DESC:COMPACT CASE ERECTOR PACKER AUTOMATION FOR POUCHES IN STRING FORM [CEPA-S]
TECHNICAL FIELD

[0001] The present invention relates to packaging industry. The present invention also relates to W, N or V folding of Pouches in string form and case packing them with Case Erector systems as a retrofit for packaging machines. Further invention additional relates to accessory systems for Pouch Packaging Machines like Form-fill-seal machines. The invention additionally relates to compactness of the automated collator and case erector features for Pouches in W, N or V folded String Form. Further, the present invention specifically relates to grouping of Pouches in String form in the pattern of W, N or V. The invention further relates to the automated collator and case erection and case packing of pouches in string form.
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 often use to produce many different labeled products. The products are traditionally packaged into 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. It is 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.
[0004] The aforementioned aspects and other objectives and advantages can now be achieved as described herein. A compact collator and case erector system for grouping and case packing strings of pouches, is disclosed herein. The compact collator and case erector system can be integrated into a form-fill-seal machine for collecting, collating and case packaging strings of pouches. The Pouches in String Form is received on a two part conveyor with differential speeds to create a dwell time. During the dwell time the String of Pouches are oriented to the top face by 90 deg. The Orientation is to achieve stability of the string while forming W, N or V fold. The orienting of the String to the 90 deg is achieved by a Rotary Indexer which has 4 sets of fingers at 90 degrees each. Once the orientation is done the vertical take up conveyor carries the string on its sides. The vertical take up conveyor is of index motion type. This is meant to hold several strings on its upward travel with strings one below the other. While in transit the String of Pouches can be checked for deflation or leaks by means of pressure pad with sensors. Only the accepted string gets drawn into the forming plate where the W, N or V is formation is made. The string which has rejected packs is made to travel upward to be dumped into a reject bin on the other side of the vertical take off conveyor. The W, N or V formed string of pouches are dropped from the forming plate by the release of a trap door on to cassette. Below this cassette there is a multi string stack holding cassette. Typically this can be 2, 3, 4 or 5 stack holding cassette. On collection of the rated number of strings a trap door below this deliveres the stack to the rotary feeder turret unit. The rotary feeder turret is a reciprocating and rotary unit capable of collecting 2, 3, 4 or 5 stacks by reciprocating movement and using rotary movement motion turns 90 degrees and travels into the Case for depositing the collected stacks. A stripper ensures the collected stacks are deposited inside the case while the Rotary Feeder returns to it home position. The proposed compact collator and case erector system can handle pouches/bags in string form. The compact collator system can effectively collate and case wrap packs in string form by making a W,N or V fold of the string which provides required stability to string packs. The Packs produced in String form are handled at the level they are delivered by the packaging machines. Once the required length is cut, the string of packs travel to the intermittent conveyor where it is oriented.
[0005] An orienting device is provided on the conveyor to tilt the string pack using multiple fingers. The string pack is thus oriented to 90degrees from its lay-flat position by means of an orienter unit. The orienter unit helps transfer the packs to a cleated finger conveyor traveling upward with a width of the maximum length of the string. The orienter conveyor picks up the string pack with its cleat fingers and takes it upward using an intermittent motion conveyor. The string packs with defects are rejected at this point in time by the conveyor. This is to separate the strings in any of the following folding forms such as W,N or V folding. W,N or V folding is the core of invention. W,N or V folding of the string of pouches on its sides ensure its stability when collating and case packing. The cleated finger conveyor is to ensure the sting of packs travel with its thin side facing up. The element of friction is at its lowest in this form. The Centre of gravity of the string in this form does not matter on what product is packed in the pouches. Support for the entire string of packs is at its best in this format. The need to lift this string is to bring it to the level where they can be W,N or V folded. The W,N and/or V folding station is aligned with the position of the stopping of string. On reaching the level of the W,N and/or V folder unit the string conveyor stops to allow the W,N or V folder to grip and pull the string pack to form a W,N or V -shaped string pack. The W,N or V formed string pack is then collapsed to form multiple parallel lines of string packs. The proposed approach reduces the length (to a fraction of the length) of the string. The W,N or V folded string pack is assembled one next to the other and held together by means of support plates on a rotary turret. The rotary turret rotates at 90 degrees to push the multiple W,N or V folded string packs into a Case.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIGS.1-7 illustrates a graphical representation a compact collator and case erector system CPAS integrated into a form-fill-seal machine or fill and seal machine for collecting, collating and case packaging of pouches in string form, in accordance with the disclosed embodiments.
