DESC:PNEUMATIC HEAP SETTLING SYSTEM FOR REDUCING USE OF PACKAGING MATERIAL
Field of the invention:
The present invention generally relates to a product packaging machine and more particularly it relates to a pneumatic heap settling system in the product packaging machine for reduced use of packaging material.
Background of the invention:
Packaging machines for powdery products are normally filling and sealing type machines in which product packages are made with flexible packaging material. The flexible packaging material is drawn from a roll of such material and a tube of packaging material is formed in the machine. This tube is sealed vertically and also at the end horizontally to make a package with three sides sealed and upper side open. A predetermined quantity of product is dropped into the partially formed package. Finally the upper side of the package is sealed and the package is cut from the tube to make an individual pouch. In this process, the product in powder form forms a heap while it gets filled into the pouch and thus demands for more space or length of the pouch. The process consumes more packaging material in making lengthy pouches. Moreover, chances of leaky pouches are higher as product material from the heap may contaminate the horizontal seal. This decreases the overall productivity and efficiency. There is also a threat to quality of the product being delivered to end customer. Controlling air inside the pouch is also challenge when lengthy pouches are being produced.
Accordingly, there exists a need to provide a system for heap settling of the product during its packaging that will overcome the drawbacks of prior arts.
Objects of the invention:
An object of the present invention is to provide a pneumatic heap settling system for a product packaging machine to reduce the consumption of packaging material.
Another object of the present invention is to provide a heap settling system for a product packaging machine to reduce the proportion of leaky pouches and also to reduce the air content in it.
Still another object of the present invention is to provide a heap settling system for a product packaging machine to make the packaging process more productive and profitable.
Summary of the invention
Accordingly, the present invention provides a pneumatic heap settling system for reducing use of packaging material. The pneumatic heap settling system is fitted in a packaging machine. The packaging machine receives a continuous web of a flexible packaging material to transform into an open package having three sides sealed and one side open for dispensing a product in powder form therein. The forth side of the open package is sealed along a sealing line at a predefined height above the product level, once the predefined amount of product is dispensed therein. The pneumatic heap settling system of the present invention mainly comprises of a pneumatic cylinder, a valve for operating the pneumatic cylinder, a PLC controller and a clamp. The pneumatic cylinder is fitted with a piston slidingly mounted therein with a cylinder shaft having one end secured to the piston and the other end extending through the pneumatic cylinder. The flow control valve is connected to the pneumatic cylinder for supplying controlled flow of compressed air to move the piston in a reciprocating linear motion. The PLC control unit is operably connected to the flow control valve for controlling the reciprocating linear motion of the piston. The clamp having a pair of rods joined in ‘Y’ shape is hinged to the cylinder shaft through a hinge pin. The distance between the pair of rods is adjusted to remain aligned with the product filled open package there between, with each rod aligned on a side surface of the product filled open package. The pneumatic cylinder is operated at a high frequency to cause quivering of the open package thereby settling the heaped product below the sealing line, in a time period ranging from 50 millisecond to 2000 millisecond.
Brief description of the drawings:
The objects and advantages of the present invention will become apparent when the disclosure is read in conjunction with the following figures, wherein
Figure 1 shows detailed view of a pneumatic heap settling system for a product packaging machine, in accordance with the present invention;
Detailed description of the embodiments:
The foregoing objects of the present invention are accomplished and the problems and shortcomings associated with the prior art, techniques and approaches are overcome by the present invention as described below in the preferred embodiments.
The present invention provides a pneumatic heap settling system for a product packaging machine to reduce the consumption of plastic/ packaging material being used to pack the product. The system consists of a pneumatic cylinder with controlled flow of air supply. The cylinder end is hinged with string of rods at a particular distance so as these rods align over the sides of the packaging pouch filled with product and having upper side open. The cylinder is operated at highest frequency which enables the rods to tremble and lightly hit the packaging pouch from either side thereof. This action vibrates the product inside and it gets settled in milliseconds. Once the product is settled, upper side of the package is sealed just near the upper level of the product inside the pouch. This reduces the length of the package and saves the quantity of packaging material needed.
The present invention is illustrated with reference to the accompanying drawings, wherein numbers indicated in the bracket represent the components of the invention throughout the description. Table 1 below enlists the reference numerals and their corresponding components.
Table 1
Ref. No. Component Ref. No. Component
100 Heap settling system 40 Open package
10 Pneumatic cylinder 50 Flow control Valve
15 Cylinder shaft 60 Controller
20 Cylinder bracket 70 Product
25 Hinge pin 80 Inlet for compressed air
30 Clamp

Referring to Figures 1 and 2, a pneumatic heap settling system (100) for a product packaging machine (not shown in the figure) is shown. Hereinafter, the pneumatic heap settling system (100) will be referred as “the system (100)”.
