Description:FORM 2

THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENT RULES, 2003

COMPLETE SPECIFICATION
[See section 10, Rule 13]

HIGH-SPEED TWIN ASEPTIC PACK PACKAGING MACHINE FOR LIQUID PRODUCTS

UFLEX LIMITED;
AN INDIAN COMPANY;
OF 305, III FLOOR, BHANOT CORNER, PAMPOSH ENCLAVE, GK-1, NEW DELHI-110048 (INDIA);

THE FOLLOWING SPECIFICATION PARTICULARLY DESCRIBES THE INVENTION AND THE MANNER IN WHICH IT IS TO BE PERFORMED:

HIGH-SPEED TWIN ASEPTIC PACK PACKAGING MACHINE FOR LIQUID PRODUCTS
FIELD OF THE INVENTION
[001] The present invention relates to a packaging machine for filling liquid and other pourable food products. More particularly the invention relates to a continuous high speed vertical form-fill-seal machine with a center seal strip for vertical sealing, an induction sealing arrangement for cross sealing of the pack, with a compact structure, enhanced rate of production and lower power consumption.
BACKGROUND OF THE INVENTION
[002] Milk and Juices are usually packaged in containers or packs. These types of packs are normally produced on fully automatic packaging machines, which advance a web of packaging substrate through a sterilization unit. Then, the sterilized web is enclosed and advanced within an isolated closed area which has a sterile environment for the packaging and filling of the product. When a pack or container is formed from a packaging web substrate, the web is folded and sealed vertically to form a tube, which is further fed downwards for product filling and cross sealing.
[003] Said tube is filled with the desired liquid food product and divided into individual pack by repeated cross seals at a predetermined distance from each other. These packs are separated from the tube by a cut along the cross seals and desired shape on top and bottom of the pack is given by a folder assembly, generally a parallelepiped by folding along the creased lines formed in the packaging web.
[004] The machine described above produces a single line of tube at a time. Since an aseptic pack packaging machine of this segment produces N number of packs per hour and to make production double, it is required to have two separate machines with all utilities individually provided to each machine. This idea is not very economical since it requires a large area to install two machines and two sets of utilities to operate both the machines.
[005] Thus, there is a need for a packaging machine which has a higher production rate, which significantly reduces manufacturing cost of machines and power consumption. The conventional machine has a speed of approx. 10,000 packs / hour.
[006] The main advantage of the present invention is to provide a packaging machine capable of producing approx. 20,000 packs/ hour while consuming less power and space. Another advantage of the present invention is to provide a packaging machine capable of producing approx. 50,000 packs/ hour. The footprint of the present invention saves significant floor space.
OBJECT OF THE PRESENT INVENTION

