EP1584560A1

EP1584560A1 - Apparatus for the manufacture of a packaged food product.

Info

Publication number: EP1584560A1
Application number: EP05251967A
Authority: EP
Inventors: Jayan Ragavan
Original assignee: Individual
Current assignee: Individual
Priority date: 2004-03-30
Filing date: 2005-03-30
Publication date: 2005-10-12
Also published as: GB0407141D0; GB2412562A

Abstract

An apparatus for the manufacture of a packaged food product in a closed package, comprising: support means arranged to carry an open packaging article for said product; first dispensing means arranged to dispense a first component of said product to a said open packaging article carried on said support means; at least one further dispensing means arranged to dispense a further component of said product onto a said first component of said product carried by said packaging article; and closing means arranged to close said packaging article whereby to provide said packaged food product.

In particular, an apparatus in which a sandwich product is constructed in a receptacle which will form at least part of the packaging of the final food product. The apparatus will reduce the spillage of sandwich filings during the manufacture of the sandwich by constructing it within the packaging article which will form part of the final packaging of the sandwich product.

Description

The present invention relates to an apparatus, and corresponding method, for the automated production of sandwiches or other food products.

Background to the Invention

Mass produced sandwich products are typically constructed on production lines in the following manner. Production line workers are provided with the means necessary to construct sandwiches. These means include bread, sandwich spreads, sandwich fillings, tools for applying the spreads and fillings to the bread and packaging in which to place the finished sandwich. The workers are distributed along the production line and the available tasks required to construct the sandwich product are distributed amongst the workers. These tasks include positioning of a first slice of bread, application of the spreads and fillings, "lidding" the sandwich, i.e. positioning a second slice of bread on the fillings, positioning the sandwich for cutting, arranging the pieces of the cut sandwich for insertion into the packaging and inserting the arranged sandwich pieces in the packaging to form the sandwich product.
Various problems can be identified with production lines of the type described here.
Due in part to the need to ensure quality in the end product and in particular the need to ensure a sufficient amount of filing is present in the sandwich, a considerable amount of the fillings are spilt during the construction of the sandwich. This problem is augmented by the speed at which the production lines operate which place a requirement on each worker to complete their task(s) in a given time. Any spilt fillings are wasted and there are obvious direct financial consequences from the waste of a certain percentage of the fillings produced for use in the production process. In addition, the presence of spilt fillings on the production line decreases the level of hygiene which can be guaranteed by those operating the sandwich production process. The presence of spilt filings on the production line means that it must be cleaned regularly and at least each time the type of sandwich being produced is changed. Cleaning the production line is time consuming and requires additional workers. This has further financial implications as a result of the stoppage of the sandwich production process and the employment of additional workers.
Furthermore, the high number of production tasks completed by hand on each production line contributes to the potential for a reduced degree of hygiene. Although there are strict hygiene standards in the food industry, each individual is responsible for their own hygiene and the more individuals present, the higher the probability of an individual with sub-standard hygiene being present.
In addition, conventional sandwich product manufacture methods in which some of the steps are undertaken by hand, require the sandwich to be placed, by hand, in the correct position for cutting and require the finished sandwich to be placed, by hand, into its packaging. Human error can result in the sandwich being cut incorrectly or at least unevenly and damage to the sandwich when placed in its packaging.
It is known to deliver, to an open sandwich, on a production line the sandwich fillings by automated means from a hopper with a suitable delivery nozzle and portion control means. However, the step of ensuring that the fillings are evenly distributed on the bread is usually carried out by hand and thus the problems of spillage are not eliminated.
Automated cutting of the finished sandwich is also known, however, the positioning of the sandwich for cutting and the removal of the sandwich from the cutting area is undertaken by hand.
The use of entirely automated lines is known and typically they utilise electro mechanical devices or 'hands' which act as substitutes for workers. Such lines are cumbersome and expensive and they do not address the spillage and hygiene problems described above.
However, each worker on a production line is a cost and it is desirable to reduce the number of workers on any given production line.
Conventionally, butter is applied to bread as it passes along the production line. This can result in inaccurate spreading and spillage onto the production line. It would be desirable if the buttering process could be improved or automated to reduce these problems.