DETAILED DESCRIPTION

[0007] 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.
[0008] 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.
[0009] 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.
[0010] 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.
[0011] FIGS.1-7 illustrates a graphical representation a compact collator and case erector system CPAS integrated into a form-fill-seal machine or fill and seal machine for collecting, collating and case packaging of pouches in string form, in accordance with the disclosed embodiments. Note that the FIGS. 1-7 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 compact collator and case erector system CPAS can be effectively integrated into a form-fill-seal machine or fill and seal machine for collecting, collating and case packaging of Pouches in String form.
[0012] The proposed compact collator and case erector system can handle pouches/bags in string form. The compact collator system can effectively collate and case wrap packs in string form by making a W,N or V fold of the string which provides required stability to string packs.
[0013] The Packs produced in String form are handled at the level they are delivered by the packaging machines. Once the required length is cut, the string of packs is checked to detect leak or unsealed packs by applying pressure on each of the Packs in the string. The string packs with defects are rejected at this point in time by the conveyor. An orienting device named as ORIENTER in Fig. is provided on the conveyor to tilt the String pack using multiple fingers.
[0014] The string pack is thus oriented to 90degrees from its lay flat position by means of an Orienter. The orienter conveyor is a cleated conveyor traveling upward with a width of the maximum length of the string. The orienter conveyor picks up the string pack with its cleats and takes it upward using an intermittent motion conveyor. On reaching the level of the ‘W’ ‘N’ or ‘V’ Folder Station the string conveyor stops to allow the W, N and/or V folder to grip and pull the string pack to form a W,N or V-shaped string pack.
[0015] The W,N or V formed string pack is then collapsed to form multiple parallel lines of string packs. The proposed approach reduces the length (to a fraction of its length) of the string. The W,N or V folded string pack is assembled one next to the other and held together by means of support plates on a Rotary feeder turret.
[0016] The Rotary feeder turret rotates at 90 degrees and travels into the case to deposit the stack of W, N or V folded string of packs into the case. The Case Erector Magazine is positioned ergonomically above the W,N or V Folder Station to stack cases. Wherein the stack format is vertical in the with a provision to place more than one stack in series at a time as buffer.
[0017] 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 collator and case erector system for grouping and case packing strings of pouches wherein the system can be integrated into a form-fill-seal machine for collecting, collating and case packaging strings of pouches and the pouches in string form is received on a two part conveyor with differential speeds to create a dwell time, during the dwell time the string of pouches are oriented to the top face by 90 degree where the orientation is to achieve stability of the string while forming W, N and V folds.
2. The system of claim 1 wherein a rotary indexer having 4 sets of fingers at 90 degrees each are used for orienting of the string wherein upon orientation of strings a vertical take up conveyor carries the string on its sides.
3. The system of claim 2 wherein the vertical take up conveyor is of index motion type which is to hold several strings on its upward travel with strings one below the other.
4. The system of claim 1 wherein the string of pouches can be checked for deflation or leaks by means of a pressure pad with sensors wherein the the accepted string gets drawn into the forming plate and the strings which has rejected packs is made to travel upward to be dumped into a reject bin on the other side of the vertical take-off conveyor.
5. The system of claim 1 wherein an orienting device is provided on the conveyor to tilt the string packs using multiple fingers wherein the string packs are oriented to 90degrees from its lay-flat position by means of the orienter unit.
6. The system of claim 1 wherein the orienter unit helps transfer the packs to a cleated finger conveyor traveling upward with a width of the maximum length of the string.
7. The system of claim 1 wherein the orienter conveyor picks up the string pack with its cleat fingers and takes it upward using an intermittent motion conveyor wherein the string packs with defects are rejected in time by the conveyor.
8. The system of claim 1 wherein the cleated finger conveyor is to ensure the sting of packs travel with its thin side facing up.
9. The system of claim 1 wherein the W, N or V formed string of pouches are dropped from the forming plate by the release of a trap door on to cassette.
10. The system of claim 1 wherein the W,N or V folded string packs are assembled one next to the other and held together by means of support plates on a rotary turret wherein the rotary turret rotates at 90 degrees push the multiple W,N or V folded string packs into a case.