[007] It is an object of the present invention is to provide an aseptic pack packaging machine having at least a pair of vertical heads which can be operated separately or simultaneously.
[008] It is another object of the present invention is to provide an aseptic pack packaging machine which can save air and energy consumption.
[009] It is another object of the present invention is to provide an aseptic pack packaging machine with a small footprint and higher productivity.
[0010] It is another object of the present invention is to provide an aseptic packaging machine with the capability of packing different volume sizes or same volume size, simultaneously or a single volume size on any one of the vertical heads.
[0011] It is another object of the present invention to provide an aseptic packaging machine which can use the same type of laminate on plurality of vertical heads or different type of laminates with different packaging on either vertical head.
[0012] It is another object of the present invention to provide a packaging machine capable of producing approx. 20,000 packs / hour while consuming less power and space.
[0013] It is another object of the present invention to provide a packaging machine capable of producing approx. 50,000 packs / hour while consuming less power and space.
[0014] It is another object of the present invention to provide a packaging machine capable of non-aseptic packaging for products which are self-sterilizable like alcoholic beverages etc. by changing a few components of the pack packaging machine.
[0015] Still other objects and advantages will become apparent from a review of the following description of a preferred embodiment of the present invention.
SUMMARY OF THE PRESENT INVENTION
[0016] The present invention is directed towards a high speed aseptic pack packaging machine having a plurality of machine frames, for forming a plurality of sealed packages filled with a pourable food product from packaging laminate, comprising a plurality of transfer paths, a plurality of strip applicator units, a plurality of vertical heads, a plurality of final folder, an output feed, a plurality of service units, an integrated PLC and a HMI panel for controlling the various units of the aseptic pack packaging machine by a operator.
[0017] To perform a task using pneumatics, there needs to be a way to initiate, monitor, and stop the process. The electro-pneumatic systems integrate pneumatic and electrical functions into one system where the signal or control medium is electrical, and the working medium is compressed air. In this type of system, devices like relays, solenoid valves, limit switches, and PLC are used to interface electrical control with pneumatic action.
[0018] According to the present invention, an integrated pneumatic air panel and an integrated water panel are provided in any one of the service units of the vertical heads and an integrated hydraulic power pack is provided in the other service unit of the other vertical head not having the integrated air panel (202) and the integrated water panel (208) of the aseptic pack packaging machine.
[0019] According to the present invention the pneumatic air panel is provided for the actuation of pneumatic cylinders of the machine and the integrated water panel is provided to control flow of chilled water of temperature 12~20 0C for cooling at various locations in the machine such as to cool cross sealing inductors, servo motors and for sprinkler and water ring air compressor to produce sterile air. Further, the integrated hydraulic power pack is provided to actuate the hydraulic cylinders or other components offering high pressure required like in cross sealing. The control signals are given by the integrated PLC for the selected vertical head’s setup, operation and control.
[0020] Each vertical head comprises a forming and filling unit and a cross sealing jaw unit to advance the reels of packaging laminate in an independent transfer path for forming packages respectively. Each vertical head has its respective forming and filling units, which can operate separately or simultaneously.
[0021] According to the present invention, a web or laminate is formed into a tube at its respective forming and filling unit as it is transferred along a transfer path which comprises a plurality of bending rollers, a sterilization bath unit, a vertical hot air sealing system, whereby the vertical sealing system comprises a hot air nozzle which comes into contact with the laminate during sealing by hot air and pressing, in the vertical direction, along the transfer paths thereby forming a tube. The tube is further fed along a vertical advancing direction for product filling and cross sealing.
[0022] The cross-sealing jaw unit of each vertical head of the present invention is a pair of cross sealing jaws, each vertical head has its respective jaws, which open and closes, and moves with sequential and cyclic manner in the vertically downwards transfer direction of the formed tube of laminate up to a desired fixed length which is correlated with sealing time of laminate. Two pairs of guide pillars are mounted on the main body of the packaging machine and help the cross-sealing jaws configured with induction heating means, to move in fixed condition while sealing the laminate in a direction parallel to the web transfer route is configured for sealing the moving web in longitudinal direction to form tube from the web.
[0023] The cross-sealing jaws press laminate tube by moving towards each other and move away from each other in sequential and cyclic manner. The cross-sealing jaws cyclic movement is driven by an actuating means. The actuating means may be mechanical, electrical, pneumatic, rotary, hydraulic or any other actuating mechanism known in the art. The cyclic motion generated by the servo driven motor, mounted on the main body of the packaging machine, the cross-sealing device to move along with the sealed web downwards in closed condition and then moving upward slightly to make the brick shape and again come down in the direction of web. The operating velocities of the devices are accelerated, decelerated, and again accelerated to make the desired pack.
[0024] According to the present invention, each vertical head is provided with a capability of packaging different volume sizes simultaneously, or same volume sizes simultaneously or any one head can also be operated individually using the integrated air panel, integrated water panel and the integrated hydraulic power pack, with the help of the HMI panel by the operator.
[0025] The present invention can use the same type of laminate on either or both the vertical heads and different types of laminates with different printed matter, on each head.
[0026] Thus, the present invention provides an improved aseptic pack packaging machine for liquid products, with higher production rate, space saving structure while meeting all the technical requirements, saving air and energy consumption. Further, the present invention also provides a packaging machine capable of non-aseptic packaging for products which are self-sterilizable like alcoholic beverages etc. by changing a few components of the aseptic pack packaging machine.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 shows an isometric view of an aseptic pack packaging machine in accordance with an exemplary embodiment of the present invention;
[0028] FIG. 2 shows an exploded isometric view of various units in accordance with an exemplary embodiment of the present invention;
[0029] FIG. 3 shows paper paths for both the vertical heads in accordance with an exemplary embodiment of the present invention;
[0030] FIG. 4 shows an integrated pneumatic air panel with an integrated water panel and an integrated hydraulic power pack in accordance with an exemplary embodiment of the present invention;
[0031] FIG. 5 shows an isometric view of the integrated pneumatic air panel in accordance with an exemplary embodiment of the present invention;
[0032] FIG. 6 shows an isometric view of the integrated water panel in accordance with an exemplary embodiment of the present invention;
[0033] FIG. 7 shows an isometric view of the integrated hydraulic power pack in accordance with an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE PRESENT INVENTION
[0034] For a thorough understanding of the invention, reference is to be made to the following description in connection with the above-mentioned drawings. Although the invention is described in connection with exemplary embodiments, the invention is not intended to be limited to the specific forms set forth herein. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but these are intended to cover the application or implementation without departing from the spirit or scope of the invention. Further, it will nevertheless be understood that no limitation in the scope of the invention is thereby intended, such alterations and further modifications in the figures and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.
