Description:TECHNICAL FIELD
[0001] The present invention generally relates to a food packaging machine and method thereof.
BACKGROUND
[0002] Vertical form, fill, and seal (VFFS) packaging machines are commonly used in the snack food industry for forming, filling and sealing bags of nuts, chips, crackers and other products. Such packaging machines take a packaging film from a sheet roll and form the film into a vertical tube around a product delivery cylinder. However, dust, moisture, or other debris, such as powder stored in the container, may adhere to the adhesive coating, and the adhesive coating may subsequently lose the ability, or the strength of the resealability will be substantially reduced, to engage the container. One disadvantage of these packages is that the resulting filled package is not rigid enough to allow the stacking of one package on top of another in a display.
[0003] The flexible packages that have a resealable or reclosure feature are sometimes difficult to manufacture on equipment that is widely available. For example, some flexible film packages may require specialized die assemblies or heat seal bars to produce the seals, package openings, and other package features related to the reclose feature. Another drawback with the manufacture of some flexible packages is the common requirement of precisely calibrated manufacturing equipment. For example, packages and processes that employ a pattern-applied adhesive may require specialized equipment that may need to be properly calibrated. As another example, some laminate structures may employ partial depth die cuts from both the interior and exterior surface of the laminate structure, which increases the complexity of the equipment. These processes also may require very precise registration of the package elements to ensure the consumer is able to easily and reliably open the package and also to ensure proper closure or sealing of the flexible package. In addition, previous package designs also tend to require additional package material to accommodate the equipment and various manufacture and consumer specifications. This extra film or other material (such as a label backing) often resulted in costly waste, which increases the cost of the packages.
[0004] As a result of the many shortfalls of the prior art, there is a need for a food packaging machine and method thereof which overcomes the aforementioned problems.
SUMMARY
[0005] Embodiments of the present disclosure present technological improvements as solutions to one or more of the above-mentioned technical problems.
[0006] Before the present subject matter relating to a food packaging machine and method thereof, it is to be understood that this application is not limited to the particular system described, as there can be multiple possible embodiments which are not expressly illustrated in the present disclosure. It is also to be understood that the terminology used in the description is for the purpose of describing the implementations or versions or embodiments only and is not intended to limit the scope of the present subject matter.
[0007] This summary is provided to introduce aspects related to a food packaging machine and method thereof. This summary is not intended to identify essential features of the claimed subject matter nor is it intended for use in determining or limiting the scope of the present subject matter.
[0008] In an embodiment, a food packaging machine, the machine includes a flexible film, a sealing station and a knife blade. The flexible film having two opposing edge portions forming a longitudinal seal extending from a first end seal to a second end seal. The sealing station further includes a first and a second engagement bars-oriented transverse to the transport path. The knife blade is configured to cut away a portion of the flexible film to separate from a remainder of the flexible film to form, at least in part, a portion of the tack free gripping portion.
[0009] In an embodiment, a method for food packaging machine, the method includes the step of defining an opening to the contents cavity upon initial opening in a flexible film. The method includes the step of transversing the flexible film towards a sealing station. The method includes the step of sealing the flexible film with food contents. The method includes the step of disposing the sealed/ packed food in a container.
BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS
[0010] The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the drawings to reference features and modules.
[0011] Figure 1 illustrates a plan view of a section of a series of flexible film package blanks.
[0012] Figure 2 illustrates a packaging machine configured to produce the flexible, stackable container.
[0013] Figure 3 is a schematic illustration of a package having a closure assembly in accordance with an embodiment of the disclosure.
[0014] It should be appreciated by those skilled in the art that any block diagrams herein represent conceptual views of illustrative methods embodying the principles of the present disclosure. Similarly, it will be appreciated that any flow charts, flow diagrams, and the like represent various processes which may be substantially represented in computer readable medium and so executed by a computer or processor, whether or not such computer or processor is explicitly shown.
DETAILED DESCRIPTION
[0015] The invention will now be described with reference to the accompanying drawings and embodiments which do not limit the scope and ambit of the invention. The description provided is purely by way of example and illustration.
[0016] One or more embodiments are provided so as to thoroughly and fully convey the scope of the present invention to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present invention. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present invention. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
[0017] The terminology used, in the present invention, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present invention. As used in the present invention, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present invention is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
[0018] In an embodiment, a food packaging machine, the machine includes a flexible film, a sealing station and a knife blade. The flexible film having two opposing edge portions forming a longitudinal seal extending from a first end seal to a second end seal. The sealing station further includes a first and a second engagement bars-oriented transverse to the transport path. The knife blade is configured to cut away a portion of the flexible film to separate from a remainder of the flexible film to form, at least in part, a portion of the tack free gripping portion.
[0019] In another implementation, the feeding mechanism for flexible film comprises a roll of flexible film material and a motorized unwinding system configured to control the advancement of the flexible film.