Summary of the Invention

The present invention provides an apparatus for the manufacture of a packaged food product in a closed package, comprising:
support means arranged to carry an open packaging article for said product;
first dispensing means arranged to dispense a first component of said product to a said open packaging article carried on said support means;
at least one further dispensing means arranged to dispense a further component of said product onto a said first component of said product carried by said packaging article; and
closing means arranged to close said packaging article whereby to provide said packaged food product.
Thus, an apparatus in which each food product is constructed in a receptacle which will form at least part of the packaging of the final food product is provided. The apparatus will reduce, and preferably eliminate, the spillage of components of the food product during the manufacture of the food product by constructing it within the packaging article which will form part of the final packaging of the food product. The reduction in food product component spillage reduces the frequency at which the apparatus must be cleaned and improves hygiene levels on the production line.
The food product may be a sandwich product. In this case the first component may be a slice of bread. The at least one further dispensing means may comprise at least one second dispensing means arranged to dispense a sandwich filling onto the slice of bread and a third dispensing means arranged to dispense a further slice of bread onto the sandwich filling(s).
The second dispenser(s) may be changed each time a different sandwich product is to be manufactured and this removes the need to clean them while 'online'. The second dispensing means can be cleaned 'offline' allowing the sandwich production process to continue. This prevents the sandwich manufacturing process from being stopped each time a new sandwich product is to be manufactured.
The present invention preferably provides that each of the first and third dispensing means comprise a butter applicator. The butter applicator may be arranged to apply, by automated means, butter or other edible fat to the underside of the bread while in transit from a stack of bread to the packaging article. The butter applicator is preferably arranged to prevent spillage of butter outside the applicator itself and to spread butter uniformly across one surface of each slice of bread.
Preferably, the present invention provides spreading means which spreads the sandwich fillings evenly over the bread while in the packaging article. By spreading the sandwich fillings on the bread while in the packaging, spillage is reduced and preferably eliminated. Preferably the spreading means is an ultrasonic head in which the ultrasonic head does not stick to the fillings and therefore prevents filling build up, reducing the hygiene and cleaning problems associated with conventional manual spreading techniques.
The apparatus may further comprise cutting means which may be an ultrasonic blade. Therefore, if the sandwich product is to be presented in two pieces, it may be cut using the ultrasonic blade and if required so can the packaging. An ultrasonic blade vibrates at ultrasonic frequencies and at this speed, non of the sandwich components stick to the blade which reduces the amount of cleaning required and increases hygiene levels.
As the sandwich is constructed in its packaging which is positioned on a support, the position of the sandwich in relation to the various means which are constructing it are known. Thus, the sandwich can be cut more accurately and the problems associated with manual placing of the sandwich in conventional methods are reduced. In addition, the problems which arise in manually inserting the sandwich into its packaging, including damage to the product, are reduced as the sandwich is already in its packaging once completed.
The present invention therefore enables at least some of the steps of the sandwich manufacture process which are conventionally undertaken by hand to be automated. Thus, the present invention reduces the number of workers required on any given production line when compared to conventional production lines.

Brief description of the drawings

In order that the present invention be more readily understood embodiments thereof will now be described by way of example only and with reference to the accompanying drawings in which:
Figure 1 shows a top view of the apparatus in an embodiment of the present invention.
Figure 2 shows a top and two side views of the infeed conveyor in an embodiment of the present invention.
Figure 3 shows a side, a top and a further side view respectively of the receptacle in an embodiment of the present invention when in position on a pallet.
Figure 4 shows two side and a top view of the bottom slice bread infeed conveyor in an embodiment of the present invention.
Figure 5 shows two side views of the butter applicator in an embodiment of the present invention.
Figure 6 shows a filling delivery station in an embodiment of the present invention.
Figure 7 shows a side view of the top slice bread infeed conveyor of an embodiment of the present invention.
Figure 8 shows a side view of the ultrasonic blade in an embodiment of the present invention.
Figure 9 shows a top and two side views of the outfeed conveyor in an embodiment of the present invention.
Figures 10, 11 and 12 show packaging articles in alternative embodiments of the present invention.

