AU2009204640A1 - Method and apparatus for providing a tray insert - Google Patents

Abstract

Provided is an apparatus and associated method for transferring nested tray inserts or containers from a tray insert support apparatus to respective trays provided by a tray provider. The apparatus and method allow for automation of the transfer of tray inserts or containers in that gravity acts to separate at least one of the stack of nested tray inserts or containers from the remainder of the tray inserts or containers.

Description

WO 2009/089583 PCT/AU2009/000042 METHOD AND APPARATUS FOR PROVIDING A TRAY INSERT TECHNICAL FIELD 5 The present invention relates to apparatus and methods for providing tray inserts. The invention has been developed in relation to a food product support tray that is formed from cardboard, plastic, silicone, metal or other formable material and includes tray inserts in the form of nestable containers or cups. The invention is hereinafter described by way of example in this context. However, it is to be 10 understood that the invention does have broader application, to a carrier for any product. BACKGROUND ART 15 In the application where the tray is a cake or muffin tray, an insert, such as a patty-pan, may be provided to act as a container, or cup, to receive and contain a portion of cake or muffin mix during baking or for storage. In this application, the tray includes apertures, or similar, in which the inserts are placed. This process of inserting the inserts is ordinarily a manual process. Automated insertion of the inserts 20 would be considered to be particularly problematical. Trays, such as food product support trays, are composed of card, plastic. flexible material such as silicone or metal. In the case where the tray is formed of card, the trays are typically delivered to a receiving plant and/or to a processing stage in a flattened form, and the trays are pre-formed with fold lines to facilitate their 25 erection into a three-dimensional shape that is suitable in any given case for supporting an intended product. Depending on the type of tray used, the erection process normally involves an initial pushing stage, during which intended side panels are forced to move from a flat (typically horizontal) position to a substantially perpendicular (typically vertical) position, and a folding stage during which end flaps 30 or panels are forced to move from the flat position to complete the three-dimensional structure.

WO 2009/089583 PCT/AU2009/000042 -2 SUMMARY OF THE INVENTION According to a first aspect of the invention there is provided apparatus for 5 releasably retaining a nested stack of containers, the apparatus comprising: a first support configured to support a bottommost container in the container stack; and a second support spaced from the first support and configured to support one or more other containers in the container stack such that a load from the one or more 10 other containers on the bottommost container is reduced. Advantageously, in providing a second support spaced from the first support configured such that a load from one or more containers on the bottommost container is reduced, this allows the apparatus to be configured such that containers in the nested stack can be removed singly given that downward pressure due to containers in 15 the stack above the bottommost container as reduced and the sidewalls of the bottommost container are not forced excessively against the first support. The load may be a gravitational load. Optionally, the apparatus comprises a support structure for supporting the first and second supports in their spaced relationship. The support structure may provide lateral support of the container stack. 20 Also, the support structure may comprise at least three longitude and all elements. Optionally, the first and/or the second support comprises an aperture. The aperture may be a circular or a polygonally-shaped aperture. Preferably, the aperture of the first support may be shaped and sized substantially identically to the aperture of the second support. 25 Optionally, the apparatus may be arranged to releasably retain a stack of nested containers each having a base and at least one upwardly extending and outwardly tapered sidewall defining an opening opposite its base. Optionally, the at least one sidewall defines an irregularly shaped opening at its end opposite the container's base. Optionally, the spaced distance between the first 30 and second supports may be greater than the distance between the first support and the opening of the bottommost container. Optionally, the spaced distance between the first WO 2009/089583 PCT/AU2009/000042 -3 and second supports is such that the first support is arranged to support a stack of about three to twenty of bottommost containers of the container stack and the second support is arranged to support the remaining containers of the container stack. Optionally, the apparatus comprises a plurality of second reports, each 5 corresponding to a respective said first support, such that the apparatus is configured to support a plurality of said stacks of containers. According to a second aspect of the invention there is provided method for transferring tray inserts from a tray insert support apparatus to respective trays provided by a tray provider, the method comprising the steps of: 10 (i) contacting a first surface of at least one tray insert to move the at least one tray insert from the tray insert support apparatus to a transfer component; and (ii) contacting a second surface of the at least one tray insert to move the at least one tray insert in the transfer component to a tray provided by a tray provider. Optionally, the method comprises the step, after the step (i), of moving the 15 transfer component between the tray insert support apparatus and the tray provider. Optionally, in steps (i) and (ii), the at least one tray insert is moved on its axis, and in the step of moving the transfer component, the at least one tray insert is moved laterally with respect to its axis. Optionally, the tray insert support apparatus is configured to support at least one stack of tray inserts and the transfer component 20 comprises aperture(s) corresponding to respective said stack(s) of tray inserts. Optionally, prior to step (i), the transfer component is located between a contact device and the tray insert support apparatus, and step (i) comprises moving at least part of the contact device through the aperture(s) of the transfer component to contact the first surface of the at least one tray insert. Optionally further, prior to step 25 (ii), the transfer component may be located between a second contact device and a tray on the tray provider, and step (ii) comprises moving at least part of the second contact device through the aperture(s) of the transfer component to contact the second surface of the at least one tray insert. The insert may be a nestable container having a base and an upstanding 30 sidewall, the first surface is an external surface of the container base and the second surface is an internal surface of the container base.

