EP4652111A1

EP4652111A1 - Machine for producing pods with extraction products

Info

Publication number: EP4652111A1
Application number: EP24700646.3A
Authority: EP
Inventors: Maurizio ATRIGNA; Sauro Rivola
Original assignee: IMA Industria Macchine Automatiche SpA
Current assignee: IMA Industria Macchine Automatiche SpA
Priority date: 2023-01-17
Filing date: 2024-01-04
Publication date: 2025-11-26
Also published as: WO2024154008A1; CN120500442A; IT202300000513A1

Abstract

Described is a machine for producing and packaging pods (1) comprising a series of stations which are able to: feed a first continuous strip (S1), feed a dose of product on the first strip (S1), feed a second continuous strip (S2) superposed on the first strip (S1) provided with doses of product, join the first (S1) and second (S2) strip to form a continuous band (N) of pods; cut the continuous band (N) of pods to form individual pods (1); receive and evacuate the formed pods (1) and package the individual pods (1) with a packaging strip (9); the machine comprises an evacuating/receiving station (7) having a plurality of grippers (10) for gripping and releasing pods (1) rotating about an axis of rotation (Z); a station (11) for folding the packaging strip (9) configured for folding the strip (9) along a folding line in such a way as to form a continuous U- shaped pocket superposing two portions of the packaging strip so as to create an opening opposite the folding line, the folded packaging strip (9) is advanced by advancement means (12) along a plane coplanar to the plane of rotation of the plurality of grippers (10), and a movement and control unit (13) connected with the grippers (10) and configured to allow the plurality of grippers (10) to substantially simultaneously grip a corresponding plurality of single pods (1) arranged on a common row of pods exiting from a cutting station (6) and subsequently to release them one at a time inside the folded packaging strip (9) by an angular rotation of each gripper (10) of said plurality of grippers (10).

Description

DESCRIPTION

MACHINE FOR PRODUCING PODS WITH EXTRACTION PRODUCTS

Technical field

This invention relates to a machine for producing pods with extraction products.

Background art

Currently, in the market of extraction products, such as coffee, barley, tea and camomile, the so-called single-use pods are also used for making the extracted product.

These pods which can be used for single-use extraction comprise two pieces of filter material placed one over the other and sealed to enclose, centrally, the dose of product in a usually circular shape.

One of the prior art machines that produces and packages these pods, which operate with an alternating motion, that is to say, step by step, comprises:

- a station for feeding a first strip of filter material;

- a station for forming (pre-forming), on the first strip, a succession of circular impressions;

- a station for dosing and feeding a dose of product inside each impression made on the first strip;

- a station for feeding a second continuous strip of filter material configured to be positioned on the first strip provided with the doses of product;

- a station for joining, by sealing, the first and second continuous strips of filter material;

- a station for cutting the two strips of filter material to form, at least partly, individual pods;

- a station for evacuating/receiving the single pods from a horizontal advancement line of the strips;

- a station for packaging the individual pods in a piece of wrapping film wrapped and closed on the pod.

The evacuating/receiving station and the packaging station, of particular interest in this description, are interconnected so as to be able to move the pods away from the pod forming line and position the individual pods in the piece of overwrapping film which will then be sealed.

The two above-mentioned evacuating/receiving and packaging stations comprise:

- an ejection element for the pod configured to detach the pod from the excessive part (waste) of the continuous strips of filter material and to direct the pods (in a direction transversal to and under the surface of arrival of the continuous strips) towards

- a rotary wheel or drum designed to receive and rotate each pod by a predetermined angle which is able to present the pod at

- a gripper configured to pick up the single pod, rotating it by a right angle and positioning it, by vertical falling, in a sheet of overwrapping film folded into a "C" shape;

- a sealing unit designed to close the wrapping film and form the individual package with pod.

The machine described above, although of good reliability, has shown technical limitations due to its reduced productivity.

More specifically, all the operating stations forming the machine work in an alternating or stepwise fashion to feed the pods moved along a feed line, with a number such that they can be correctly handled by the receiving and packaging stations described above, which are also moved in an alternating fashion.

In order to increase productivity the lines for feeding the pods might, for example, be doubled so as to present two pods side by side simultaneously for the evacuating and packaging.

However, that solution would have resulted in a complete doubling of the components of the evacuating and packaging stations.

This increase in the components of the evacuating and packaging stations would have resulted in an increase in the volumes and costs of the machine which cannot be offset with the increase in productivity of the machine.

Aim of the invention

The aim of the invention is to provide a machine for producing pods with extraction products which overcomes the above-mentioned drawbacks of the prior art.

More specifically, the aim of the invention is to provide a machine for producing pods for extraction products which can keep the overall dimensions reduced, but increases the productivity of the machine.

A further aim of the invention is to provide a machine for producing pods with extraction products which is structured in such a way as to make the operating line extremely flexible according to the production requirements. Said aims are fully achieved by the machine for producing pods with extraction products according to the invention, as characterised in the appended claims.