Detailed description of the preferred embodiments of the present invention

Figure 1 shows a sandwich production apparatus 1 for the production of sandwich products in the preferred embodiment of the present invention. The sandwich production apparatus comprises an infeed conveyor 2, a production conveyor 3, a bottom slice infeed conveyor 4, at least one filling delivery station 5, a top slice bread infeed conveyor 6, a ultrasonic blade 7, an outfeed conveyor 8 and two butter applicators 9, one associated with each bread infeed conveyor. Each module will be described herein in more detail and in relation to the other modules together with the operation of the sandwich production apparatus. It should be noted that the apparatus shown in Figure 1 and described herein is done so in relation to the production of conventional triangular sandwich products. For the avoidance of doubt such sandwich products typically comprise two equilateral triangular shaped sandwich portions which are placed side by side and inserted into equilateral triangular shaped packaging. However, it will be appreciated that the present invention is not limited to the production of such sandwich products. The type of sandwich products and packaging which may be made the subject of the present invention are discussed in more detail below.
The infeed conveyor is shown in detail in Figure 2 which shows the top and two side views of the infeed conveyor.
Figures 2 shows two stacks of containers 10. These containers are shown in more detail in Figure 3 in which two containers are shown laid side by side.
When laid side by side the two containers form a receptacle 14 with a space suitable for the receipt of two conventional square sandwiches, one placed on top of the other. The containers are folded and cut such that when laid in the position shown in Figure 3, each of the upper triangular shaped sides 11 can be folded out into a vertical position whereby the substantially square foot print of the receptacle is entirely accessible from vertically above the receptacle.
Figure 2 shows two pick and place rotating robots 12. Each robot is located beneath a stack of containers and each comprise an extendable arm 17. Also shown is a first clamp 13 and a side panel separator 16. The initial operation of the infeed conveyor is as follows.
Each rotating robot is rotated so that the extendable arm is facing the vertical. i.e. facing the underside of the respective stack of containers. At the end of each extendable arm is a means 18 arranged to receive a container. Once positioned beneath the stack of containers the extendable arm extends into contact with the container at the bottom of the stack of containers. The extendable arm then retracts with a container attached to means 18. The extendable arm is arranged to retract a distance which is sufficient to ensure the container is clear of the remaining stack of containers. Each rotating robot then rotates its respective container through 90° so that the two picked containers are facing each other. At this stage the first clamp 13 and the separator 16 are each in their respective position A. The extendable arm of each rotating robot is the extended until the two containers attached to each means 18 are in contact. Each container comprises flaps 15 around the periphery of the edges which meet as shown in, amongst others, Figures 2 and 3. These flaps serve dual purposes. Firstly when the containers are placed side by side as shown in Figure 2, the flaps enable the containers to be securely held together as a single receptacle. Secondly as will become apparent herein below, the flaps also enable the finished sandwich product to be sealed shut.
Once the flaps 15 are in contact with those flaps of the opposing container the first clamp moves from position A to position B thereby holding the two containers together.
It will be apparent form the described operations that the separator is now positioned within the two containers with its stem connected to the separator holder 19 through the gap between the side panels 11. The holder then moves vertically away from the containers whereby the arms of the separator raise the side panels to the vertical position. Once the side panels are raised to the vertical the separator remains in position B to keep the side panels vertical. The means 18 then release the containers at the same time as the extendable arm retracts and the rotary robot readies itself to receive a further container from the stack.
Following the positioning of two containers side by side and the separation of a side panel of each container from the rest of the container, the containers form a receptacle 14 which is of the shape required for the receipt of a conventional square sandwich. The next stage of the sandwich production process is to load the receptacle onto a pallet 20 while substantially maintaining its shape.
A pallet 20 is shown in Figure 3. The pallet comprises a base 21, a pair of receptacle retainers 22 attached to opposing sides of the base and spaced apart a distance equivalent to the diagonal across the two containers forming the substantially square receptacle, a pair of side panel retaining arms 23 each attached to a receptacle retainer, a recess portion 24 in the middle of the base, a groove 25 running through the middle of the base between the receptacle retainers and through recess portion and a pair of sprung strips 26 positioned in the recess and arranged to clamp any article positioned in the groove.
