devices for the pre-folding of the bottom
surfaces and gable surfaces of the carton sleeves. In this
connection those fold lines are formed that are located between
adjacent bottom surfaces and adjacent gable surfaces, between
bottom surfaces and adjacent side surfaces, and between gable
surfaces and adjacent side surfaces. This procedure has the
advantage of making the fold lines more flexible, so that the
subsequent folding can take place more quickly, more simply and
more precisely.
[0021] The reliability of the arrangement can be increased if,
according to a further development of the invention, it is
envisaged that the system comprises at least one device for
ejecting defective carton sleeves from the cells and--in so far as
the device is arranged in the region of the aseptic chamber--from
the aseptic chamber itself. Defective carton sleeves can cause the
system to stop. For example, a carton sleeve that is not folded
properly could fall out of the cells. In addition an unsatisfactory
folding could result in an insufficiently tight sealing of the
bottom or gable. A carton sleeve that has fallen out of the cell as
well as a non-airtight packaging sealing could mean that the
contents do not remain in the carton sleeve during the filling, but
contaminate the system, necessitating a cleaning and disinfection
of the system that often takes several hours. This can be avoided
by devices by which defective carton sleeves are sorted out and
ejected. To this end sensors, in particular optical sensors, are
preferably provided that determine the state of the carton sleeves.
Since it would be a complicated and expensive procedure to replace
the defective carton sleeves by non-defective carton sleeves, it is
instead proposed to suspend or at any rate temporarily stop the
filling and the further processing steps in the region of that cell
that contains the defective carton sleeve or no carton sleeve at
all.
[0022] According to a further arrangement of the invention it is
proposed that the system comprises a device for the final
fabrication of the carton sleeves, in particular for attaching the
flaps or tabs of the carton sleeves. The final fabrication brings
the already filled and closed carton sleeves into their
ready-for-sale shape. In particular the projecting regions of
packaging material ("flaps") are attached during the final
fabrication. A fastening of the flaps can take place for example by
treatment with hot air or adhesive. Preferably the carton sleeves
in the region of the final fabrication have already been removed
from the cells.
[0023] A further improvement in hygiene can be achieved according
to a further development of the invention if the system comprises a
device for the conditioning of the cells, in particular for
cleaning, disinfecting and/or drying the cells. Preferably the
conditioning device is arranged between the device for removing the
carton sleeves and the device for feeding the carton sleeves. This
has the advantage that the cells in this region do not carry any
carton sleeves, so that the cleaning, disinfection and drying of
the cells can be carried out particularly thoroughly.
[0024] According to a further arrangement of the invention it is
envisaged that the device for filling the carton sleeves with
contents is a carousel-type device. The advantage of a carousel for
the filling is above all a more compact design and construction of
the system, since also the region in which the conveyor belt
reverses direction is utilised for filling the carton sleeves.
Preferably the carousel has co-rotating filling outlets.
[0025] In a method according to the preamble of Claim 11 the
afore-described object is achieved in that the cells at least in a
partial region of the method are guided through an aseptic chamber,
while the conveyor belt is guided outside the aseptic chamber.
[0026] As was already explained for the system, an advantage of
having the conveyor belt outside the aseptic chamber is a more
compact shape of the aseptic chamber and also an improved
hygiene.
[0027] In a further modification of the method it is proposed that
the cells are guided at least during the steps b), c), d) and e)
through the aseptic chamber. A restriction of the guidance of the
cells in the aseptic chamber to the hygienically particularly
critical steps of sterilisation, bottom folding/sealing, filling
and gable folding/sealing means that the volume to be maintained
sterile can be reduced. The cells are for this purpose introduced
before or during the sterilisation into the aseptic chamber and are
removed again from the aseptic chamber during or after the gable
folding/sealing.
[0028] A further teaching of the invention envisages that after
step a) and before step b) the following step is carried out: aa)
pre-folding of the bottom surfaces and/or of the gable surfaces of
the carton sleeves. In this connection those fold lines are formed
that are located respectively between adjacent bottom surfaces and
adjacent gable surfaces, between bottom surfaces and adjacent side
surfaces, and between gable surfaces and adjacent side surfaces.