Brief description of the drawings

The features of the machine will become more apparent from the following detailed description of a preferred, non-limiting embodiment of it, illustrated by way of example in the accompanying drawings, in which:

- Figure 1 is a schematic side view, with some parts cut away to better illustrate others, of a machine for producing pods according to this invention;

- Figure 2 is a perspective view from above of a receiving/evacuating station forming part of the machine of Figure 1 in a first operating configuration;

- Figure 3 is a perspective view from above of the receiving/evacuating station of Figure 2 in a second operating configuration;

- Figure 4 is a perspective view from above of a detail of the receiving/evacuating station of Figures 2 and 3 in a third operating configuration;

- Figures 5 and 6 are perspective views, with some parts cut away to better illustrate others, of the gripper units forming part of the receiving/evacuating station in two different operating configurations;

- Figure 7 is a perspective view of a gripper unit and a relative arm for supporting and moving the gripper unit;

- Figure 8 is a perspective view of the gripper units and the supporting turret equipped with movement devices;

- Figure 9 is a side view of a single gripper unit;

- Figures 10 and 11 are cross section side views of the individual gripper unit of Figure 9 in two different operating configurations.

Detailed description of preferred embodiments of the invention

With reference to the accompanying drawings, in particular Figure 1 , the machine according to the invention, labelled 100 in its entirety, is used for producing and packaging pods with extraction products such as, for example, but not exclusively, coffee, barley, tea, camomile. These singleuse pods, as described below, comprise two pieces of material (filter) superposed and sealed to each other which enclose, centrally, the dose of product in a usually circular shape.

The machine 100 extends along a relative feed line and comprises a sequence in substantial succession of operating stations.

The machine 100 comprises a first feeding station 2 (having a feed reel) configured for feeding a first continuous strip S1 (of filter material).

The machine 100 comprises a dosing station 3 configured to dose a product on the first continuous strip S1 in such a way to form a plurality of single portions of dosed product arranged along a plurality of side-by-side lines.

The machine 100 also comprises a second feeding station 4 (having a feed reel) configured to feed a second continuous strip S2 (of filter material) to be placed on the first continuous strip S1 having the dosed portions of product.

The machine 100 also comprises a joining station 5 (by sealing, usually hot sealing) configured to seal the first S1 and the second S2 continuous strips together to form a continuous band N comprising a plurality of pods arranged along a plurality of adjacent lines advancing on an advancement plane P.

The machine 100 also comprises a cutting station 6 (comprising a pair of rotary knives) configured to cut individual pods 1 from the continuous band N.

The machine 100 also comprises a receiving/evacuating station 7 configured to receive and evacuate the single pods 1 .

The machine also comprises a packaging station 8 configured to pack the pods 1 .

If necessary, the machine 100 may comprise a forming (or pre-forming) station 33 configured to create on the first strip S1 , by means of a pusher 34, a succession of depressions or impressions.

This station is arranged upstream of the dosing station 3 in such a way as to allow the dosing of product inside each depression created by the pusher 34.

This forming station is active if "symmetrical" type pods 1 must be obtained (that is to say, with the pod having a dose of spherical product) whilst it is not present or inactive if "asymmetrical" type pods must be produced (that is to say, with the pod having a dose of hemispherical product).

As illustrated (Figures 2 to 4) the evacuating/receiving station 7 comprises a plurality of grippers 10 which rotate (continuously) about an axis of rotation Z lying in a plane of rotation parallel to the advancement plane P of the pods 1 .

Each gripper 10 is configured to grip and release one single pod 1 at a time. Again as illustrated, there is a folding station 11 configured for folding a packaging strip 9 along a folding line in such a way as to form a continuous pocket in the shape of a “LT, superposing two portions of the packaging strip 9 forming an opening opposite the folding line.

The folded packaging strip 9 is advanced by (continuous) advancement means 12 along a plane coplanar with the plane of rotation of the plurality of grippers 10.

A handling and control unit 13 is connected to the grippers 10 and configured to allow the plurality of grippers 10 to substantially simultaneously grip a corresponding plurality of single pods 1 arranged (side by side) on a common row exiting from the cutting station 6, and subsequently to release them inside the continuous folded packaging strip 9 in the shape of a “LT one at a time, by an angular rotation of each gripper 10 of the plurality of grippers 10.

In other words, the groups of pods 1 obtained at the exit from the cutting station (in this case, a row of three) are picked up almost simultaneously by the grippers present (movable continuously) and carried directly into the packaging strip which also advances continuously. Whilst all the preceding stations up to the cutting station operate with stepping or discontinuous motion.

This "mixed" solution makes it possible to form a band of pods having multiple rows which are then picked up quickly and precisely by the grippers with their consequent positioning inside the folded packaging strip located, as described below, alongside the cutting station and in the same plane as the rotation plane of the grippers.

The receiving/evacuating station 7 comprises a plurality of arms 14 (motor- driven and rotating continuously about the axis of rotation Z) and along a plane parallel to the advancement plane of the pods 1 .

A respective gripper 10 is mounted and slidable on each of the arms 14.