Figure 3 also shows the receptacle 14 positioned on the pallet. When in position the bottom of the receptacle rests of the base of the pallet with the portion of the flap 15 running along the bottom of the receptacle poisoned in the groove. As will become apparent from the description of the process of loading the receptacle onto the pallet, the receptacle is slid in from one side such that the flap 15 slips along the groove thereby being clamped by the sprung strips 26. The receptacle retainers ensure that the receptacle is positioned on the pallet correctly by way of flaps 27. The side panel retaining arms ensure that the side panels remain in a vertical position once positioned on the pallet.
Referring now to Figure 2 which shows the infeed apparatus.
The first clamp 13 is attached to a first rail runner 28 which is arranged to run along a first rail 29. Immediately following the formation of the receptacle in the shape shown in Figure 2, the first rail runner is in position A. The first step is for the first rail runner to move to position B. However, the separator 16 remains in a fixed position with respect to the horizontal movement of the first rail runner and thus as the receptacle is moved with the first rail runner the separator will not be able to maintain separation of the side panels. Thus, a pair of side panel separation maintainers 30 are provided as shown in Figure 2. As the first rail runner begins to move towards position B the separation maintainers engage with the side panels ensuring that once the separator 16 is left behind the side panels remain in the vertical position. The separation maintainers extend all the way to the pallet on the production conveyor 3. The receptacle side thus remain in the vertical by virtue of the separation maintainer until the receptacle is positioned on the pallet.
Once first rail runner 28 is in position B a second clamp 31 clamps onto flap 15 as shown in Figure 2. Once the second clamp is clamped round flap 15 the first clamp 13 releases the flap 15 and returns together with the first rail runner to its position A in readiness to receive further receptacles.
Second clamp 31 is attached to a second rail runner 32 which is arranged to run along a second rail 33. When the second clamp receives the receptacle the second rail runner 32 is in position A. The second rail runner then moves to position B. In doing so the side panels 11 of the receptacle remain in the vertical by moving along the separation maintainer 30. Once the second rail runner is in position B an overhead double clamp 34 is lowered over the receptacle by extendable arm 35. A pair of clamps 36 and 37 clamp the portions of the flap 15 which run along the side of the receptacle. Once the pair of clamps are clamped in place the second clamp 31 releases the flap 15. The second rail runner then returns to its position A in readiness to receive a further receptacle.
The overhead double clamp is connected to an extendable arm 35 which is in turn connected to a third rail runner 38 which is arrange to run along a third rail. When the receptacle is first clamped by the pair of clamps 36, 37 the third rail runner is in position A. It then moves to position B. In doing so the receptacle is positioned on the pallet 20 as described above and is released from the separation maintainer 30. The pair of clamps 36, 37 then release the receptacle, the extendable arm 35 retracts and the third rail runner 38 returns to position A in readiness to clamp a further receptacle.
The pallet then progresses along the production conveyor towards the next stage of the process, the provision of a bottom slice of bread to the receptacle by the bottom slice bread infeed conveyor 4, as shown in Figure 1.
Figure 4 shows the details of the bottom slice bread infeed conveyor 4.
Figure 4 shows dual conveyor belts 39, 40, rotatable vacuum pick-up head 41, arm 42, butter applicator 9 and inverted bread escapement 43. Stacks of conventional square bread slices are moved into position in line with the butter applicator by the dual conveyor belts. The arm 42 positions the rotatable vacuum pick-up head above a stack of bread 44 so that the surface of the vacuum pick-up head is level with the top slice of bread. The vacuum pick-up head is then lowered onto the top slice of bread and turned on. The top slice of bread is sucked against the vacuum pick-up head and the arm can be moved to take the top slice of bread away from the stack. The slice of bread 45 is then moved to the butter applicator (described in more detail herein below) where a layer of butter is applied to the exposed underside of the slice of bread 45. The slice of bread is then moved into position C, above a receptacle and inverted by the rotatable vacuum pick-up head so that the butter side faces upwards.
The detail of the inverted bread escapement 43 shows an extendable arm 46, which lowers an inverted bread holder 47 towards the upturned slice of bread 45. The inverted bread holder comprises two extendable arms 48, 49 which extend horizontally from opposing sides of the head 50 of the inverted bread holder. Attached to either extendable arm 48, 49 are plates 51 with bent ends 52 which are arranged to hold the slice of bread. When the inverted bread holder is lowered to the slice of bread the extendable arms 48, 49 are extended such that the bent ends 52 clear the slice of bread. Once in position the extendable arms 48, 49 retract and the bent ends clamp the slice of bread. The vacuum pick-up head can then be turned off and returned to the stack 44 in readiness to collect a new slice of bread.
The extendable arm 46 then lowers the inverted slice of bread to the receptacle and when low enough the extendable arms 48, 49 extend dropping the bread onto the base of the receptacle. The inverted bread holder then returns to its original position in readiness for receiving a new slice of bread.