[0035] In other instances, detailed descriptions of well-known methods, layout and procedures, and devices are omitted so, not to obscure the description of the present invention with unnecessary detail. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. Further, reference herein to "one embodiment" or "an embodiment" means that a particular feature, characteristic, or function described in connection with the embodiment is included in at least one embodiment of the disclosure. Furthermore, the appearances of such phrase at various places herein are not necessarily all referring to the same embodiment. The terms "a" and "an" herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. The terms "pack" and “package” used herein have the same meaning.
[0036] Further, “plurality” can be more than one, two, three or more, however, the preferred embodiment of the present invention is explained with respect to “two transfer paths for forming the packages” for understanding.
[0037] For reference purposes and to explain the preferred but not limited embodiment of the present invention, reference numerals in brackets separated by the commas (_, _) are used to refer to the respective unit of the vertical heads of the machine.
[0038] Further, many of the mechanisms which are to be described are identical on the other vertical head. Now different embodiments of the present invention will be described in light of the drawings of the present invention.
[0039] FIG. 1 & 2 show an assembled and exploded view of an aseptic pack packaging machine (100) having a plurality of machine frames (110, 120), for liquid products in accordance with the present invention. The aseptic pack packaging machine (100), comprising a plurality of transfer paths (200PP, 220PP), a plurality of strip applicators (9, 59), a plurality of vertical heads (200, 220), a plurality of final folder units (290, 300), an output feed (400), a plurality of service units (201, 221), an integrated PLC (320) and an HMI panel of the aseptic pack packaging machine (100). The final folder units (290, 300) to give desired shape to plurality of packages (P1, P2). Further, the output feed (400) is provided for the vertical heads (200, 220) to collect the final packages (P1, P2). The HMI panel (500) is provided to digitally control the operations and set parameters on the machine.
[0040] According to the present invention each vertical heads (200, 220) comprising a plurality of tube forming and filling units (250, 260) to form plurality of tubes (T1, T2) from a plurality of reel (R1, R2) of packaging laminate (1, 51), a plurality of cross sealing jaw units (270, 280) to cross- sealing the plurality of tubes (T1, T2) to form plurality of packages (P1, P2). Each cross sealing jaw unit (270, 280) comprises a pair of Forming and cross sealing assembly (A, A’) and (B, B’) respectively for forming and cross sealing of the tube |(T1, T2) using an induction sealing. Further, each Forming and cross sealing assembly (A and A’) of cross sealing jaw unit (270) comprises a pair of cross sealing jaws i.e. front and rear cross sealing jaws (27, 27’) for cross sealing the tube (T1). Similarly, each Forming and cross sealing assembly (B and B’) of cross sealing jaw unit (280) also comprises a pair of cross sealing jaws i.e. front and rear cross sealing jaws (77, 77’) for cross sealing the tube (T2). The rear cross sealing jaws (27, 77) have an inductor for heating by induction for heat sealing and front cross sealing jaws (27’ 77’) comprise a polymer pad for cushioning effect.
[0041] FIG. 3 shows a schematic view of paper path (200 PP, 220 PP) for forming the packs (P1, P2) from plurality of reel (R1, R2) of packaging laminate (1, 51) loaded on un-winders, according to an embodiment of the present invention. Two independent transfer paths (200PP, 220PP) for laminate (1, 51) lead to forming the packages (P1, P2). Both the reels of packaging laminate (1, 51) may be same or different in terms of structure, printing or width, based on the requirement.
[0042] Further, the plurality of forming and filling units (250, 260) comprise vertical hot air sealing devices (not shown in figure) comprising a hot air nozzle with a guide for Longitudinal seal (LS) strip (7, 57) for vertical sealing by hot air and pressing, in the vertical direction, along the transfer path (200PP, 220PP) to form the laminate tube (T1, T2).The cross sealing jaw units (270, 280) cross seals the tubes (T1, T2) to form the pack (P1, P2) by means of induction heating and pressing. The process is explained later in detail.
[0043] FIG. 4 shows the preferred but not limited configuration of the present invention, the service unit (201) comprises the integrated pneumatic air panel (202) and the integrated water panel (208) and the other service unit (221) comprises the integrated hydraulic power pack (222), to feed laminate (1, 51) and control various operations along both or any one of the transfer paths (200PP, 220 PP).
[0044] FIG. 5 shows a front and an isometric view of the integrated pneumatic air panel (202) of the present embodiment. The integrated pneumatic air panel (202) of the present invention is configured preferably but not limited, in the service unit (201). The integrated pneumatic air panel (202) comprises at least one or a combination of the plurality of an air filter, regulator & lubricator unit (203), a plurality of solenoid valves (204), a plurality of flow meters (205), a plurality of pressure regulators (206), a plurality of pressure gauges (207) and other circuitry components in accordance with the present invention. The integrated pneumatic air panel (202) is provided for actuation of various pneumatic cylinders and other components for the operation of the aseptic pack packaging machine (100). Pneumatic air is supplied by the pneumatic air panel (203) to actuate the pneumatic cylinders and other pneumatically operated devices to perform various operations along the transfer paths (200PP, 220PP) from laminate roll (R1, R2) feeding till discharge of final aseptic packs (P1, P2). This pneumatic air is also used in the LS nozzles (23, 73) for hot air vertical sealing.
[0045] Further, compressed air flows through multiple devices, components, pipes, and fittings that can add particulates, oil, and moisture. Even though the compressor includes an air dryer, filter, water separator and regulator, the air should still be prepared at the machine before it is used. This compressed air is supplied to the air filter, regulator & lubricator assembly or FRL (203) in the integrated pneumatic air panel (202) where it filters the air and the pressure of the air is also regulated.
[0046] According to another embodiment, sterile air, nitrogen or any inert gas can also be used.
[0047] The pneumatic air panel (202) comprises a plurality of solenoid valves (204), which are controlled by the integrated PLC (320). The flow meters (205) are provided to read the flow of air through the circuit to set and monitor operation of the machine (100). Further, the integrated pneumatic air panel (202) comprises the pressure regulators (206) which further comprises the pressure regulators (206) having pressure switch and pressure regulators (206) having precision pressure regulators with pressure switch and precision valves to reduce and regulate the pressure of the air through multiple circuits, as per desired value.
[0048] According to the preferred but not limited embodiment of the present invention, six lines are provided to install six air pressure regulators at the desired pressure level in each line.
According to the present invention, the desired pneumatic pressure for the actuation of the pneumatic components is approx. 6 bar.
[0049] Further, according to another embodiment of the present invention, the integrated pneumatic air panel (202) comprises of valves assemblies, which may work on Ethernet / Profibus protocols / Interface. Further a plurality of prepositional regulators may be provided which may be connected through IOT based application for remote monitoring and maintenance purpose.
[0050] According to the present invention, the integrated pneumatic air panel (202) of service unit (201) of the vertical head (200) is designed in such a way that any or both the vertical heads (200, 220) of the aseptic pack packaging machine (100) can be operated individually as well simultaneously as per the requirement and can be selected by the HMI panel (500).
[0051] In a preferable embodiment of the invention, the integrated pneumatic air panel (202) is provided for the various compressed air-based operations along both or any one of the transfer paths (200PP, 220PP).
[0052] FIG. 6 shows a front and an isometric view of the integrated water panel (208) in accordance with the present invention. The integrated water panel (208) is configured, preferably but not limited, in the service unit (201). Further, the integrated water panel (208) is configured preferably along with the integrated pneumatic air panel (202).