WO 2009/089583 PCT/AU2009/000042 -4 As will be understood, the method of this aspect is advantageous in that it allows for the withdrawal of a nested container from a stack of containers and subsequent placement of the container into a tray which may have a base upon which the container rests. 5 According to a third aspect of the invention there is provided an apparatus for transferring tray inserts from a tray insert support apparatus to respective trays provided by a tray provider, the apparatus comprising: (i) a first contact device configured to contact a first surface of at least one tray insert to move the at least one tray insert from the tray insert support apparatus to a 10 transfer component; and (ii) a second contact device configured to contact a second surface of the at least one tray insert to move the at least one tray insert in the transfer component to a tray provided by a tray provider. Optionally, the transfer component may be configured to move between the 15 tray insert support apparatus and the tray provider. Optionally, the first and second contact devices may be configured to move the at least one tray insert on its axis, and the transfer component is configured to move the at least one tray insert laterally with respect to its axis. The tray insert support apparatus may be further configured to support at least one stack of tray inserts and the transfer component comprises 20 aperture(s) corresponding to respective said stack(s) of tray inserts. The insert may be a nestable container having a base and an upstanding sidewall, the first surface is an external surface of the container base and the second surface is an internal surface of the container base. Also, the transfer component may comprise comprises a plurality of said 25 apertures arranged in an array. Optionally, the first contact device may comprise an arm arranged to attach to a bottom surface of a container and to withdraw the container from the tray insert support device and locate it in the transfer device. The arm may comprise a suction device on an end thereof for releasably attaching to the bottom surface. The second 30 contact device may comprise a second arm arranged to push a container from the transfer device to a corresponding aperture in a tray on the tray provider. Optionally, WO 2009/089583 PCT/AU2009/000042 -5 the first mentioned arm and second arm are arranged such that they each move the container in the same axial direction. The apparatus is advantageous in that that it allows for the withdrawal of a nested container from a stack of containers and subsequent placement of the container 5 into a tray which may have a base upon which the container rests. According to another aspect of the invention there is provided an apparatus for providing a tray insert comprising a tray insert support device; a tray provider for providing trays configured to receive at least one said tray insert; and the apparatus for transferring tray inserts of the abovementioned aspect. 10 Optionally, the tray insert support device may comprise the apparatus of the first mentioned aspect, wherein each said container from the stack of containers is a tray insert. According to another aspect of the invention there is provided an apparatus for releasably retaining a stack of nested containers, the apparatus comprising a support 15 configured to support the stack of nested containers such that gravity acts to separate at least one of the stack of nested containers from the remainder of the containers. In one form the support comprises a hopper configured to support the stack of nested containers, the hopper adapted to orient the stack of nested containers such that gravity acts to separate the nested containers. 20 According to another aspect of the invention there is provided an apparatus for releasably retaining a stack of nested containers, the apparatus comprising: a support configured to support the stack of nested containers; and a transfer device for transferring containers from the support to a delivery tray, the transfer device comprising a rotatable arm, the rotatable arm having a contact device 25 configured to contact a surface of the container to move the container from the support to the delivery tray. According to another aspect of the invention there is provided an apparatus for transferring tray inserts from a tray insert support apparatus to respective trays provided by a tray provider, the apparatus comprising: 30 a support configured to support the stack of nested containers; and, a transfer device for transferring containers from the support to a transfer tray, WO 2009/089583 PCT/AU2009/000042 -6 the transfer device being configured to move through the transfer tray to transfer containers from the support to the transfer tray. According to another aspect of the invention there is provided an apparatus for transferring tray inserts from a tray insert support apparatus to respective trays 5 provided by a tray provider, the apparatus comprising a support configured to support the stack of nested containers; and, a transfer device for transferring containers from the support to a transfer tray, the transfer tray being rotatable about its axis. As will be appreciated, the use of spatial terms, such as "bottommost", "uppermost", "above", "below", "upper", "lower", "vertical", "horizontal", etc, are 10 not to be taken in an exact literal sense but rather in a relative sense, unless the context requires otherwise. BRIEF DESCRIPTION OF THE DRAWINGS 15 Preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which: Figure 1 is a perspective view of an embodiment of an apparatus; Figure 2 is a right side end elevation of the apparatus