[0020] In another implementation, the sealing station includes a heating element for applying heat to the flexible film, facilitating the sealing process; and a pressure mechanism configured to apply pressure to the flexible film, ensuring a secure and effective seal around the food product.
[0021] In another implementation, the knife blade assembly includes a movable knife blade, a control system configured to regulate the movement of the knife blade, ensuring precise cutting of the sealed flexible film and a waste disposal system configured to collect and remove excess film material resulting from the cutting process.
[0022] In another implementation, an adhesive disposed on one side of flexible film and the reclosable flap of the second sheet such that the reclosable flap is releasably attached to the flexible film.
[0023] In another implementation, the flexible film comprises a multi-layer material, providing enhanced durability, flexibility, and barrier properties for preserving the freshness and quality of the packaged food products.
[0024] In an embodiment, a method for food packaging machine, the method includes the step of defining an opening to the contents cavity upon initial opening in a flexible film. The method includes the step of transversing the flexible film towards a sealing station. The method includes the step of sealing the flexible film with food contents. The method includes the step of disposing the sealed/ packed food in a container.
[0025] In another implementation, the method includes the step of removing or separating the excess flexible film from the cut, sealed package using a knife blade.
[0026] In another implementation, the method includes the step of extending beyond the first end seal to form a laminate pull tab of the elongated closure layer and the flexible film.
[0027] In another implementation, the pressure sensitive adhesive having a peel force less than an end seal peel force.
[0028] Figure 1 illustrates a plan view of a section of a series of flexible film package blanks.
[0029] In an embodiment, a series of flexible package blanks 10 are shown. A continuous flexible film web 12 has a width and a longitudinal axis along the length of the packages formed therefrom. An elongated or continuous closure layer 14 is continuously applied along the longitudinal length of the package blanks to a portion of the width of the continuous flexible film web 12. For example, the continuous closure layer 14 may be applied substantially along the entire longitudinal axis of the continuous flexible film web 12. A pressure sensitive adhesive 18 is disposed between the continuous flexible film web 12 and the continuous closure layer 14. The pressure sensitive adhesive 18, like the continuous closure layer 14, is continuously applied between the continuous flexible film web 12 and the continuous closure layer 14 so that there are no areas between the two layers without the pressure sensitive adhesive. A score 16 is formed in the continuous flexible film web 12 and will subsequently form a package opening when the continuous closure layer 14 is pulled away from the continuous flexible film web 12.
[0030] In one example, the score line includes an opening, such as a teardrop-shaped opening, adjacent the first package end that extends to a single score line running generally longitudinally toward the second package end, which provides an opening to the package interior. In another configuration, the score includes an opening, such as a teardrop-shaped opening, adjacent the first package end and two generally straight portions extending therefrom and extending longitudinally down the package. The generally straight portions may be parallel and may be spaced about 5 mm or less apart. The score also may include a narrow arcuate section joining the two generally straight portions adjacent the second end. In one configuration, the label extends beyond the first end seal and at least to the leading edge of the package.
[0031] In an embodiment, the tab score 15 includes a series of arcuate die cuts that result in an arcuate portion of the flexible film 38 separating from the remainder of the continuous flexible web 12. In addition, as discussed in more detail below, the tab score 15 includes a series of score lines so that the longitudinal registration of the continuous flexible film web does not need to be precisely calibrated with the seal bars and separation or knife cuts that form or separate the individual film packages 5 from the series of flexible packages 10. The score line 16 having a bulbous or arcuate section 30 extending into two generally elongated, straight sections 32 that terminate at ends 34, which have hooks in the illustrated configuration. The hooks or J-shaped ends help prevent the score 16 from propagating or continuing to tear the flexible film 12. In addition, depending on the product contained within flexible film 12, the arcuate section 30 of the score 16 permits the package opening to be sufficiently large enough to easily serve and access a substantial portion of the product contained therein.
[0032] In an embodiment, stiffeners are added to flexible film 12, to increase the stiffness of the film. These stiffeners may be in addition to the stiffness adjustments that can be made by changing the thicknesses or densities of the previously mentioned laminate layers. These stiffeners can be added as a component of the extruded film or as a separate layer.
[0033] Figure 2 illustrates a packaging machine configured to produce the flexible, stackable container.
[0034] In an embodiment, the machine 100 may be of the type known to those skilled in the art as a vertical form, fill and seal (VFFS) packaging machine. The packaging machine 100 is capable of continuously forming a series of containers 10 from a web of film that may be fed into the packaging machine 100. In most applications, the web is pre-printed with graphics relating to the product to be disposed within the container, such as product information, manufacturer information, nutritional information, bar coding and the like. The web of packaging film is provided on a film roll 102 rotatably mounted on a shaft at the inlet end of the packaging machine 100. The packaging film is typically fed into the packaging machine 100 over a series of dancer rolls and guide rolls 104, one or more of which may be driven to direct the web of film in the direction of the transport path of the packaging machine 100.