The purpose of this procedure is to make the fold lines more
flexible, so that the subsequent folding can be carried out more
quickly, more simply and more precisely. It may be envisaged that
the bottom surfaces as well as the gable surfaces are pre-folded
before step b) (sterilisation). This has the advantage that dust
produced in the pre-folding does not endanger the result of the
sterilisation. It is also sufficient however if the bottom surfaces
are pre-folded before step c) and if the gable surfaces are
pre-folded before step e).
[0029] According to a further modification of the invention it is
envisaged that after step a), in particular after step aa) and
before step b), the following step is carried out: ab) ejection of
defective carton sleeves from the cells of the transportation
device. Alternatively or in addition it is envisaged that after
step c) and before step d) the following step is carried out: ca)
ejection of defective carton sleeves from the cells of the
transporting device and from the aseptic chamber. An ejection of
defective carton sleeves has in particular the already described
advantage that the system operates more reliably and as far as
possible without interruptions.
[0030] According to a further modification of the invention it is
envisaged that the carton sleeves are guided during step d) along a
circular path. The guidance of the carton sleeves along the
circular path has the advantage of a more compact design and
construction of the system. In order to compensate the centrifugal
forces produced by the rotation of the filling device, it may be
envisaged that the carton sleeves are guided in an inclined manner
in the region of the filling device.
[0031] A further modification of the invention envisages that after
step e) the following step is carried out: f) removal of the filled
and sealed carton sleeves from the cells of the transportation
device. The removal of the carton sleeves in a system with a
continuously circulating conveyor belt is necessary in order to be
able to reload the cells with carton sleeves.
[0032] According to a further arrangement of the invention it is
proposed that after step f) the following step is carried out: g)
final fabrication of the carton sleeves, in particular attachment
of the flaps of the carton sleeves. By means of the final
fabrication the carton sleeves are brought into a ready-for-sale
state.
[0033] According to a further modification of the invention it is
envisaged that after step f) the following step is carried: h)
conditioning of the cells of the transporting device, in particular
cleaning, disinfection and/or drying the cells of the transporting
device. As a result of the conditioning of the cells the hygiene of
the method can be improved further. Preferably the steps g) (final
fabrication) and h) (conditioning) can take place simultaneously,
since the carton sleeves in the final fabrication are already no
longer contained in the cells that are to be conditioned.
[0034] A particularly more uniform and thus less wear-affected
operation can be achieved if, according to a further modification
of the method, the conveyor belt and the cells have a constant
speed. Alternatively it may be envisaged that the speed of the
conveyor belt is changed, the speed always being greater than zero.
For example, a cyclical variation of the speed, in particular a
fluctuation about a mean value, may be envisaged. The conveyor belt
should thus at no time be stopped, as would be the case in an
intermittent operation. A cyclical variation of the speed of the
conveyor belt permits an optimisation of specific process steps,
for example the introduction of the carton sleeves into the
cells.
[0035] According to a further modification of the method it is
envisaged that the conveyor belt and the cells are guided in a
horizontal plane. As has already been described hereinbefore in
connection with the system, an advantage of the arrangement in a
horizontal plane is the avoidance of vertical accelerations as well
as a good accessibility to the carton sleeves and in addition a
simpler construction of the system.
[0036] Finally, according to a further arrangement of the method it
is proposed that a continuous inflow of sterile air takes place
within the aseptic chamber. The aseptic chamber cannot be closed in
an absolutely airtight manner during operation, despite seals and
airlocks. In order to avoid non-sterile air from the surroundings
penetrating the aseptic chamber, a continuous feed of sterile air
into the aseptic chamber is proposed. As the result sterile air
escapes in small amounts from the not completely airtight aseptic
chamber. In this way the inflow of non-sterile air into the aseptic
chamber is prevented.