of Figure 1; Figure 3 is a front elevation of the apparatus of Figure 1; 20 Figures 4 and 5 are the front elevation of Figure 3 illustrating a transfer plate superimposed in first and second conditions, respectively, on the Figure of the apparatus; Figure 5 are front elevations of the apparatus of Figure 1 illustrating a transfer tray in various configurations; 25 Figure 6 is a left side end elevation of the apparatus of Figure 1; Figure 7 is a perspective view of a food support tray for use with one or more embodiments; Figure 8 is a plan view of a transfer plate for use with at least one of the embodiments; 30 Figure 9 is a side cross-sectional view of an apparatus according to a second embodiment; WO 2009/089583 PCT/AU2009/000042 -7 Figure 10 is a perspective view of the apparatus of Figure 9; Figure 11 is a is a top plan view of an apparatus according to a third embodiment; Figure 12 is a side plan view of the apparatus of Figure 11; 5 Figure 13 is a perspective view of the apparatus of Figure 11 in use; Figure 14 is a perspective view of the apparatus of Figure 11 in use; Figure 15 is a perspective view of the apparatus of Figure 11 in use; Figure 16 is a perspective view of the apparatus of Figure 11 in use; Figure 17 is a perspective view of a transfer apparatus of a further embodiment 10 of the invention; Figure 18 is a perspective view of the transfer apparatus of Figure 17; Figure 19 is a perspective view of a packaging machine including the transfer apparatus of Figure 17; Figure 20 is a perspective view of the packaging machine of Figure 19; 15 Figure 21 is a side view of the packaging machine of Figure 19; Figure 22 is a front view of the packaging machine of Figure 19. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 20 Referring to Figures 1 - 8, a first embodiment of the invention is an apparatus 10 for use with a packaging machine 11. The apparatus is configured for releasably retaining a nested stack of containers in the form of cups 12. The cups 12 in the present embodiment are typically formed from a square piece of paper or card and 25 whose edges are folded upwardly from a central region to form the cup and are configured to be inserted into corresponding apertures 13 in food support trays 14 which are passed through the machine 11. The central region of the cups 12 forms each cup's base 15 and the upwardly folded edges form each cups sidewalls 16. In the embodiment illustrated, the sidewalls 6 define an irregularly shaped opening at a 30 sidewall end opposite to the base 15, although the shape does not necessarily affect the utility of this embodiment. In the present embodiment, the food support trays are WO 2009/089583 PCT/AU2009/000042 such trays as are described in the applicant's Australian Provisional Patent Application Number 2007906526, filed 29 November 2007, which is incorporated herein by reference or alternatively food support trays made of silicone or metal. Referring to Figure 7, the trays 14 comprise a base 17 and a top face 18. Apertures 13 5 are provided in the top face for receiving the cups 12. The trays 14 are configured such that the base 15 of each cup 12 rests on the tray base 17 when the respective cups 12 are received in the apertures 13 with their sidewalls 16 supported by the respective edges of the apertures 13. The apparatus 10 comprises a 2x3 array of first supports in the form of lower 10 octagonal rings 19 and a corresponding array of second supports in the form of upper octagonal rings 20. In this embodiment, the upper octagonal rings 20 are sized and shaped to form an aperture which is substantially identical to the aperture formed by the lower rings 19. The array is configured to correspond to an array of the apertures 13 in the food support trays 14. The lower rings 19-support the bottommost cup 12a 15 of stacks 21 of nested containers, where the bottommost cups 12a are in direct contact with their respective lower rings 19. The upper rings 20 support one or more other cups in the stacks 21. In this embodiment, the lower and upper rings 19, 20 are spaced such that the upper rings 20 are in direct support contact with a cup 12b in the stack which is about ten cups above the bottommost cup 12a. The upper rings 20 20 therefore also support the cups 12 above the tenth bottommost cup 12b. In this way, a gravitational load from the tenth bottommost cup 12b and the cups thereabove on the lower rings 19 is reduced, in that it is taken by the upper rings 20. In an alternative embodiment or in conjunction with the present embodiment, the lower and upper rings 19, 20 are spaced such that the sidewall end defining the opening of the 25 bottommost cup 12a lies between the lower and upper rings 19, 20. The inventor has found that if no second support is used, the gravitational load from the nested stack on the bottommost cup 12a is such that the cups supported by the bottommost cup 12a provide an outward force on the bottommost cup's 12a sidewall 16 and can in effect jam the bottommost cup 12a into the support making it 30 difficult to remove, particularly in an automated process. The provision of the spaced second support allows withdrawal of lower cups one by one and further allows the WO 2009/089583 PCT/AU2009/000042 -9 provision of an automated process for singly removing the bottommost cup 12a, as is described in more detail below. The apparatus 10 further comprises a support structure in the form of upwardly standing rods 22 which provide lateral support to the nested stacks 21. They also 5 provide support for the lower and upper rings 19, 20, which are connected therebetween. The machine 11 also has a device 25 for passing food support trays 14 though