Butter applicator

Figure 5 shows the details of the butter application and in particular shows a temperature controlled water tank 53, a removable butter reservoir 54, a removable butter applicator roller 55, a butter applicator blade 56, a sizing roller with scraper 57, the above-mentioned servo controlled articulated vacuum pick up head 41, a slice of bread 45, a servo drive 58, a gear train 59 and a timing belt drive 60. The operation of the butter applicator is as follows. The leading edge 61 of the slice of bread is first positioned on the butter applicator roller at the point where the butter applicator blade rests on the roller. The blade is sprung so that it exerts downwards pressure on the roller. Simultaneously, the arm 42 moves the slice of bread so that the underside of the bread remains in contact with the roller and such that the trailing edge 62 of the slice of bread moves towards the point where the blade 56 meets the roller 55 and the servo drive 58 drives the applicator roller.
As the roller rotates it collects butter from the reservoir 54. The butter is heated so that it is viscous enough to stick to the roller and is runny enough to spread on the slice of bread. The sizing roller 57 controls the thickness of the layer of butter which is presented to the slice of bread. The sizing roller includes a scrapper 63 which scrapes any excess butter off the sizing roller. The controlled layer of butter on the roller continues to the blade 56 where it is scrapped off the roller and onto the bread. Once the slice of bread is buttered the training edge has reached the point on the roller where the blade contacts the roller, the arm 42 moves the bread away from the roller and the servo drive stops the roller. The process is repeated for further slices of bread.
The robot head holding the bread can utilise a pressure sensor and a controlling device which are arranged to control the robot head speed and contact pressure between the bread and the roller, thus providing better control of the butter application process.
Returning to Figure 1 once the receptacle has received a slice of buttered bread the pallet progresses along the production conveyor to a first filling delivery station 5.
Figure 6 shows a filing delivery station 5 in an embodiment of the present invention. The filling delivery station comprises a hopper 90 and a conveyor 91. The hopper and conveyor are arranged to deliver fillings to the first slice of bread in the receptacle 14.
The sandwich production apparatus 1 may comprise one or more filing delivery stations depending on the type of sandwich product being manufactured. When a change in sandwich type is required the entire filling delivery(s) can be removed and new ones put in place with different fillings contained therein. The removed filling delivery stations can then be cleaned "off-line" allowing production of the new sandwich type to continue.
The apparatus 1 may further comprise an ultrasonic spreader. An ultrasonic spreader vibrates at ultrasonic frequencies and thus fillings do not stick to it. An ultrasonic spreader can be used to spread the fillings on the bread once the filling delivery station has delivered the fillings to the receptacle.
Once the receptacle has received all the fillings for the particular sandwich being produced the pallet progress to the next stage of the sandwich production process, the provision of a top slice of bread to the receptacle.
The top slice bread infeed conveyor 6 operates in substantially the same way as the bottom slice bread infeed conveyor 4 except that there is no inverted bread escapement. Figure 7 shows the details of the top slice bread infeed conveyor and features which correspond to features of the bottom slice of bread infeed conveyor 4 are identified with like reference numerals.
The pallet then performs another loop of the sandwich productive process so that two conventional square sandwiches are positioned in the receptacle one top of another.
Following the second provision of a top slice of bread the pallet progresses to the ultrasonic blade 7. The details of the ultrasonic blade are shown in Figure 8. The ultrasonic blade is lowered to the sandwich in the receptacle and cuts the square sandwiches along the diagonal which is in alignment with the diagonal of the receptacle where the containers join. The ultrasonic blade cuts the sandwich only and not the containers. The receptacle containing the cut sandwiches is then progressed on its pallet to the next stage of the process which is the outfeed conveyor 8.
Figure 9 shows the details of the outfeed conveyor. The first stage of the outfeed process is the removal of the receptacle from the pallet. This is done by a second overhead double clamp 70 which is identical to the overhead double clamp 34.The second overhead double clamp acts in the reverse manner to the first overhead double clamp and is not described here in detail. The second overhead double clamp slides the receptacle away from position A and into position B.
There is no separation maintainer on the outfeed conveyor as there is no longer a need to keep the side panels 11 in the vertical.
Once in position B a third clamp 71 clamps onto flap 15 on the bottom of the receptacle. The overhead double clamp then releases the receptacle and returns to position A to collect a further receptacle. The third clamp 71 is attached to a fourth rail runner 72 which is arranged to run along rail 73. When clamp 71 receives the receptacle, rail runner 72 is in position A. The rail runner then moves to position B.
In doing so the side flaps 11 are gradually closed by side panel closer 74. Once the fourth rail runner is in position B a fifth clamp 75, clamps onto the exposed part of flap 15. The fourth clamp then releases the flap 15 and returns with the forth rail runner to position A in readiness for a further receptacle. The fifth clamp is connected to a fifth rail runner 76 which is arranged to run along rail 77. When the fifth clamp receives the receiver the receptacle it is in position A. The rail runner then moves to position 13. Once in position B the side panels of the receptacle are completely closed.
Two rotating robots 78, 79, each has attached to it means for picking up one of the two containers making up the receptacle. When the fifth rail runner 76 has moved to position B each means for picking up, attaches itself to one of the respective containers. Once the means for picking up have attached to the containers the fifth clamp 75 releases the flap 15 and the fifth rail runner returns to position A in readiness to receive a further receptacle.
Each container is then turned through 90° so that the open side is facing upwards. In doing so the containers become supported by a respective conveyor 80. Around each conveyor 80 are placed supporting arms 81 which are spaced a distance apart substantially equal to the length of the open side of the containers. The flap 15 then rests on the supporting arms 81.The containers can then progress along the top horizontal section of the conveyor.
The next stage in the outfeed process is the provision and sealing of lids on the open side of the containers. The containers progress along the conveyor to the lid machine 82 which is arranged to seal the containers.
Once the container has been sealed with a lid it progresses to the label applicator 83 which is arranged to label the sandwich products.
Once the container has been labelled the finished sandwich product is removed from the conveyor. This is achieved using product remover 84. The product remover comprises a suction head 85, an extendable arm 86, a rail runner 87 and a rail 88. The rail runner begins at position A and when a finished sandwich product arrives beneath the such head the extendable arm extends so that the suction head is in contact with the lid of the sandwich product. The suction head is then turned on and the extendable arm is retracted thereby lifting the sandwich product clear of the conveyor. The rail runner 87 then moves to position B from where the sandwich product can be placed into an appropriate storage device for transportation.
The preferred embodiment of the present invention has been described above in terms of a particular production line layout, sandwich type and packaging type, amongst other things. The modular nature of the production line means that various other arrangements of the various elements which make up the sandwich production apparatus can be made to achieve the same result as the particular apparatus described above. That result being the construction of a sandwich or other food product in a receptacle which will form at least part of the packaging of the final food product.
Additionally, although the embodiment described here is an apparatus in which each element of the apparatus is an automated machine, some of the elements may be substituted with a manual process. For example, the delivery or spreading of the fillings in the receptacle may be undertaken by a worker if this is, for example, more convenient than using a filling delivery station or ultrasonic spreading means. The use of manual stages maintains the advantages associated with the present invention in that the sandwich product is still constructed in the receptacle that will form at least part of the final product.