[0035] In an embodiment, the treatments performed at the pre-processing station 106 may include mechanical or laser perforating, scoring or punching or other appropriate processing for defining the flap 22 that may be disposed under the lid fitment 14, application of a peel or pull tab 24 to the flap 22, code dating, applying RFID chips, or any other appropriate pre-processing of the film that should occur at the time the containers 10 are formed. In some embodiments of the packaging machine 100, it may even be desirable to attach the lid fitments 14 at the pre-processing station 106 prior to forming the film into the flexible packages 12. In other embodiments, the pre-processing station 106 may be omitted such that no pre-processing occurs as the sheet of film is unrolled from the film roll 102.
[0036] Further on, after the film is formed around the forming tube 112, the web of film moves along the transport path to a combination edge seal/corner seal station 118 to form corner seals 58-62 at the corners 52-56 between the sides 42-48 of the package 12, and to create a combination edge seal and corner seal 64 at the lateral edges 32, 34 of the web of film. In one implementation of the packaging machine 100, the corner seals 56-64 may be formed at the station 118 by providing flat forming plates projecting outwardly from the square or rectangular forming tube 112.
[0037] The seals 70, 72 of the adjacent packages 12 are formed, a gas flushing operation may be performed if necessary to place a desired atmosphere in the package 12. Of course, gas flushing may occur continuously or at other times as the package 12 is formed and filled. Once the package 12 is sealed, it may be detached from the web of film in preparation for any final processing steps and containerization. After separation, the package 12 may drop or otherwise be transported to a conveyor 138 for delivery to the remaining processing stations. The conveyor 138 may include a timing belt or timing chain 140 for maintaining proper spacing between the packages 12 and alignment with the remaining processing stations.
[0038] Figure 3 is a schematic illustration of a package having a closure assembly in accordance with an embodiment of the disclosure.
[0039] In an embodiment, the closure assembly may include a locking mechanism that includes a locking feature that is received into a receiving feature when the lid member is in a fully open position. The locking feature may be a protrusion that upwardly extends from the lid member, and the protrusion may have a rectangular, square, round, or any other suitable cross-sectional shape or combination of cross-sectional shapes. Each of the pair of receiver protrusions may have a rectangular, square, round, or any other suitable cross-sectional shape or combination of cross-sectional shapes. The width of the receiving slot is approximately equal to or slightly less than a corresponding width of the locking feature such that the locking feature (and, consequently, the entire lid member is retained in the receiving slot when the lid member is pivoted about the hinge portion such that the lid member is in a fully open position. An undercut may be formed in the pair of receiver protrusions and/or in the locking feature to positively lock the locking feature within the receiving slot. The locking mechanism may be formed in a thermoforming operation using one of the molds.
[0040] The foregoing description of the invention has been set merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the substance of the invention may occur to person skilled in the art, the invention should be construed to include everything within the scope of the invention.
, Claims:We claim:
1. A food packaging machine, comprising:
a feeding mechanism for flexible film, adapted to supply a continuous sheet of flexible film;
a sealing station configured to receive said continuous sheet of flexible film and seal it around a food product, creating a hermetically sealed package;
a knife blade assembly positioned downstream from the sealing station, the knife blade assembly configured to cut the sealed flexible film, thereby separating individual packages.
2. The food packaging machine as claimed in claim 1, wherein the feeding mechanism for flexible film comprises a roll of flexible film material and a motorized unwinding system configured to control the advancement of the flexible film.
3. The food packaging machine as claimed in claim 1, wherein the sealing station comprises:
a heating element for applying heat to the flexible film, facilitating the sealing process; and
a pressure mechanism configured to apply pressure to the flexible film, ensuring a secure and effective seal around the food product.
4. The food packaging machine as claimed in claim 1, wherein the knife blade assembly comprises:
a movable knife blade;
a control system configured to regulate the movement of the knife blade, ensuring precise cutting of the sealed flexible film; and
a waste disposal system configured to collect and remove excess film material resulting from the cutting process.
5. wherein an adhesive disposed on one side of flexible film and the reclosable flap of the second sheet such that the reclosable flap is releasably attached to the flexible film.
6. The food packaging machine as claimed in claim 1, wherein the flexible film comprises a multi-layer material, providing enhanced durability, flexibility, and barrier properties for preserving the freshness and quality of the packaged food products.
7. A method for food packaging machine, comprising:
defining an opening to the contents cavity upon initial opening in a flexible film;
transversing the flexible film towards a sealing station;
sealing the flexible film with food contents;
disposing the sealed/ packed food in a container.
8. The method as claimed in claim 7, wherein the step of removing or separating the excess flexible film from the cut, sealed package using a knife blade.
9. The method as claimed in claim 7, wherein the step of extending beyond the first end seal to form a laminate pull tab of the elongated closure layer and the flexible film.
10. The method as claimed in claim 7, wherein the pressure sensitive adhesive having a peel force less than an end seal peel force.