[0037] The invention is described in more detail hereinafter with
the aid of a drawing simply illustrating a preferred exemplary
embodiment. In the drawing:
[0038] FIG. 1A shows a blank known from the prior art for folding a
carton sleeve,
[0039] FIG. 1B shows a carton sleeve known from the prior art,
formed from the blank illustrated in FIG. 1A, in the flat folded
state,
[0040] FIG. 1C shows the carton sleeve of FIG. 1B in the folded
state,
[0041] FIG. 1D shows the carton sleeve of FIG. 1C in the filled and
sealed state,
[0042] FIG. 1E shows the carton sleeve of FIG. 1C in the filled,
sealed and ready-for-sale state,
[0043] FIG. 2 shows a system according to the invention for the
folding, filling and sealing of carton sleeves, in a plan view,
[0044] FIG. 3 shows part of the system illustrated in FIG. 2 in
cross-section along the cutting plane III-III identified in FIG. 2,
and
[0045] FIG. 4 shows the course of a method according to the
invention for the folding, filling and sealing of carton sleeves,
in a schematic view.
[0046] FIG. 1A shows a blank known from the prior art, from which a
carton sleeve can be formed. The blank 1 can comprise a plurality
of plies or layers of different materials, for example paper,
cardboard, plastic or metal, in particular aluminium. The blank 1
has a plurality of fold lines 2, which are intended to facilitate
the folding of the blank 1 and subdivide the blank 1 into several
surfaces. The blank 1 can be subdivided into a first side surface
3, a second side surface 4, a front surface 5, a rear surface 6, a
sealing surface 7, bottom surfaces 8 and gable surfaces 9. A carton
sleeve can be formed from the blank 1 by folding the blank 1 in
such a way that the sealing surface 7 can be joined, in particular
welded, to the front surface 5.
[0047] FIG. 1B shows a carton sleeve 10 known from the prior art in
the flat folded state. The regions of the carton sleeve already
described in connection with FIG. 1A are provided with
corresponding reference numerals in FIG. 1B. The carton sleeve 10
is formed from the blank 1 illustrated in FIG. 1A. For this purpose
the blank 1 was folded in such a way that the sealing surface 7 and
the front surface 5 are arranged overlapping, so that the two
surfaces can be welded to one another over their whole area. A
longitudinal seam 11 is thereby formed. In FIG. 1B the carton
sleeve 10 is illustrated in a flat folded up state. In this state a
side surface 4 (covered in FIG. 1B) lies underneath the front
surface 5, while the other side surface 3 lies on the rear surface
6 (covered in FIG. 1B). In the flat folded up state a plurality of
packing casings 10 can be stacked in a particularly space-saving
manner. The carton sleeves 10 are therefore often stacked at the
site of production and transported stacked to the filling site.
Only there are the carton sleeves unstacked and folded, so that
they can be filled with contents, for example with foodstuffs.
[0048] FIG. 1C shows the carton sleeve 10 of FIG. 1B in the folded
state. Here too the regions of the carton sleeve already described
in connection with FIG. 1A or FIG. 1B are provided with
corresponding reference numerals. A folded state is understood to
be a configuration in which an angle of about 90.degree. is formed
between the two respectively adjacent surfaces 3, 4, 5, 6, so that
the carton sleeve 10 has, depending on the shape of these surfaces,
a square or rectangular cross-section. Corresponding to this the
opposite side surfaces 3, 4 are arranged parallel to one another.
The same also applies to the front surface 5 and the rear surface
6.
[0049] FIGS. 1D and 1E show the carton sleeve 10 of FIG. 1C in the
filled and sealed state. In the region of the bottom surfaces 8 and
in the region of the gable surfaces 9 a fin seam 12 is formed after
the sealing operation. In addition, in the edge regions of the
bottom surfaces 8 and of the gable surfaces 9 projecting regions of
excess material are formed, which are also termed "flaps" 13. In
FIG. 1D the fin seams 12 and the flaps 13 project upwards and
outwards respectively. In FIG. 1E the fin seams 12 and also the
flaps 13 have been attached, for example by bonding. The flaps 13
formed by the gable surfaces 9, i.e. the upper flaps, are attached
to the side surfaces 3, 4, while the flaps 13 formed by the bottom
surfaces, i.e. the lower flaps, are attached to the lower side of
the carton sleeve 10. (Note: FIG. 1E is also appropriately
adapted). In FIG. 1E the carton sleeve 10 is therefore shown in a
ready-for-sale state.
