DESC:COMPACT CASE ERECTOR PACKER AUTOMATION FOR POUCH/BAG [CEPA-P]

TECHNICAL FIELD

[0001] The present invention relates to packaging industry. The present invention also relates to Pouch/Bag handling, Collation and Case erector systems for packaging machines. Further invention additionally relates to accessory systems for Pouch Packaging Machines like Form-fill-seal machines or Fill and seal machines. The invention additionally relates to Pouch/Bag handling, compactness of the automated collator and case erector features. Further, the present invention specifically relates to an improved automated collator and case erector systems with specific Pouch/Bag handling methodology for grouping and case packing pouches and/or bags .
BACKGROUND OF THE INVENTION
[0002] With the advantage of industrial automation technology, packaging systems for packaging, bundling, bagging or wrapping a product (in form of pouches and bags) are generally known in the industry; however, such packaging systems do not realize certain advantageous features (and/or combinations of features). Many production lines for packing products into pouches and bags often use to produce many different labeled products. The products are traditionally packaged into corrugated cardboard cases to provide “case-packed” products for ease of handling and shipping.
[0003] A more recent method packages a group of products in a film “overwrap” often referred to as a “bundle”. The bundles can be handled similarly to the case-packed products. The method of packaging products into a bundle is generally less expensive than the method of producing case-packed products due to a lower cost of the film packaging material. Bagging and wrapping are other available packaging methods. Many wholesalers and distributors of the products may prefer a variety of packaging forms for the products such as, case-packed, bundled, bagged, wrapped, etc. Therefore a need exists for advancements in packaging machines to be able to handle a variety of products using different packaging methods on a single production line. These form Secondary or Tertiary Packaging formats. With modern trade these assume great importance in the packaging and supply chain.
[0004] In such packaging systems, collating operation is commonly used in preparing packed pouches/bags for shipment. Typically, the pouches/bags are received from an automatic packaging machine, conveyed, spaced apart and lying flat in edge-to-edge relationship. Collation brings the pouches/bags together, generally upright in a horizontally extending column, so that successive, multiple-bag portions of the column may be conveniently handled and placed in a shipping container. Such conventional collating of pouches/bags involves high labor cost for manual collation. Furthermore, if the product is fragile, there is a risk of damage from operator error or carelessness. Machines and systems were introduced by many prior arts for collation of bagged products which are not easily damaged and able to stand some pressure in the process. Such prior art collated columns may be assembled in a delivery chute or on a takeoff conveyor. However such prior art collator and case erector systems are unable to provide a compact solution where the collator and erectors are built with long conveyors, transfer systems and pick and place systems, which may include Robotic arms as well. Also such prior art collator systems are very space occupying to use and are, cost consuming systems in the packaging industry.
[0005] Based on the foregoing, it is believed that a need exists for an improved automated integrated compact collator and case erector features with a unique Pouch/bag handling. Integration to any Form Fill and Seal machine with very small foot print [1200mm x 3000mm] making it the smallest integrated Case Packer for Pouches. Also, a need exists for a compact collator and case erector system for grouping and case packing pouches and/or bags, as described in greater detail herein.
SUMMARY OF THE INVENTION
[0006] The following summary is provided to facilitate an understanding of some of the innovative features unique to the disclosed embodiment and is not intended to be a full description.
[0007] It is, therefore, one aspect of the disclosed embodiments to provide for an improved integrated Pouch/bag handling, automated collator and case packer for packaging machines.
[0008] It is another aspect of the disclosed embodiments to provide for an improved automated compact collator and case erector features.
[0009] It is further aspect of the disclosed embodiments to provide for an improved need existing for a better Pouch/bag handling, compact collator and case erector system for integrating into form-fill-seal machines and fill and seal machines.
[0010] The system comprises Leak inspection system, Orienter & Grouping conveyor, Collection Shuttle, Feeding Tray, Case Magazine and Case Erector as the main assemblies. The Pouches/bags are received from the Form Fill and Seal/Fill and Seal machines [FFS/PFS] by the Leak Inspection system which delivers accepted Pouches/bags to the Orienter & Grouping conveyor for transport on its sides. Crucial find is the transportation of the pack on its sides. When the sides of the pack are the contact points only seal edges are relevant. The length of the bag is the base and the width of the bag is the height. Seal edges incidentally, is the strongest part of a Pouch/bag. Pouches/bags travels in tandem on a race track with two or more such groups. The function of this is to change the orientation of the packs received from lay flat to 90deg on its side. The objective of this orientation and grouping is to make the Pouches/bags have very minimal frictional load when they are finally pushed into the case. With this formation the packs are always with the leading side being the bottom of the pack right from the FFS machine to the Case.
[0011] The compact foot print is achieved by the vertical take off of the Orienter group ensures optimal use of space in front of the FFS/PFS machine. Collection shuttle receives the group of pouches/bags which are pushed by means of Ploughs. Desired matrix of Pouches/bags are achieved with this operation. Once the layer of Pouches/bags are ready, the collection shuttle is ready to allow transfer of the layer to the Feeding Tray. Feeding tray is a reciprocating one to feed multiple layers into the Case. Each row has a separator to ensure no two packs rub against each other causing disarray. The Feeding tray moves front back and up down. The front back movement is for inserting one layer of Pouches/Bags into the case. The tray inserting the layer of Pouches/Bags ensures no jumbling of the layer. A stripper plate is used to leave the layer of Pouches/Bags inside the Case. The up down movement is to stack one layer after another inside the case. This x and z axis movement of the Feeding Tray optimized the space requirements of the complete system. Case Erector assembly consists of a magazine to store the Cases to be erected, forming arms for the Cases and a Tipping unit.