[0053] The integrated water panel (208) comprises a plurality of solenoid valves (209), a plurality of flow meters (210), a plurality of pressure gauges (215), a plurality of ball valves (211), a plurality of strainers (212) and other circuitry components in accordance with an embodiment of the present invention.
[0054] The integrated water panel (208) is provided to control flow of chilled water of temperature 12~20 0C for cooling at various locations in the machine such as to cool cross sealing inductors, servo motors and for sprinkler and water ring air compressor to produce sterile air in the aseptic pack packaging machine (100).
[0055] The integrated water panel (208), as shown in FIG. 6, is provided with filters to remove dirt, and other particulate contamination from water for circulation.
[0056] The integrated water panel (208) provides flow control in different circuits by using the plurality of solenoid valves (209). The solenoid valve (209) uses an electrical coil which actuates or energizes the selected valve for the designated operation.
[0057] The plurality of flow meters (210) are provided to check the flow rate of the water in a circuit. The plurality of pressure regulators (214) are provided to regulate the pressure of the water in different circuits to maintain pressure as per the requirement.
[0058] FIG. 7 shows an isometric view of the integrated hydraulic power pack (222) of the present invention. According to preferred but not limited embodiment of the present invention, the integrated hydraulic power pack (222) is provided in the service unit (221). The integrated hydraulic system (222) is provided to operate any one or both the vertical heads (200, 220) of the aseptic pack packaging machine (100).
[0059] The integrated hydraulic power pack (222) comprises hydraulic pump and motor, pressure relief valve, solenoid valves or actuators and other circuitry components, to provide high pressure hydraulic fluid to drive cylinders through connecting hoses or pipes during the cross sealing by cross sealing jaw units (270, 280) and other operations as required, which is controlled by the integrated PLC (320) of the machine (100).
[0060] The plurality of actuators is actuated by a low amount of energy, however, these actuators control a very high pressure in the hydraulic system (222). Thus, the high-pressure hydraulic fluid actuates the hydraulic cylinders or other components offering high pressure required like in cross sealing.
[0061] Further, the integrated hydraulic Power pack (222) is provided to operate cross sealing jaws (270, 280) to perform cross sealing of laminate tubes (T1, T2) and actuate the cutting knife to packs (P1, P2) along both or any one of the transfer paths (200PP, 220PP).
[0062] The advantage of the present embodiment and the integrated hydraulic power pack (222) of the present invention as shown in FIG. 7 can be better understood by the following example.
[0063] For example, in the case of two conventional machines, two motors with total 4 HP power are required for operating both systems. However, according to the present invention (100), the hydraulic power pack (222) requires only one 3 HP motor to operate pair of vertical heads (200, 220) of aseptic pack packaging machine (100), thus the present invention saves 1 HP power requirement. Further, in a conventional version, filter, check valve, pressure relief valve, pressure reducing valve, manifold & heat exchanger is required in double quantity, each operating for operating the two separate machines. On the other hand, the aseptic pack packaging machine (100) of the present invention requires components like filter, check valve, pressure relief valve, pressure reducing valve, manifold & heat exchanger etc., only in a single quantity for operating the vertical heads (200, 220) simultaneously as well as individually of the present invention (100). Thus, the present invention (100) saves one quantity for each of these components, thus reducing the overall machine manufacturing, operating and maintenance cost.
[0064] The present invention is directed towards a high-speed aseptic pack packaging machine (100) as shown in FIG. 1 & FIG. 2, to form a plurality of sealed packages (P1, P2) filled with a calibrated quantity of pourable product, from a plurality of reel (R1, R2) of packaging laminate (1, 51) along the respective transfer paths (200 PP, 220 PP) according to the present invention.
[0065] FIG. 3 shows the transfer paths (200 PP, 220 PP) for the pair of vertical heads (200, 220) for forming the packs (P1, P2) from the pair of reels (R1, R2) of packaging laminate (1, 51) loaded at respective un-winders, according to the present invention.
[0066] According to the present invention, the desired vertical head (200, 220) either one or both, are selected as per the requirement through the HMI panel (500) by the operator. Further, the center strip which is used for longitudinal seal is LS strip (7, 57).
[0067] According to an embodiment, both the vertical heads (200, 220) are operating. Each paper path (200PP, 220 PP) of the present invention comprises a plurality of forming and filling unit (250, 260) which are configured to advance the respective reel (R1, R2) of packaging laminate (1, 51) with a plurality of rollers like a paper guide roller (2, 52), a power feed roller (3, 53), a dancing roller (4, 54), another bending roller (5, 55) to advance and bend the reel of packaging laminate (1, 51) and a pair of marking units (6, 56) to print the details.
[0068] Further the paper path (200PP, 220 PP) of the respective vertical heads (200, 220) comprises a strip applicator (9, 59) which further comprises a Longitudinal seal (LS) strip reel (7, 57) to perform the vertical sealing and a splicing unit (8, 58) for continued uninterrupted supply of the LS strip (7, 57), which apply the LS strip, preferably made of LDPE or LLDPE, along the one edge of the packaging laminate (1, 51) from the inside by the induction sealing method. Only a half width of the LS-strip (7, 57) seals with the edge of the packaging laminate (1, 51) and the other half will be sealed to the other edge later, when the packaging laminate (1, 51) is formed into a tube (T1, T2). A plurality of bending rollers (10, 60), (11, 61) to advance the packaging laminate and then the packaging laminate (1, 51) of reels (R1, R2) are fed through an aseptic chamber for sterilization.
[0069] Each paper path (200PP, 220PP) comprises a sterilization bath unit (12, 62) and a cover (13, 63) for sterilization bath to make the inner environment suitable for sterilization which is performed by applying a sterilizing agent such as hydrogen peroxide or nitrogen peroxide solution or any other mean, which is subsequently evaporated by heating by means known in the art. Sterilization of the laminate by hydrogen peroxide and system sterilization by sterile air and hydrogen peroxide spray are required. The flow of sterile air is needed to maintain aseptic conditions and for hot air sealing which are fully controlled. An aseptic environment around the sterilized laminate is maintained with an overpressure of heat sterilized air.
[0070] According to the present invention the overpressure in the aseptic environment is preferably around +20 to +40 mmWC (1.96 millibar to 3.92 millibar). This pressure is maintained as a positive pressure to avoid entry of the atmospheric air into the chamber.
[0071] Each Transfer route (200PP, 220PP) further comprises a calender roller (14, 64) to smoothen the packaging laminate (1, 51), an air knife (15, 65) to remove residual sterilizing agent from laminate’s surface, a bending roller (16, 66) (driven) and another bending roller (17, 67) are provided for smooth transfer of the laminate (1, 51) along the path (200PP, 220PP).
[0072] A pair of upper forming rings (18, 68), a crease roller (19, 69) provided to ensure the creases are formed for the pack’s (P1, P2) final shape, and a pair of movable forming rings (20, 70) are provided along each transfer route (200PP, 220PP). Further, the upper forming ring (18, 68), the movable forming rings (20, 70) and a pair of lower forming rings (25, 75) are provided to pinch and fold the respective laminate (1, 51) there between and seal the longitudinal joining edges of the packaging laminate (1, 51) at respective transfer path (200PP, 220 PP) of vertical heads (200, 220).
[0073] Each transfer route (200PP, 220 PP) comprises a vertical hot air sealing device (not shown), comprises hot air nozzles i.e., a LS Nozzle (23, 73), a LS short stop nozzle (24, 74), through which hot air is sprayed for sealing, which comes in contact with the edges of the packaging laminate (1, 51) during the hot air sealing, in the vertical direction thereby forming a continuous tube (T1, T2). The center seal strip (LS Strip) (7, 57) overlaps the laminate edges along the longitudinal sealing, thus ensure leak proof longitudinal seal and covered cross section of laminate edge inside the formed tube.