In the packaging machine, a continuous web of a flexible packaging material, preferably plastic sheet is transformed into an open package (40) having three sides sealed and one side open for dispensing the product (70) therein. Once the predetermined amount of product (70) is dispensed into the open package (40), the open side of the package (40) is sealed along a sealing line at a predefined height (A) just above the product level. The product (70) is preferably in the form of fine powder.
The system (100) consists of a pneumatic cylinder (10) supplied with a controlled flow of compressed air and controlled using a PLC control unit (60). The pneumatic cylinder (10) secured to a bracket (20), uses the power of compressed air to produce a force in a reciprocating linear motion. The pneumatic cylinder (10) is fitted with a piston (not shown) slidingly mounted therein with a cylinder shaft (15) having one end secured to the piston and the other end extending through the pneumatic cylinder (10). In an embodiment, the pneumatic cylinder (10) is any one selected from a single acting pneumatic cylinder, a double acting pneumatic cylinder and a rotary cylinder
A flow control valve (50) is connected to the pneumatic cylinder (10) for supplying controlled flow of compressed air to move the piston in a reciprocating linear motion. The flow control valve (50) receives compressed air through an inlet (80) for compressed air. In an embodiment, the flow control valve (50) is any one selected from: a one way, three ports solenoid valve; a two way, five ports solenoid valve; etc. The PLC control unit (60) is operably connected to the flow control valve (50) for controlling the reciprocating linear motion of the piston. The type of flow control valve is suitably selected depending upon the type of pneumatic cylinder (10) used. In another embodiment, the pneumatic cylinder (10) is a servo-Pneumatic cylinder with controllers.
A clamp (30) having a pair of rods joined in ‘Y’ shape is hinged to the other end of cylinder shaft (15) through a hinge pin (25). Distance between two rods is adjusted in such a way that each rod of the pair of rods remains aligned on side surfaces of the product filled open package (40).
The product to be packaged is dispensed into the open package (40) with each rod of the pair of rods of the clamp (30) aligned on side surfaces of the product filled open package (40). The pneumatic cylinder (10) is operated at high frequency to cause quivering of the product filled package (40) thereby vibrating the inside product and settling the heaped product very short time period ranging from 50 millisecond to 2000 millisecond. Once the product (70) is settled below the sealing line, the upper end of the package (40) is sealed. The height (A) of sealing line is decided in such a way that the resulting package is having ‘length just enough’ to accommodate the product, thereby saving packaging material for every package.
Advantages of the invention:
• Saving in length of every pouch.
• Lesser consumption of packaging material;
• Lesser consumption of secondary packaging; hence saving in secondary packaging and logistic (distribution) cost of the product as size of each individual pouch is reduced.
• Better Seal Integrity
• Higher productivity
• More reliable output.
• Less air in pouch keeps product fresh for longer time. So extended shelf life.
The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention 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 invention and its practical application, and to thereby enable others skilled in the art to best utilize the present invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but such omissions and substitutions are intended to cover the application or implementation without departing from the scope of the claims of the present invention.
,CLAIMS:CLAIMS
We claim:
1. A pneumatic heap settling system (100) for reducing use of packaging material, the pneumatic heap settling system (100) to be fitted in a packaging machine, the packaging machine receiving a continuous web of a flexible packaging material to transform into an open package (40) having three sides sealed and one side open for dispensing a product therein, and sealing the open side of the open package (40) along a sealing line at a predefined height (A) above the product level once the predefined amount of product is dispensed therein; the system (100) comprising:
a pneumatic cylinder (10) secured to a bracket (20) and fitted with a flow control valve (50); the pneumatic cylinder (10) having a piston slidingly mounted therein with a cylinder shaft (15) having one end secured to the piston and the other end extending through the pneumatic cylinder (10); the flow control valve (50) receiving compressed air through an inlet (80) and supplying controlled flow of compressed air to move the piston in a reciprocating linear motion;
a PLC control unit (60) operably connected to the flow control valve (50) for controlling the reciprocating linear motion of the piston; and
a clamp (30) hinged to the other end of the cylinder shaft (15) through a hinge pin (25), the clamp (30) having a pair of rods joined in ‘Y’ shape with each rod of the pair of rods remaining aligned on a side surface of the product filled open package (40),
wherein and the pneumatic cylinder (10) is operated at high frequency to cause quivering of the open package (40) thereby settling the heaped product to a height below the height (A) of the sealing line, in a time period ranging from 50 millisecond to 2000 millisecond.
2. The pneumatic heap settling system (100) as claimed in claim 1, wherein the pneumatic cylinder (10) is any one selected from a double acting pneumatic cylinder, a single acting pneumatic cylinder and a rotary cylinder
3. The pneumatic heap settling system (100) as claimed in claim 1, wherein the flow control valve (50) is any one selected from: a two way, five port, pilot operated solenoid valve and a one way, three port solenoid valve.
Dated this on 1st day of April, 2020

Ashwini Kelkar
(Agent for the applicant)
(IN/PA-2461)