[0050] FIG. 2 shows a system 14 according to the invention for the
folding, filling and sealing of carton sleeves 10 in a plan view.
The system 14 includes first of all a transporting device, which in
the preferred exemplary embodiment illustrated in FIG. 2 is a
circulating, endless conveyor belt 15 with cells 16 fastened
thereto for accommodating and transporting the carton sleeves 10.
The conveyor belt 15 and the cells 16 are preferably arranged in a
horizontal plane. The system 14 also includes a device 17 for
folding and conveying the carton sleeves 10 to the transporting
device. This device 17 includes a separating device 18 for
individually separating and preparing the flat carton sleeves 10
and a transfer unit 19. The separating device 18 can for example be
a magazine, from which the flat carton sleeves 10 are expelled
individually. The transfer unit 19 can for example be designed as a
rotating drum with suction elements for suctioning the carton
sleeves 10. The device 17 is also termed an "infeed" device.
[0051] After the pre-folding (not illustrated in FIG. 2) a first
device 20 is provided for ejecting defective carton sleeves 10 from
the cells 16 of the transporting device. In order to detect damaged
carton sleeves 10 the device 20 can comprise a sensor. In addition
the system 14 can comprise a device 21 for sterilising the carton
sleeves 10. In this connection this may be a device known from WO
2010/142278 A1. Following this a device 22 for folding and sealing
the bottom surfaces 8 of the carton sleeves 10 is provided as part
of the system 14, which in turn is followed by a second device 24
for ejecting defective carton sleeves 10. The sealing of the bottom
surfaces 8 can take place by activating the packaging material with
hot air or by suitable welding or bonding methods. The devices 20,
21, 22 are arranged in a region in which the cells 16 of the
transporting device are guided along a straight line.
[0052] In addition the system 14 illustrated in FIG. 2 comprises a
device 23 for filling the carton sleeves 10 with contents. This
device 23 is designed as a carousel, so that the carton sleeves 10
are also guided in the region of this device 23 along a circular
path. After the filling operation the carton sleeve 10 are conveyed
to a device 24 for folding and sealing the gable surfaces 9 of the
carton sleeves 10. The sealing of the gable surfaces 9 can also
take place by an activation of the packaging material with hot air
or by suitable welding or bonding methods. The system 14 includes
in addition a device 25 for removing the now filled and sealed
carton sleeves 10 from the cells 16 of the transporting device.
This device 25 can for example include gripping arms and a conveyor
belt, so as to move the carton sleeves 10 removed from the
transporting device away from the system 14. The device 25 is also
termed an "outfeed" device. Furthermore a device 26 is provided for
the final fabrication of the carton sleeves 10, by which is
understood for example the attachment and bonding of the projecting
"flaps" 13 of the carton sleeves 10. Finally a device 27 is
provided for conditioning the cells 16. This device 27 is arranged
between the "outfeed" 25 and the "infeed" 17 and is therefore
disposed in a region in which the cells 16 do not carry any carton
sleeves 10. In this way the cells 16 can be conditioned
particularly well by the device 27, by which is understood for
example a cleaning, disinfection or drying of the cells 16.
[0053] The system 14 illustrated in FIG. 2 is characterised by a
specially designed aseptic chamber 28. The cells 16 of the
transporting device are at least in the region of the devices 21,
22, 23 and 24 arranged within the aseptic chamber 28. In this way
the level of asepsis achieved in the device 21 by the sterilisation
can be largely maintained in the following devices 22, 23 and 24.
The conveyor belt 15 on the other hand always runs outside the
aseptic chamber 28.