the machine to receive cups 12 from their stacks. The passing device 25 comprises stacking arms 26 configured to support laterally a vertical stack (not shown) of trays 10 14. The passing device further comprises a tray movement device in the form of catches 28 which are eccentrically moveable within corresponding slots 30 (see Figure 1) to advance trays 14, beginning with the bottommost tray 14 in the tray stack, through the machine 11 in the direction of arrow 32 (illustrated in Figures 1, 2 and 6). A transfer component in the form of a transfer plate 34 is provided in the 15 machine 11 for transferring cups 12 from the apparatus 10 to the support trays 14. The transfer plate 34 and the machine 10 are configured for lateral reciprocal motion of the plate between the apparatus 10 and the passing device 25. As illustrated in more detail in Figure 8, the transfer plate 34 comprises apertures 36 whose layout corresponds with the nested stack 21 arrangement, in this embodiment being a 2x3 20 array. As will be understood, the apertures 36 of the transfer plate 34 are sized to receive and hold cups 12 therein. In use, nested cup stacks 21 are located between the support rods 22, such that the bottommost cup 12a of each stack is held in the aperture of its corresponding lower ring 19. As illustrated in Figures 2 to 6, the base 15 of each of the bottommost 25 cups 12a is exposed below the lower rings 19. As illustrated in Figure 4, the transfer plate 34 is located in a first condition in the form of a receiving position below the bottommost cups 12a. First contact devices in the form of first axially movable arms 38 with suction device ends 40 are then moved upwardly through the apertures 36 of the transfer plate 34 to attach respective external surfaces of the exposed cup bases 15 30 of each of the bottommost cups 12a. Air is drawn through the first arms 38 such that the suction device ends 40 attach to respective external surfaces of the bottommost WO 2009/089583 PCT/AU2009/000042 -10 cup bases 15. Once attached, the first arms are drawn back down through the transfer plate apertures 36. When the cups 12 are positioned in a supported position in the apertures 36, the drawing of air through the first arms 38 is stopped and the first arms removed. 5 The transfer plate, now with cups 12 in its apertures 36, moves laterally to a second condition in the form of a release position as illustrated in Figure 5. When in this position, second contact devices in the form of second axially movable arms 42 with abutment ends 44 are moved downwardly from a location above the transfer plate 34 and through the apertures 36 Gf the transfer plate 34 to abut against respective 10 internal surfaces of each of the cup bases 15 of the cups 12 held by the transfer plate 34. The second arms 42 then push the cups 12 from and through the transfer plate 34 and into an awaiting food support tray 14. Once the cups 12 have been located in the food support tray 14, the second arms 42 are returned to their location above the transfer plate 34 in its release position and the tray 14 moved in the direction of arrow 15 32 by a succeeding tray which is itself moved by the passing device 25. Therefore, each of the first and second arms, are movable on their axes, and the first arms are laterally spaced from the second arms. Also, this embodiment is configured such that the cups move in one relative direction along their axes. This is achievable by use of the transfer plate 34 which allows for a relatively simple 20 configuration of automated devices for retrieving cups 12 from the nested stacks 21 and placing the cups 12 into the food support trays 14. In an alternative embodiment, the transfer plate is stationary and the first and second contact devices move laterally with respect to the transfer plate. The above embodiment has been described as having a configuration of lower 25 and upper octagonal rings 19,20 to correspond to holes of food trays in which the cups 12 are to be placed. As will be understood, the invention is not limited to this configuration. In alternative embodiments, more or fewer lower and upper octagonal rings 19,20 may be used depending on the application required. Also, as would be understood, one lower and corresponding upper octagonal ring 19,20 may be used, 30 and so on. In another alternative embodiment, the first and second supports may be in the form of lower and upper circular rings or polygonal rings of shape other than WO 2009/089583 PCT/AU2009/000042 - 11 octagonal. Also, in alternative embodiments, the first support may be in the form of apertures in a lower plate and/or the second support may be in the form of apertures in an upper plate. In a third embodiment, shown in Figures 9 and 10, the apparatus 50 comprises 5 a 2x3 array of first supports in the form of six curved hoppers 52. As in previous embodiments the array is configured to correspond to an array of the apertures 13 in the food support trays 14. The hoppers 52 support stacks 51 of nested containers, where the first retrieved cups 51 a are positioned first in the direction of movement of the stacks 51 through the hopper 52. 