[0074] The Filler tubes (21, 71) are provided for each forming and filling unit (250, 260) in the vertical heads (200, 220) to fill the liquid product in the respective tube (T1, T2). Liquid product to be packaged is supplied by an external product storage tank having conveying system to fill a calibrated quantity of product into the filler tubes (21, 71), at an appropriate over-pressure i.e. approx. +20 to +40 mmWC (1.96 millibar to 3.92 millibar), which is maintained in the aseptic chamber through the filtered compressed air coming from integrated pneumatic air panel (202). Further, each transfer path (200PP, 220PP) comprises a pair of divided forming rings (22, 72), to divide each pack (P1, P2) as per the length according to the volume, as set earlier.
[0075] A pair of tube support rollers (26, 76) in each transfer path (200PP, 220PP) are provided to keep the respective tube in place while the product is filling and tube is moving downwards.
[0076] Now the filled tube (T1, T2) moves downwards along the respective transfer path (200PP, 220PP) and comes in the cross sealing assembly (270, 280). Each cross sealing jaw unit (270, 280) comprises a pair of Forming and cross sealing assembly (A, A’) and (B, B’) for the forming and cross-sealing of the tube (T1, T2) using an induction sealing respectively. Further, each Forming and cross sealing assembly (A and A’) of cross sealing jaw unit (270) comprises two cross-sealing jaws (27, 27’) as front and rear cross sealing jaws (27, 27’). Similarly, each Forming and cross sealing assembly (B and B’) of cross sealing jaw unit (280) also comprises two cross sealing jaws (77, 77’) as front and rear cross sealing jaws. The rear cross sealing jaws (27, 77) of (A, A’) (B, B’) have the inductor for heating by induction for heat sealing and front cross sealing jaws (27’ 77’) of (A, A’) (B, B’) comprise a polymer pad for cushioning effect. Each pair of jaws (27, 27’) (77, 77’) of forming and sealing assemblies (A, A’) (B, B’) of (270, 280) respectively opens and closes in perpendicular direction to the downwards movement of formed tube (T1, T2) and each pair of jaws (27, 27’) (77, 77’) also moves in a sequential and cyclic manner, in the downwards transfer direction of the formed tube (T1, T2) up to fixed length depending upon the desired pack height. Further, each pair of forming and sealing assembly (A, A’) (B, B’) comprises a pair of volume flaps (not shown), which forms the initial shape of the pack based on volume. The integrated water panel (208) provides chilled water circulation for water spray before the cross sealing, through inductors for cross sealing, servo motor cooling and water ring vacuum pump.
[0077] Two pair of guide pillars (not shown) are mounted on the main body of the machine (100) and helps the cross sealing jaw unit (270, 280), to move in fixed path, while sealing the laminate (1, 51) in a direction perpendicular to the downwards web transfer, to seal the formed tube (T1, T2) and simultaneously cut in the middle of the cross sealed band on the formed and filled tube (T1, T2), to separate each pack (P1, P2).
[0078] Further, the cyclic motion generated by the servo motor mounted on the main body of the packaging machine (100), each cross sealing jaw unit (270, 280) is configured to move along with the sealed laminate downwards in closed condition as shown in forming and cross sealing assemblies (A, B) of (270, 280) and then moving upward slightly as shown in forming and cross sealing assemblies (A’, B’) of (270, 280) to make the initial shape by volume flaps (provided in forming and cross sealing assemblies) and again come down in the direction of laminate. The operating velocities of the devices are accelerated, deaccelerated, and again accelerated by servo driven mechanism to make the desired pack.
[0079] In preferable embodiment of the present invention, the integrated hydraulic power pack (222) is provided to operate cross sealing jaw units (270, 280) to perform cross sealing of laminate tubes (T1, T2) and actuate the cutting knife to separate the formed packs (P1, P2) along both or any one of the transfer paths.The cross sealed tube (T1, T2) cut the middle of cross sealed band and moves along the transfer path (200PP, 220PP) which further comprises a pair of final folder assembly (290, 300) for vertical heads (200, 220) respectively. Each final folder (290, 300) comprises a final folder station chain (28, 78) to shape the package (P1, P2). The package (P1, P2) moves to the final folder station chain (28, 78) respectively, to fold fins and flaps on top and bottom of the packs (P1, P2) of the aseptic pack packaging machine (100). The final packs (P1, P2) can be withdrawn from the common outfeed (400) of the packaging machine (100) and conveyed further for sorting and packing. Further, top and side squeezing of packages (P1, P2) is performed mechanically by pressure device and pull-down device. The final folder (290, 300) works in indexing mode.
[0080] According to an embodiment, the integrated pneumatic air panel (202) and the integrated water panel (208) are provided in any one of the service units (201 or 221) and the integrated hydraulic power pack (222) is provided in the service unit (221 or 201) not having the integrated air panel (202) and the integrated water panel (208), to operate the packaging machine (100).
[0081] According to the present invention, to make the packaging machine (100) compact in size and to reduce the energy consumption, the integrated pneumatic air panel (202) along with the integrated water panel (208) may be configured in any one of the service units (201 or 221). Similarly, the integrated hydraulic power pack (222) may be configured in either service units (201 or 221) of the aseptic pack packaging machine (100) of the present invention which does not comprise the integrated pneumatic air panel (202) and the integrated water panel (208).
[0082] According to another embodiment of the present invention, the integrated hydraulic power pack (222) may be provided in the service unit (201) of the vertical head (200) or in the service unit which does not comprises the integrated pneumatic air panel (202) and the integrated water panel (208) to saves the space thereby reducing the overall size of the machine.
[0083] According to another embodiment of the present invention, the integrated pneumatic air panel (202) and the integrated water panel (208) may be provided in the service unit (221) of the vertical head (220) or in the service unit which does not comprises the integrated hydraulic power pack (222) to saves the space thereby reducing the overall size of the machine.
[0084] According to another embodiment of the present invention, if the machine (100) has more than two vertical heads for example if the machine (100) has three vertical heads (200, 220, 230-not shown) for forming a plurality of sealed packages (P1, P2, P3) filled with a pourable product from a plurality of reels (R1, R2, R3) of packaging laminate, in this case, the integrated pneumatic air panel (202), integrated water panel (208) and the integrated hydraulic power pack (222) can be arranged in any known combination in the service units of machine (100). Further, the service unit of the machine (100) can be divided based on the number of vertical heads, and the integrated pneumatic air panel (202), integrated water panel (208) and the integrated hydraulic power pack (222) can be modified to operate the various units of the machine (100) accordingly.
[0085] According to another embodiment, it may be contemplated that output feed (400) may be provided separately for each vertical head (200 or 220), as per the requirement of products of different sizes.
[0086] In an exemplary embodiment, the preferred and optimum conditions to operate the aseptic pack packaging machine (100) of the present invention are given below in Table-1. However, it is to be understood that other variations and modifications of the present invention may be made without departing from the scope thereof.
TABLE -1
S. No. Parameters Range or Values
1. Longitudinal Sealing Temperature 280 °C
2. Cross Sealing Temperature 380 °C
3. Pneumatic Pressure 6 bar
4. Chilled water Temp. ~ 15oC
[0087] In an exemplary embodiment, the aseptic pack packaging machine (100) of the present invention can pack large quantity of the product. The main advantage of the present invention is to provide a packaging machine (100) which is capable of producing approx. 20,000 packs / hour while consuming less power as against approx. 10,000 packs / hour by a conventional machine. Another advantage according to another embodiment is to provide a packaging machine capable of producing approx. 50,000 packs/ hour. The present invention is capable of packaging different volume sizes, simultaneously, by each vertical head (200 or 220) individually, packaging same volume sizes simultaneously, by operating each vertical head (200 or 220) individually.