Sandwich product variants and packaging

Although the present invention has been described here in detail with reference to a conventional triangular shaped sandwich products, the present invention is not limited to them. Additionally, although the present invention has been described here in relation to the manufacture of conventional triangular sandwiches using a receptacle comprising two containers which each form a different one of two triangular sandwich products made from two square sandwiches, the present invention is not limited to such packaging arrangements. Some examples of alternative packaging and sandwich types are described here by way of example only.
Generally, the packaging is substantially preformed although this may be done either off site or by a package making machine at the beginning of the production line before the infeed conveyor. The packaging may be made of thermoform plastic, as in conventional sandwich production, or with any suitable materials.
Figure 10 shows a square packaging article 100 which is arranged to receive two conventional square sandwiches, one on top of another. The article 100 comprises a fold 101 which runs horizontally down one side panel of the article and a cut 102 which runs along the base, in line with the fold 101, and up the side wall opposing that in which the fold 101 is made.
Once the sandwiches have been placed in the packaging article 100 the ultrasonic blade cuts the sandwiches in line with the cut 102 and fold 101. The packaging article may then be folded along fold 101, such that side panel portions 104 and 105 are touching. The packaging article is then be subjected to a process such as flow-wrapping to seal the sandwiches in the packaging article and the fold 101 is cut. The result is two rectangular shaped sandwich products each containing two rectangular shaped sandwiches, one placed on top of the other.
Figure 11 shows a further square packaging article 200. This article may be arranged to receive a single conventional square sandwich. In this case, once the sandwich is in place, the lid 201 is folded along fold 202 and sealed to flaps 203 to 205. Thus a single square sandwich product is produced.
Figure 12 shows a triangular packaging article 300. The process for producing triangular sandwich products using this article is similar to the main embodiment described above.
The article 300 is positioned by an infeed conveyor on a pallet side by side with another article 300. Each of two articles are folded along fold 301 such that panels 302 and 303 point vertically downwards. The panels 302 and 303 of two opposing articles are positioned against each other so as to form a single square space. Two conventional square sandwiches are then positioned in the space as for the main embodiment. Once the sandwiches have been placed and cut the two articles can be separated in much the same way as for the main embodiment. However, in this case, the panels 302 and 303 are folded over the sandwich portions and sealed against flaps 304 and 305.