[0054] FIG. 3 shows part of the system 14 illustrated in FIG. 2 in
cross-section along the sectional plane identified in FIG. 2. In
the selected view this is a cross-section through the aseptic
chamber 28. The aseptic chamber 28 has a wall 29, which encloses
the cells 16 of the transporting device. The cells 16 comprise a
rear wall 30, side walls 31 and--not shown in FIG. 3--spring
elements. The spring elements are produced from an elastic
material, for example spring steel or a flexible plastic, and serve
to tightly hold or clamp the carton sleeves 10 in the cells 16. The
size of the cell 16 is adapted to the size of the carton sleeve 10
in such a way that the bottom surfaces 8 as well as the gable
surfaces 9 of the carton sleeves 10 project respectively downwardly
and upwardly from the cell 16. This facilitates access to the
bottom and gable surfaces 8, 9, so that these can easily be folded
and sealed while they are held by the cells 16.
[0055] The rear wall 30 of the cell 16 illustrated in FIG. 2 is
connected via a holding arm 32 and a fastening plate 33 to the
conveyor belt 15. The holding arm 32 projects from the aseptic
chamber 28 through a slit 34, this slit 34 being tightly sealed by
a seal 35. In other words, the cell 16 is therefore arranged within
the aseptic chamber 28 and enclosed by the wall 29, while the
conveyor belt 15 is arranged outside the aseptic chamber 28.
[0056] Finally, the course of a method according to the invention
for the folding, filling and sealing of carton sleeves 10 is shown
in a schematic representation in FIG. 4. The stations of the system
14 already described in connection with FIG. 2 are provided with
corresponding reference numerals in FIG. 4.
[0057] First of all an inward transfer of the carton sleeves 10
into the cells 16 of the transporting device takes place. This is
carried out by the device 17. In the device 20 the defective carton
sleeves 10 are then ejected from the transporting device while the
regular and undamaged carton sleeves 10 enter the sterilisation
device 21 and also the aseptic chamber 28. Following the
sterilisation the folding and sealing of the bottom surfaces 8
takes place in the device 22. This is then followed by a renewed
ejection of the defective carton sleeves 10, wherein this time the
carton sleeves not only have to be ejected from the transporting
device but also from the aseptic chamber 28. In the device 23 the
carton sleeves 10 are then filled with contents, before the gable
surfaces 9 are folded together and sealed in the device 24.
Following this the filled and sealed carton sleeves 10 are ejected
by the device 25 from the transporting device as well as from the
aseptic chamber 28. A final fabrication of the carton sleeves 10
takes place in the device 26. Before the cells 16 receive the next
carton sleeve 10 a conditioning is carried out, thus for example a
cleaning of the cells 16 in the device 27. The final fabrication of
the carton sleeves 10 in the device 26 and the conditioning of the
cells 16 in the device 27 can take place simultaneously.
LIST OF REFERENCE NUMERALS
[0058] 1: Blank [0059] 2: Fold line [0060] 3, 4: Side surfaces
[0061] 5: Front surface [0062] 6: Rear surface [0063] 7: Sealing
surface [0064] 8: Bottom surface [0065] 9: Gable surface [0066] 10:
Carton sleeve [0067] 11: Longitudinal seam [0068] 12: Fin seam
[0069] 13: Flaps [0070] 14: System for the folding, filling and
sealing of carton sleeves [0071] 15: Conveyor belt [0072] 16: Cells
[0073] 17: Device for the folding and conveying of carton sleeves
[0074] 18: Separating device [0075] 19: Transfer unit [0076] 20:
Device for ejecting defective carton sleeves [0077] 21: Device for
sterilising carton sleeves [0078] 22: Device for folding and
sealing the bottom surfaces of the carton sleeves [0079] 23: Device
for filling carton sleeves [0080] 24: Device for folding and
sealing the gable surfaces of the carton sleeves [0081] 25: Device
for removing carton sleeves from the transporting device [0082] 26:
Device for the final fabrication of carton sleeves [0083] 27:
Device for conditioning the cells of the transporting device [0084]
28: Aseptic chamber [0085] 29: Wall of the aseptic chamber [0086]
30: Rear wall of the cell [0087] 31: Side wall of the cell [0088]
32: Holding arm [0089] 33: Fastening plate [0090] 34: Slit [0091]
35: Seal
* * * * *