[0088] In a preferable embodiment of the invention, the strip applicator unit (9, 59) along each transfer path (200PP, 220PP) is provided for respective vertical head (200 or 220) for applying a longitudinal seal (LS) strip on the laminate (1, 51) by means of induction heat sealing.
[0089] According to the present invention, to operate either vertical head (200 or 220) individually or both the vertical heads (200, 220) of the machine (100) simultaneously, the pressure of the pneumatic air should be maintained at desired value of approx. 6 bar which can be further adjusted for various circuits using plurality of pressure regulators (206).
[0090] In preferable embodiment of the present invention, the lubrication system is provided to ensure proper lubrication of the moving parts of the machine (100).
[0091] In preferable embodiment of this invention, the integrated PLC (320) is provided to setup and control various functions of the aseptic pack packaging machine (100).
[0092] In preferable embodiment of the present invention, the HMI panel (500) is provided to digitally set up and control the operation of aseptic pack packaging machine (100) by an operator.
[0093] According to another embodiment, in order to increase the speed to more than 20,000 packs per hour, it is necessary to replace the transverse seal jaw unit (270, 280) with different transverse seal jaw units having a conveyor jaws system. Further, each forming and filling unit (250, 260) may adapt two reels (R1, R1’) of laminate (1, 1’) and (R2, R2’) of (51, 51’) loaded at unwinders for forming the tube (T1, T2). However, one of the two reels (R1 or R1’) is kept as a reserve. Similarly, one of the two reels (R2 or R2’) is kept as a reserve. The spare web reel is kept to minimize the machine downtime due to reel changeover. The active web reel (R1, R2) of laminate (1, 51) is spliced to the spare web reel (R1’, R2’) by the automatic splicer mechanism as soon as the active web reel reaches near end. Further, each forming and filling unit (250, 260) comprises an induction sealing arrangement to vertically seal the overlapping ends of laminate to form the respective tubes (T1, T2) along the transfer path (200PP, 220PP) instead of hot air sealing in the machine with speed of less than 20,000 packs per hour. Since the laminate moves at a very high speed, the laminate may shift sideways. To eliminate this issue and to control the laminate alignment, a laminate edge guide is used before the tube formation in each forming and filling unit (250, 260).
[0094] For a very high-speed machine of approx. 50,000 packs per hour output, each forming and cross sealing assembly (A1) (B1) of cross-sealing jaw units (270, 280) may comprise a conveyor jaws system. The Forming and cross sealing assembly (A1) of cross-sealing jaw unit (270) may comprises a conveyor system having two chain (C1, C1’), each having a number of first jaws (27) and second jaws (27’), each chain preferably has ten jaws i.e., five first jaw (27) and five second jaw (27’) in total in one chain conveyor (C1, C1’) defining an endless first lateral path (200LP, 200LP’) along which said first and second jaws (27, 27’) travel. Similarly the Forming and cross sealing assembly (B1) of cross-sealing jaw unit (280) may comprises a conveyor system having two chain (C2, C2’) having a number of first jaws (77) and second jaws (77’), each chain (C2, C2’) preferably has ten jaws i.e., five first jaw (77) and five second jaw (77’) in total in one chain conveyor (C2, C2’) preferably ten in numbers and defining an endless first lateral path (220LP, 220LP’) along which said first jaws (77) and second jaws (77’), travel.
[0095] The jaws (27) and (77) comprises the inductors for heating the laminate with aluminum foil. The other jaw (27’, 77’) comprises the polymer pad for cushioning effect are arranged such that jaws (27’) and (77’) always travel opposite to the jaws (27) and (77). The first and second jaws (27, 27’) are mounted on the conveyor chains (C1, C1’) and (77, 77’) are mounted on the conveyor chains (C2, C2’) in alternate fashion i.e. (27, 27’, 27, 27’------) and (77, 77’, 77, 77’ ------). The jaws moving in two loops, pressing the tube (T1, T2) of laminate (1, 51). Further, it is not possible to provide the induction energy through cables to each jaw (27, 77), so a system of non-contact transfer of induction energy to each jaw is provided. Whenever a jaw on the conveyor chain comes in proximity of an inductor source, the jaw with inductor transmits energy to the aluminum foil in the laminate, which gets heated and melts the PE layer for cross sealing the two layers of laminate together between the jaws with inductor and opposite jaw with a polymer pad for cushioning effect, in order to balance the loops (two chain (C1, C1’) (C2, C2’) of the conveyor system of cross sealing jaw unit (270, 280)). The alternate jaws on both the chains may be energized by induction and the other jaws having a polymer pad for cushioning effect, are mounted such that when two chains (C1, C1’) move, the jaw on one side has induction heating means and the opposite jaw has a polymer pad for cushioning effect face each other. Similarly, two chains (C2, C2’) move.
[0096] The first and said second path (220LP, 220LP’) comprising respective branches substantially facing and parallel to each other, and between which the tube (T1, T2) of laminate (1) (51,) is fed so that the jaws (27, 27’) on one chain (C1), cooperate with opposite jaws (27’, 27) on the other chain (C1’) along said branches of the respective paths (200LP, 200LP’), to grip the tube (T1) at a number of successive cross sections, and to seal the packs. Each jaw (27 or 77) on one conveyor (C1 or C2) and the corresponding jaw (27’ or 77’) on the other conveyor (C1’ or C2’) define a forming and cross sealing assembly (A1 or B1) which interacts cyclically with the tube (T1, T2) of laminate (1, 51). The portion of the tube (T1, T2) gripped between each pair of jaws (27, 27’) (77, 77’) is normally cross sealed by a contact less induction sealing carried by one of the jaws preferably (27 and 77), and which melts the layers of heat-seal laminates gripped tightly between the jaws. As each pair of jaws (27, 27’) of chain (C1, C1’) and similarly jaws (77, 77’) of chain (C2, C2’) completes the cross-sealing operation. A cutter carried by one of the jaws, preferably jaw (27’and 77’) with polymer pad for cushioning effect, is activated and interacts with the tube of laminate to cut it in the middle of the cross-sealing band just sealed, and so detach packages (P1, P2) from the bottom end of the tube (T1, T2) of laminates (1) (51). The bottom end being cross sealed, the relative jaws, on reaching the bottom position, can be opened to avoid interfering with the top portion of the tube (T1, T2). At the same time, the other pair of jaws (27, 27’) (77, 77’), operated in exactly the same way, moves down from the top position, and repeats the above grip / form, seal and cut process. Package cutting is performed by hydraulic pressure in machine for less than 20,000 packs/ hour, however for high-speed operation, the speed of hydraulic movements cannot match the machine speed for cutting the packages, so mechanical cam and rollers mechanism is used for high-speed operation.
[0097] A large number of packages cannot move by a chute to final folder (290, 300), so an infeed conveyor is used and the final folder (290, 300) folds in continuous mode instead of indexing mode of machine with less than 20,000 packs / hour output. The top and side squeezing of fins and flaps is done by squeezing belts for continuous operation.
[0098] According to another embodiment, since due to very high speed, print design registration with respect to forming the packages, is corrected by servo driven mechanism. To adjust the product volume in high-speed operation of the machine servo driven mechanism is provided. However, for machines with less than 20,000 packs / hour, design correction is performed by pneumatic cylinder and volume correction is performed mechanically.
[0099] In preferable embodiment of the present invention, the forming and cross-sealing assembly (A, A’) (B, B’) are opening and closing with up-down movement, by actuating means. The actuating means can be hydraulic, mechanical, electrical, pneumatic, rotary, or any other actuating mechanism known in the art.
[00100] The present invention is used for packaging liquid products like juice, milk, oils and alcohol etc. In preferable embodiment of the present invention, the packaging machine is for aseptic packaging.
[00101] According to another embodiment, by changing a few components of the aseptic pack packaging machine (100), the present invention may be used to fill different volume sizes in the capacity of 100 ml, 125 ml, 160 ml, and 200 ml.
[00102] According to the present embodiment the reel (R1, R2) of packaging laminate (1, 51) may have a multilayer structure, which includes at least one paperboard layer which on both sides thereof configures with at least one polymeric layer and at least one layer of metal foil.
[00103] The single or multilayer polymeric layer can be at least one or in combinations with Polyethylene (PE), Polyethylene Terephthalate (PET) web, Biaxially-Oriented Polypropylene (BOPP) web, Polyvinyl Chloride (PVC) web, Poly Carbonate (PC), Cast Polypropylene (CPP) web, Mylar, Nylon (PA), and Ethylene Vinyl Acetate or any other polymer or Biodegradable polymer.
[00104] Further, the laminate comprises at least a layer of fibrous material, such as e.g., a paper or cardboard layer.
[00105] The laminate shall have at least one barrier protection layer within the laminate structure comprising Aluminum foil or vacuum metalized Aluminum layer, Aluminum Oxide, zinc Sulphide, Silicon Oxide, Silver, Gold, Copper, Chrome, Silicon monoxide, Silicon dioxide, Magnesium fluoride, Titanium dioxide, Tin tungsten oxide and Indium tin oxide or any other suitable metal which provides resistance against water, oxygen and other gases permeation.
[00106] Further, typical laminate structures can be referred from Indian patent application Number 202011023791.
[00107] It is to be understood that while the present invention is discussed in the context of producing aseptic packages, one skilled in the art could use the method and apparatus in other areas including, but not limited to, packages of different sizes, non-aseptic packages, or packages that must be kept refrigerated. Therefore, the foregoing and following description is to be viewed as illustrative and not in a limiting sense. By changing a few components and modifications, the machine of the present invention can be used for non- aseptic packaging also.
[00108] According to another embodiment, by changing a few components of the aseptic pack packaging machine (100) can be used for non-aseptic packaging for products which are self-sterilizable like alcoholic beverages etc. When used as non-aseptic, the forming and filling unit (250, 260) of the machine (100), excludes sterilization bath unit (12, 62), cover for sterilization (13, 63) and air knife (15, 65) for vertical heads (200, 220) along the respective transfer paths (200PP, 220PP). Further, sterilization of the laminate (1, 51) by hydrogen peroxide and system sterilization by sterile air and hydrogen peroxide spray are also not required. Alkali tank and Nitric acid (HNO3) tank for cleaning purposes are also not required in the non-aseptic packaging condition. Further, the main water ring compressor is also excluded when non-aseptic arrangement is required.
[00109] The foregoing descriptions of specific embodiments of the present disclosure have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present disclosure to the precise forms disclosed and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the present disclosure. Further, the present invention comprises various electronics components but for the sake of brevity, conventional components of the systems and units may not be described in detail herein. It is also understood that various omission and substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but such are intended to cover the application or implementation without departing from the spirit or scope of the present disclosure.