Claims

1. Apparatus for the manufacture of a packaged food product in a closed package, comprising:

support means arranged to carry an open packaging article for said product;

first dispensing means arranged to dispense a first component of said product to a said open packaging article carried on said support means;

at least one further dispensing means arranged to dispense a further component of said product onto a said first component of said product carried by said packaging article; and

closing means arranged to close said packaging article whereby to provide said packaged food product.

2. Apparatus according to claim 1 further comprising supply means arranged to provide said support means with said packaging article.

3. Apparatus according to claim 1 or 2 further comprising transport means arranged to transport said support means.

4. Apparatus according to claim 3 when dependent on claim 2 wherein said transport means is arranged to transport said support means between the supply means, the first dispensing means, the at least one further dipensing means and said closing means.

5. Apparatus according to claim 4 wherein said transport means is arranged to move said support means between said supply means, the first dispensing means, the at least one further dispensing means and said closing means in that order.

5. Apparatus according to claims 3, 4 or 5 in which said transport means is a conveyor belt.

6. Apparatus according to any preceding claim in which said food product is a sandwich product.

7. Apparatus according to claim 6 wherein said first component means is a slice of bread.

8. Apparatus according to claim 7 wherein said first dispensing means further comprises bread supply means arranged to supply said first dispensing means with bread.

9. Apparatus according to claims 6, 7 or 8 wherein said at least one further dispensing means comprises at least one second dispensing means arranged to dispense a sandwich filling onto said slice of bread.

10. Appartaus according to claim 9 further comprising spreading means arranged to spread said sandwich fillings on said slice of bread.

11. Apparatus according to claim 10 wherein said speading means is an ultrasonic spreading means.

12. Apparatus according to any of claims 6 to 11 wherein said at least one further dispensing means further comprises a third dispensing means arranged to dispense a slice of bread onto said sandwich filling(s).

13. Apparatus according to claim 12 wherein said third dispensing means further comprises bread supply means arranged to supply said third dispensing means with bread.

14. Apparatus according to any preceding claim further comprising cutting means arranged to cut said food components.

15. Apparatus according to claim 14 in which said cutting means cuts said food components and said packaging article.

16. Apparatus according to claims 14 or 15 when ultimately dependent on claim 4 wherein said transport means is further arranged to transport said support means to and from said cutting means.

17. Apparatus according to any preceding claim in which said closing means is arranged to fold or otherwise manipulate said packaging article to close it.

18. Apparatus according to claim 17 wherein said closing means is a removal means arranged to remove said open packaging article containing said food components from said support and close said packaging article whereby to provide said packaged food product.

19. Apparatus according to claim 18 in which said closing means is arranged to apply a further packaging component to a said opening packaging component to close it.

20. Apparatus according to any of claims 7 to 19 when ultimately dependent on claim 7 further comprising means arranged to apply edible fat to said slices of bread.

21. Apparatus according to claim 20 wherein said first and third dispensing means each further comprise said means arranged to apply edible fat to said slices of bread.

22. Apparatus according to claims 20 or 21 wherein said means arranged to apply edible fat is further arranged to apply edible fat to said slice of bread before said slices of bread are dispensed to said packaging article.

23. Apparatus according to claim 20, 21 or 22 in which said edible fat is butter.

24. Apparatus according to any of claims 14 to 23 when ultimately dependent on claim 14 in which said cutting means is an ultrasonic blade.

25. Apparatus according to any of claims 6 to 24 when ultimately dependent on claim 6 wherein said sandwich product is a conventional triangular sandwich product.