[0012] The Case Erector is a side loading system where the Pouches/bags are loaded from its sides. Hot melt applicator can be added to close the Trays. The length of width of space used by this system is 1200 x 3000mm. The case forming is a parallel activity. The positioning of the Case Erector Magazine is directly above the Orienter conveyor and is ergonomically positioned for operator ease. Case to be erected is drawn down and opened to receive the Pouches. Interlocks for no-pouch-no-index and no-group-no-case and no-case-machine stop is enabled to ensure maximum uptime in operation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIGS.1-8 illustrates a various graphical representations of a compact collator and case erector system integrated into a form-fill-seal machine or fill and seal machine for collecting, collating and case packaging of individual pouches/bags, in accordance with the disclosed embodiments.
DETAILED DESCRIPTION
[0014] The particular values and configurations discussed in these non-limiting examples can be varied and are cited merely to illustrate at least one embodiment and are not intended to limit the scope thereof.
[0015] The embodiments now will be described more fully hereinafter with reference to the accompanying drawings, in which illustrative embodiments of the invention are shown. The embodiments disclosed herein can be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.
[0016] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and/or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
[0017] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
[0018] FIGS. 1-8 illustrates various graphical representations 100-800 of a Leak inspection system, pouch/bag handling, compact collator and case erector system integrated into a form-fill-seal machine/fill and seal machine for collecting, inspecting, orienting, collating and case packaging of string pouches/bags, in accordance with the disclosed embodiments. Note that the FIGS. 1-8 represent various views of the proposed system. The views can support the understanding of the different functional aspects of the invention in a better way. A person skilled in the art can appropriately interpret and appreciate the technical functions of the invention by using the drawings. The system comprises Leak inspection system, Pouch/bag handling, Orienter & Grouping conveyor, Collection Shuttle, Feeding Tray and Case Erector as the main assemblies. The Pouches/bags are received from the Form Fill and Seal/Fill and Seal machines [FFS/PFS] by the Orienter & Grouping conveyor which travels in tandem on a race track with two or more such groups. The function of this is to change the orientation of the packs received from lay flat to 90deg on its side.
[0019] The objective of this orientation and grouping is to make the Pouches/bags have very minimal frictional load when they are finally pushed into the case. The compact foot print is achieved by the vertical take off of the Orienter group ensures optimal use of space in front of the FFS/PFS machine. Collection shuttle receives the group of pouches/bags which are pushed by means of Ploughs. Desired matrix of Pouches/bags are achieved with this operation.
[0020] Once the layer of Pouches/bags are ready, the collection shuttle is ready to allow transfer of the layer to the Feeding Tray. Feeding tray is a reciprocating one to feed multiple layers into the case. The Feeding tray moves front back and up down. The front back movement is for delivering one layer of Pouches/Bags into the case.
[0021] The up down movement is to stack one layer after another inside the case. This x and z axis movement of the Feeding Tray optimized the space requirements of the complete system. Case Erector assembly consists of a magazine to store the Cases to be erected, a forming arms for the Cases and a Tipping unit. The Case Erector is a side loading system where the Pouches/bags are loaded from its sides. Hot melt applicator can be added to seal the Case. The length of width of space used by this system is 1200 x 3000mm.
[0022] The case forming is a parallel activity. The positioning of the Case Erector Magazine is directly above the Orienter conveyor and is ergonomically positioned for the operator ease. Case to be erected is drawn down and opened to receive the Pouches. Interlocks for no-pouch-no index, no-group-no-case and no-case-machine-stop is enabled to ensure maximum uptime in operation.
[0001] It will be appreciated that variations of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.
,CLAIMS:I/We Claim:
1. A compact case erector packer automation device for pouch/bag, said device comprising:
a leak inspection system;
an orienter & grouping conveyor;
a collection shuttle;
a feeding tray;
a case magazine; and
a case erector.
2. The device of claim 1 wherein the leak inspection system receive pouches/bags from a Form Fill and Seal/Fill and Seal machines [FFS/PFS] which delivers accepted Pouches/bags to the Orienter & Grouping conveyor for transport on its sides.
3. The device of claim 2 wherein the pouches/bags travels in tandem on a race track in more than two groups wherein the orientation of the packs received are changed from lay flat to 90degree on its side.
4. The device of claim 3 wherein the orientation and grouping of pouches/bags have very minimal frictional load when they are finally pushed into the case wherein formation the packs are always with the leading side being the bottom of the pack right from the FFS machine to the case.
5. The device of claim 1 wherein the collection shuttle receives the group of pouches/bags which are pushed by means of a plurality of ploughs wherein the desired matrix of Pouches/bags is achieved at the collection shuttle.
6. The device of claim 1 wherein the collection shuttle is ready to allow transfer of the layer to the feeding tray once the layer of pouches/bags are ready wherein the feeding tray is a reciprocating one to feed multiple layers into the case wherein each row has a separator to ensure no two packs rub against each other causing disarray.
7. The device of claim 1 wherein the case Erector assembly consists of a magazine to store the cases to be erected, forming arms for the cases and a Tipping unit wherein the case erector is a side loading system where the Pouches/bags are loaded from its sides.
8. The device of claim 1 wherein a hot melt applicator can be added to close the trays.
9. The device of claim 1 wherein the feeding tray moves front back and up down wherein the front back movement is for inserting one layer of Pouches/Bags into the case and the up down movement is to stack one layer after another inside the case.
10. The system of claim 9 wherein the tray inserting the layer of pouches/Bags ensures no jumbling of the layer and a stripper plate is used to leave the layer of pouches/Bags inside the case.