LIST OF REFERENCE NUMERALS
100 Aseptic Pack Packaging Machine
110, 120 Machine frames
200, 220 Vertical heads of the Machine (100)
201, 221 Service Units
202 Integrated Pneumatic Air Panel
203 Air Filter, Regulator & Lubricator Unit or FRL
204 Solenoid Valves of Pneumatic Air Panel
205 Flow Meters of Pneumatic air Panel
206 Pressure Regulators of Pneumatic Air Panel
207 Pressure Gauges of Pneumatic Air Panel
208 Integrated Water Panel
209 Solenoid valves of Water Panel
210 Flow Meters of Water Panel
211 Ball Valves
212 Strainer
213 Water Filter
214 Pressure Regulators of Water Panel
215 Pressure Gauges for vertical heads in Water panel
222 Integrated Hydraulic Power Pack
250, 260 Forming and Filling Units
270, 280 Cross Sealing Jaw Units
290, 300 Final Folders
320 Integrated PLC
400 Output Feed
500 HMI Panel
R1, R2 Reels of Packaging Laminate
1, 51 Packaging laminate of Reel (R1, R2)
2, 52 Paper Guide Rollers
3, 53 Power Feed Rollers
4, 54 Dancer Rollers
5, 55 First Pair of Bending Rollers
6, 56 Marking Units
7, 57 LS (longitudinal seal) Strip Reels
8, 58 Splicing Units for Ls Strip
9, 59 Strip Applicators Units
10, 60 Bending Rollers
11, 61 Bending Rollers
12, 62 Sterilization Bath Units for vertical heads (200, 220)
13, 63 Cover of Sterilization Bath
14, 64 Calender Rollers
15, 65 Air Knives
16, 66 Bending Rollers (Driven)
17, 67 Bending Rollers
18, 68 Upper Forming Ring
19, 69 Crease Rollers
20, 70 Movable Forming Rings
21, 71 Filler Tubes for vertical heads (200, 220)
22, 72 Divided Forming Rings
23, 73 LS Nozzles
24, 74 LS Short Stop Nozzles
25, 75 Lower Forming Rings
26, 76 Tube Support Rollers
T1, T2 Tube at (200PP, 220PP)
(A, A’) and (B, B’) Pair of Forming and Cross Sealing assembly of (270) and (280)
(27’, 27) and
(77’, 77) Front and Rear Cross-sealing jaws of (A, A’) of (270) and
Front and Rear Cross-sealing jaws of (B, B’) of (280)
(28, 78) Final Folder Station Chain of Folders (290, 300)
P1, P2 Formed packages at vertical heads (200, 220) of machine (100)
(200 PP) Transfer Path for vertical heads (200)
(220 PP) Transfer Path for vertical heads (220)
(200LP, 200LP’) Lateral path of Chain C1 & C1’ of conveyor of forming and cross sealing assembly (A1) of (270)
(220LP, 220LP’) Lateral path of Chain C2 & C2’ of conveyor of forming and cross sealing assembly (B1) of (280)
(27 and 77) Jaws with Inductor
(27’ and 77’) Jaws with Polymer pad