10 In use, in this embodiment, nested cup stacks 51 are located in and move through the hoppers 52. The hoppers 52 are curved such that the curve of each hopper 52 acts to orient the cup stacks 51 such that the base of the first retrieved cup 51 a in the stack 5-1 is.in a position for retrieval. In this position for retrieval the cup stack 51 is tilted such that the base of the lowermost cup 51 a in the cup stack faces at least 15 partly upwardly. This position for retrieval is adapted such that upon retrieval of the first retrieved cup 51 a, gravity acts to assist in the separation of the first retrieved cup 51 a from the remainder of the cups in the cup stacks 51. Retrieval is performed by retrieval arm 53. Retrieval arm 53 comprises three arm elements each of which have two suction device ends 55 positioned on contact 20 devices 54. Thus six cups 51a are collected be the retrieval arm 53. The retrieval arm 53 is rotated about an axis such that contact devices 54 are positioned against the first retrieved cup 51 a in the cup stacks 51. Air is drawn through the retrieval arm 53 such that the suction device ends 55 attach to respective external surfaces of the first retrieved cups 51a. The suction device ends 55 attach 25 respective external surfaces of the exposed cup bases to collect the first retrieved cups 5 1a from each cup stack 51 in the hopper 52. The retrieval arm 53 is then rotated about its axis, moving each first retrieved cup 51 a with them. The angle of each cup stack 51 assists in allowing a single cup 51 a to be retrieved from each stack 51. The retrieval arm 53 rotates back to pull each cup 51 a into position on a 30 transfer plate 56. The retrieval arm 53 is drawn about its axis and through transfer plate 56 and its apertures 57 such that the cups 51 a rest within transfer plate apertures WO 2009/089583 PCT/AU2009/000042 -12 57. When the cups 51a are positioned in a supported position in the apertures 57, the drawing of air through the retrieval arm 53 is stopped and the retrieval arm 53 is removed leaving the cups 51 a in position on the transfer plate 56. The transfer plate 56, now with cups 51 a in its apertures 57, moves laterally to 5 a second position in the form of a release position as described in previous embodiments. In a fourth embodiment, shown in Figures 11 through 16, the apparatus 100 comprises an array of first supports in the form of a line of horizontal chutes 102. The array is configured to correspond to an array of the apertures in the food support trays 10 113. The chutes 102 support stacks 101 of nested containers, where the first retrieved containers 101a are positioned first in the direction of movement of the stacks 101 through the chutes 102. In use, in this embodiment, nested cup stacks 101 are located in and move through the chutes 102. The chutes 102 are horizontal, supporting the nested cup 15 stacks 101 while orienting the nested cup stacks such that removal of the first retrieved cup 101a in the stack 101 is not hindered by the force of gravity upon the remainder of the stack 101. Retrieval is performed by retrieval arm 104. Retrieval arm 104 comprises three arm elements each of which have a single or double suction device ends 105 20 positioned on contact devices 106. Figures 11 and 12 show the retrieval arm with two suction device ends105 on each arm while figures 13 through 16 show the retrieval arm 104 with a single suction device end 105 on each retrieval arm 104. Thus three or six cups 101a are collected by the retrieval arm 104. The retrieval arm 104 extends horizontally such that the contact devices 106 25 are placed in contact with the first retrieved cup 101 a in each stack 101. Air is drawn through the retrieval arm 104 such that the suction device ends 105 attach to respective external surfaces of the first retrieved cups 101a. The suction device ends 105 attach respective external surfaces of the exposed cup bases to collect the first retrieved cups 101a from each cup stack 101 in the chute 102. The retrieval arm 104 is 30 then retracted horizontally, moving each first retrieved cup 101a with them. The angle WO 2009/089583 PCT/AU2009/000042 -13 of each cup stack 101 assists in allowing a single cup 101a to be retrieved from each stack 101. The retrieval arm 104 moves horizontally to pull each cup 101a into position on a transfer plate 109. Each cup 101a is positioned in an aperture 107 of the transfer 5 plate 109. When the cups 101a are positioned in a supported position in the apertures 107, the drawing of air through the retrieval arm 104 is stopped and the retrieval arm 104 is removed leaving the cups 101a in position on the transfer plate 109. The transfer plate 109, now with cups 1G1a in its apertures 107, is turned about its longitudinal axis to a second position in the form of a release position in which the 10 apertures 107 extend vertically and the cups 101a are positioned vertically with the cup base surface facing downwardly. This is best shown in Figures 15 and 16. Each cup 101a is aligned with tray 113. Release arms 110 are aligned with each aperture 107 and positioned above each aperture 107. The release arms 110 extend downwardly such that a contact 15 surface 111 is aligned with the apertures 107. The release arms 110 move downwardly such that the contact surface 111 contacts an inner surface of each cup 101a in the transfer plate 109. The movement of the release arms 110 acts to push each cup 101a through the apertures 107 in the transfer plate 109 onto tray insert 113. The fourth embodiment is shown in use in Figures 13 through 16. Figure 13 20 shows retrieval arm 104 extending toward the first retrieved cup 101a. Figure 14 shows the cup 101a being retrieved by the retrieval arm and pulled into the transfer plate 109. Transfer plate 109 then rotates through 90 degrees such that cup 101a is aligned with tray insert 113. Figure 15 shows release arms 110 moving downwardly to contact cup 101a which is positioned within transfer plate 109. Figure 16 shows 25 release arm 110 pushing the cup 101a through apertures 107 in transfer plate 109 and into tray insert 113. Tray insert 113 can then be moved for filling a second array. A fifth embodiment of the invention is shown