Dated this 1st day of September 2023.

For UFLEX LIMITED
Digitally Signed::Filed via e-Filing-
Rachana Soni [IN/PA-4162]
AGENT FOR THE APPLICANT

, Claims:WE CLAIM:
1. An aseptic pack packaging machine (100) comprising:
a. a plurality of transfer paths (200PP, 220PP);
b. a plurality of strip applicator units (9, 59);
c. a plurality of vertical heads (200, 220);
d. a plurality of final folder assembly (290, 300);
e. an output feed (400);
f. a plurality of service units (201, 221);
g. an integrated PLC (320); and
h. an HMI panel (500) for setting and controlling the various units of the aseptic pack packaging machine (100).

2. The aseptic pack packaging machine (100) as claimed in claim 1, wherein an integrated pneumatic air panel (202) and an integrated water panel (208) are provided in any one of the service units (201 or 221) of the aseptic pack packaging machine (100).

3. The aseptic pack packaging machine (100) as claimed in claim 1 and claim 2, wherein an integrated hydraulic power pack (222) is provided in the service unit (221 or 201) not having the integrated air panel (202) and the integrated water panel (208) of the aseptic pack packaging machine (100).

4. The aseptic pack packaging machine (100) as claimed in claim 1, wherein each strip applicator unit (9, 59) is provided for uninterrupted supply and sealing of longitudinal seal (LS) strip (7, 57) on the packaging laminate (1, 51) by means of induction sealing.

5. The aseptic pack packaging machine (100) as claimed in claim 1, wherein each vertical head (200, 220) comprises a forming and filling unit (250, 260); and a cross sealing jaw unit (270, 280) for forming packages (P1, P2) in an independent transfer path (200PP, 220PP).

6. The aseptic pack packaging machine (100) as claimed in claim 1 and claim 5, wherein each forming and filling unit (250, 260) comprises a vertical sealing system with sealing either by hot air and pressing or induction sealing and pressing, in the vertical direction, along the transfer path (200PP, 220PP).

7. The aseptic pack packaging machine (100) as claimed in claim 1, wherein each cross-sealing jaw unit (270, 280) comprises a pair of Forming and cross sealing assemblies (A, A’) and (B, B’) respectively for the forming and cross-sealing of the tube (T1, T2) using an induction sealing.

8. The aseptic pack packaging machine (100) as claimed in claim 1, wherein each final folder (290, 300) comprises a final folder station chain (28, 78) to fold fins and flaps on top and bottom of the packages (P1, P2) of the aseptic pack packaging machine (100).

9. The aseptic pack packaging machine (100) as claimed in claim 1, wherein the output feed (400) may be provided separately for each vertical head (200 or 220) of the aseptic pack packaging machine (100).

10. The aseptic pack packaging machine (100) as claimed in claim 1, wherein the machine (100) is capable of packaging different volume sizes, simultaneously, by each vertical head (200 or 220) individually.

11. The aseptic pack packaging machine (100) as claimed in claim 1, wherein the machine (100) is capable of packaging same volume sizes simultaneously, by operating each vertical head (200 or 220) individually.

12. The aseptic pack packaging machine (100) as claimed in claim 1, wherein the machine (100) comprises two transfer paths (200PP, 220PP) for forming packages (P1, P2).

13. The aseptic pack packaging machine (100) as claimed in claim 1, wherein the machine (100) is used for non-aseptic packaging for products which are self-sterilizable like alcoholic beverages etc., by excluding a sterilization bath unit (12, 62), a cover for sterilization (13, 63) and an air knife (15, 65) from the forming and filling unit (250, 260) of the vertical heads (200, 220) of the machine (100).

Dated this 1st day of September 2023.

For UFLEX LIMITED

Digitally Signed::Filed via e-Filing-
Rachana Soni [IN/PA-4162]
AGENT FOR THE APPLICANT