in Figures 17 - 22. These figures show a transfer apparatus 150 for use with a packaging machine 151. The apparatus is configured for transferring cups 12 from a hopper 153. The cups 12 in the present 30 embodiment are typically formed from a square piece of paper or card and whose edges are folded upwardly from a central region to form the cup and are configured to WO 2009/089583 PCT/AU2009/000042 -14 be inserted into corresponding apertures 13 in food support trays 14 which are passed through the machine 11. The central region of the cups 12 forms each cup's base 15 and the upwardly folded edges form each cups sidewalls 16. In the embodiment illustrated, the sidewalls 16 define an irregularly shaped opening at a sidewall end 5 opposite to the base 15, although the shape does not necessarily affect the utility of this embodiment. In the present embodiment, the food support trays are such trays as are described in the applicant's Australian Provisional Patent Application Number 2007906526, filed 29 November 2007, which is incorporated herein by reference or alternatively food support trays made of silicone or metal. 10 The transfer apparatus 150 comprises a 4x3 array of supports 155 rotatably connected with a frame 156. The supports155 have side walls 157 which define three internal cavities 158 which are adapted to retain a cup 12. The cavities 158 extend through the support 155 such that the cavities have two openings, opposite one another. The first opening 164 is oriented in a first direction and the second opening 15 165 is oriented directly opposite such that the cavity extends through the support 155. The supports 155 are longitudinally rotatable with respect to the frame 156 about an axis 159. The packaging machine 151 includes curved hoppers 153 which retain a stack of cups 12 for transfer into food support trays 14. The first presented cup (not 20 illustrated) is positioned such that the base 15 of the cup extends from the hopper. A transfer element 161 utilises suction forces to pull the cup 12 from the hopper 153 and through the second opening 165 in the cavity 158 into the transfer apparatus 150. The suction element 161 extends through the first opening 164 into the cavity 158 to contact the base 15 of the cup 12 and suction thereto to pull the cup into the cavity 25 158. The support 155 of the transfer apparatus 150 is then rotated about the axis 159 such that the cup 12 is oriented in a different direction. The support 155 is generally rotated through 180 degrees such that the cup is rotated through 180 degrees. The transfer element 161 then acts to push on the internal side of the base 15 30 to remove the cup from the cavity 158 in the support 155. The transfer element 161 WO 2009/089583 PCT/AU2009/000042 -15 extends through the second opening 165 and pushes the cup 12 out of the cavity through the first opening 164. As such the cup has moved through 180 degrees. The machine 11 also has a device 25 for passing food support trays 14 though the machine to receive cups 12 from their stacks. 5 In use, nested cup stacks 21 are located in the curved hoppers 153, such that the uppermost cup of each stack is held facing upwardly at the top of the curved hopper 153. The base 15 of each of the bottommost cups 12a is exposed from the hopper 153. The transfer apparatus 150 is located in a first condition in the form of a receiving position above the uppermost cup. Transfer device 161 in includes suction 10 device ends 168 are then moved downwardly through the first opening 164 in the cavities 158 of the transfer apparatus 150 to engage respective external surfaces of the exposed cup bases 15 of each of the uppermost cups. Air is drawn through the suction device ends 168 such that the suction device ends 168 attach to respective external surfaces of the bottommost cup bases 15. Once attached, the transfer device 161 is 15 drawn back up through the transfer apparatus cavities 158. When the cups 12 are positioned in the cavities 158, the drawing of air is stopped and the transfer device removed. Each support 155 of the transfer apparatus 150, now with cups 12 in its apertures 158, rotates about axis 159 through 80 degrees. When in position, transfer 20 device 161 moves downwardly through the second opening 165 and through the cavity 158 of the transfer apparatus 150 to abut against respective internal surfaces of each of the cup bases 15 of the cups 12. The transfer device 161 then pushes the cups 12 from and through the transfer apparatus 150 and into an awaiting food support tray 14. Once the cups 12 have been located in the food support tray 14, the transfer 25 device 161 is returned to its location above the transfer apparatus 150. The tray 14is then moved laterally out of the packaging assembly 151. As will be understood, unless the context requires or suggests otherwise, features of any one of the above described embodiments may be used in conjunction with another one or more of the above described embodiments. 30 While the invention has been described in reference to its preferred embodiments, it is to be understood that the words which have been used are words of WO 2009/089583 PCT/AU2009/000042 -16 description rather than limitation and that changes may be made to the invention without departing from its scope as defined by the appended claims. In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary 5 implication, the word "comprise" or variations such as "comprises" or "comprising" is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention. A reference herein to prior art information is not an admission that the 10 document forms part of the common general knowledge in the art in Australia.

Claims (45)

1. Apparatus for releasably retaining a nested stack of containers, the 5 apparatus comprising: a first support configured to support a bottommost container in the container stack; and a second support spaced from the first support and configured to support one or more other containers in the container stack such that a load from the one or more 10 other containers on the bottommost container is reduced.

2. The apparatus of claim 1 wherein the supports are configured such that the containers can be singly and consecutively withdrawn from the container stack, beginning with the bottommost container. 15

3. The apparatus of any one of the preceding claims wherein the load is a gravitational load.

4. The apparatus of any one of the preceding claims comprising a support 20 structure for supporting the first and second supports in their spaced relationship.

5. The apparatus of claim 4 wherein the support structure provides lateral support of the container stack. 25

6. The apparatus of claims 4 or 5 wherein the support structure comprises at least three longitudinal elements.

7. The apparatus of any one of the preceding claims wherein the first and/or the second support comprises an aperture. 30

8. The apparatus of claim 7 wherein the aperture is a circular aperture. WO 2009/089583 PCT/AU2009/000042 -18

9. The apparatus of claim 7 wherein the aperture is a polygonally-shaped aperture. 5

10. The apparatus of any one of claims 7 to 9 wherein the aperture of the first support is shaped and sized substantially identically to the aperture of the second support.

11. The apparatus of any one of the preceding claims wherein the 10 apparatus is arranged to releasably retain a stack of nested containers each having a base and at least one upwardly extending and outwardly tapered sidewall defining an opening opposite its base.

12. Wherein the at least one sidewall defines an irregularly shaped opening 15 at its end opposite the container's base.

13. The apparatus of any one of the preceding claims wherein the spaced distance between the first and second supports is greater than the distance between the first support and the opening of the bottommost container. 20

14. The apparatus of any one of the preceding claims wherein the spaced distance between the first and second supports is such that the first support is arranged to support a stack of about 3 to 20 of bottommost containers of the container stack and the second support is arranged to support the remaining containers of the container 25 stack.

15. The apparatus of any one of the preceding claims comprising a plurality of first supports arranged in an array and a plurality of second supports, each second support corresponding to a respective said first support, such that the apparatus 30 is configured to support a plurality of said stacks of containers. WO 2009/089583 PCT/AU2009/000042 -19

16. Method for transferring tray inserts from a tray insert support apparatus to respective trays provided by a tray provider, the method comprising the steps of: (i) contacting a first surface of at least one tray insert to move the at least one tray insert from the tray insert support apparatus to a transfer component; and 5 (ii) contacting a second surface of the at least one tray insert to move the at least one tray insert in the transfer component to a tray provided by a tray provider.

17. The method of claim 16 comprising the step, after the step (i), of moving the transfer component between the tray insert support apparatus and the tray 10 provider.

18. The method of claim 17 wherein in steps (i) and (ii), the at least one tray insert is moved on its axis, and in the step of moving the transfer component, the at least one tray insert is moved laterally with respect to its axis. 15

19. The method of claim 16 comprising the step, after the step (i), of rotating the transfer component.

20. The method of any one of claims 16 to 19 wherein the tray insert 20 support apparatus is configured to support at least one stack of tray inserts and the transfer component comprises aperture(s) corresponding to respective said stack(s) of tray inserts.

21. The method of claim 20 wherein, prior to step (i), the transfer 25 component is located between a contact device and the tray insert support apparatus, and step (i) comprises moving at least part of the contact device through the aperture(s) of the transfer component to contact the first surface of the at least one tray insert. 30

22. The method of claims 20 or 21 wherein, prior to step (ii), the transfer component is located between a second contact device and a tray on the tray provider, WO 2009/089583 PCT/AU2009/000042 - 20 and step (ii) comprises moving at least part of the second contact device through the aperture(s) of the transfer component to contact the second surface of the at least one tray insert. 5

23. The method of any one of claims 16 to 22 wherein the insert is a nestable container having a base and an upstanding sidewall, the first surface is an external surface of the container base and the second surface is an internal surface of the container base. 10

24. Apparatus for transferring tray inserts from a tray insert support apparatus to respective trays provided by a tray provider, the apparatus comprising: (i) a first contact device configured to contact a first surface of at least one tray insert to move the at least one tray insert from the tray insert support apparatus to a transfer component; and 15 (ii) a second contact device configured to contact a second surface of the at least one tray insert to move the at least one tray insert in the transfer component to a tray provided by a tray provider.

25. The apparatus of claim 24, wherein the transfer component is 20 configured to rotate about its axis.

26. The apparatus of claim 24, wherein the first and second contact devices are configured to move the at least one tray insert on its axis, and the transfer component is configured to move the at least one tray insert laterally with respect to 25 its axis.

27. The apparatus of any one of claims 24 to 26 wherein the tray insert support apparatus is configured to support at least one stack of tray inserts and the transfer component comprises aperture(s) corresponding to respective said stack(s) of 30 tray inserts. WO 2009/089583 PCT/AU2009/000042 -21

28. The apparatus of any one of claims 24 to 27 wherein the insert is a nestable container having a base and an upstanding sidewall, the first surface is an external surface of the container base and the second surface is an internal surface of the container base. 5

29. The apparatus of any one of claims 24 to 28 wherein the transfer component comprises a plurality of said apertures arranged in an array.

30. The apparatus of any one of claims 24 to 29 wherein the first contact 10 device comprises an arm arranged to attach to a bottom surface of a container and to withdraw the container from the tray insert support device and locate it in the transfer device.

31. The apparatus of claim 30, wherein the arm comprises a suction device 15 on an end thereof for releasably attaching to the bottom surface.

32. The apparatus of claim 30 or 31, wherein the second contact device comprises a second arm arranged to push a container from the transfer device to a corresponding aperture in a tray on the tray provider. 20

33. The apparatus of any one of claims 30 to 32, wherein the first mentioned arm and second arm are arranged such that they each move the container in the same axial direction. 25

34. Apparatus for providing a tray insert comprising: a tray insert support device; a tray provider for providing trays configured to receive at least one said tray insert; and the apparatus for transferring tray inserts of any one of claims 23 to 32. 30

35. The apparatus of claim 34 wherein the tray insert support device WO 2009/089583 PCT/AU2009/000042 -22 comprises the apparatus of any one of claims 1 to 15, wherein each said container from the stack of containers is a tray insert.

36. Apparatus for releasably retaining a stack of nested containers, the 5 apparatus comprising: a support configured to support the stack of nested containers such that gravity acts to separate at least one of the stack of nested containers from the remainder of the containers. 10

37. The apparatus of claim 36, wherein the support comprises a hopper configured to support the stack of nested containers, the hopper adapted to orient the stack of nested containers such that gravity acts to separate the nested containers. 15

38. Apparatus for releasably retaining a stack of nested containers as defined in claim 37, wherein the hopper is configured such that the containers can be singly and consecutively withdrawn from the container stack, by contacting the base of a single nested container. 20

39. Apparatus for releasably retaining a stack of nested containers as defined in claim 37 or 38, wherein the hopper is curved.

40. Apparatus for releasably retaining a stack of nested containers, the apparatus comprising: 25 a support configured to support the stack of nested containers; and a transfer device for transferring containers from the support to a delivery tray, the transfer device comprising a rotatable arm, the rotatable arm having a contact device configured to contact a surface of the container to move the container from the support to the delivery tray. 30

41. Apparatus for releasably retaining a stack of nested containers as WO 2009/089583 PCT/AU2009/000042 - 23 defined in claim 40, wherein the transfer device further comprises a transfer support tray.

42. Apparatus for releasably retaining a stack of nested containers as 5 defined in claim 40, wherein the rotatable arm is configured to move through the transfer support tray and deposit the container on the transfer support tray.

43. Apparatus for transferring tray inserts from a tray insert support apparatus to respective trays provided by a tray provider, the apparatus comprising: 10 a support configured to support the stack of nested containers; and, a transfer device for transferring containers from the support to a transfer tray, the transfer device being configured to move through the transfer tray to transfer containers from the support to the transfer tray. 15

44. Apparatus as defined in claim 43, further comprising a delivery tray, wherein the transfer tray is configured to move the containers into position for deposit on the delivery tray.

45. Apparatus for transferring tray inserts from a tray insert support 20 apparatus to respective trays provided by a tray provider, the apparatus comprising: a support configured to support the stack of nested containers; and, a transfer device for transferring containers from the support to a transfer tray, the transfer tray being rotatable about an axis. 25