Again as illustrated, the movement and control unit 13 comprises a cam track 15 on which the plurality of grippers 10 slides. In light of this, the cam track 15 extends (about the axis Z of rotation) along a circular arc (of at least 180°) shaped and configured to move each gripper 10 from a minimum distance from the axis Z of rotation (such as the three gripper units 10 positioned in a pod outfeed area of Figure 2) to a maximum distance from the axis Z of rotation (such as the three gripper units 10 positioned in the pod release area in the strip 9 in Figure 2) so as to allow each gripper 10 to move (continuously) between several transit positions and at least one position for releasing the single pod 1 inside the folded packaging strip 9 (see also Figure 3).

The movement and control unit 13 also comprises a head 16 for translating (in both directions) the plurality of grippers 10 at an outfeed area of the pods 1 downstream of the cutting station 6.

The translation head 16 has an actuator unit 17 configured to intercept each gripper 10 so as to move each gripper 10 at the exiting zone of the pods 1 (see Figure 2) in such a manner as to protrude the gripper 10 for gripping the pod 1 and retract the gripper 10 when the pod 1 has been gripped and, subsequently, to protrude the gripper 10 for releasing the gripped pod 1 inside the folded packaging strip 9 (see Figure 4).

As illustrated in Figures 2 to 6 and 8, the translation head 16 interacts with the grippers 10 along a portion of the above-mentioned circular arc (that is to say, a segment of the path about the axis of rotation Z). In this specific case, the cam track 15 is interrupted along the above-mentioned circular arc.

In other words, the path of the gripper units 10 is a closed loop formed by the cam track 15 and by the segment engaged by the translation head 16. As illustrated in Figure 7, each arm 14 for supporting a respective gripper 10 is articulated to a shaft 24 which is connected by a kinematic mechanism to a respective independent drive unit 25.

Each shaft 24 is also housed in a turret 26 extending along the axis Z of rotation (Figure 8).

Moreover, each arm 14 comprises a shelf 27 positioned parallel to the plane of rotation.

Each shelf 27 supports a slidable bushing 28 housing a respective gripper 10.

On the upper end of the turret 26 are positioned the cam track 15 and the translation head 16.

Along the turret 26 there is also a unit 16a for moving the actuator unit 17 of the translation head 15.

As illustrated in Figures 9 to 11 , each gripper 10 comprises a pair of jaws 18 for gripping the pod 1 articulated to a support sleeve 19 and movable from a closed position to grip the pod 1 (Figures 9 and 10) to an open position to release the pod 1 (Figure 11 ).

Each gripper 10 also comprises a cylinder 20 axially slidable inside the sleeve 19 and joined to a cam follower unit 21 positioned at one end of the cylinder 20.

The cylinder 20 is movable, upon command of the cam follower 21 , between a first idle position in which the cylinder 20 is moved away from the pair of jaws 18 (Figure) 10 and a second operating position in which the cylinder 20 is approached to the pair of jaws 18 (Figure 11 ).

Each gripper 10 comprises a control head 22 arranged at an internal end of the cylinder 20 and configured to intercept a pair of prongs 23 protruding from the gripping jaws 18 when the cylinder 20 moves from the first to the second position, and further to bring the pair of jaws 18 from the closed position to the open position.

In light of this, the control head 22 comprises an idle roller 22a connected to the cylinder 20 and configured to come into contact with the front surfaces of the prongs 23 positioned crossed to each other in such a way as to allow a rotation with an opposite direction of the respective jaws 18.

It should be noted that each pair of jaws 18 has an elastic element 35 interposed between the jaws 18 designed to keep (or return) the jaws 18 to a closed position in the absence of an activation of the control head 22.

Between the sleeve 19 and the cylinder 20 there is a further elastic element 36 (fitted on the cylinder 20) designed to keep (or return) the cylinder 20 away from the jaws 18 in the absence of a pushing action by the cam follower unit 21 .

Thanks to this structure, each gripper 10 can be actuated (in particular in the gripping and the release of the pods) both by movement along the cam track 15 and by the translation head 16.

The above-mentioned means 12 for advancing the folded packaging strip 9 comprise a first pair of rollers 29 for dragging the folded packaging strip 9, arranged downstream of the folding station 11 of the folded packaging strip 9, and configured to allow an advancement of the folded packaging strip 9 (along a horizontal plane) alongside the cutting station 6.

The means 12 for advancing the packaging strip 9 also comprise a second pair of dragging rollers 30, arranged downstream of the first pair of rollers 29, and configured to advance the folded packaging strip 9 in which the pods 1 are housed.

The two pairs of rollers 29 and 30 are configured to avoid modifications to the configuration of the folded packaging strip 9 both during its advancement (continuously) when empty and during its advancement (again continuously) with the pods housed inside it.

It should be noted that the packaging station 8 comprises a station 31 configured to close the advancing (continuously) folded packaging strip 9 and in which the pods 1 are housed.

The closing station 31 is configured to form individual packages including a predetermined number of pods 1 .

The packaging station 8 also comprises a cutting station 32, arranged downstream of the closing station 31 , suitable for separating the individual formed packages from each other.

The closing station 31 comprises groups of hot sealing heads designed to form individual packages, whilst the cutting station 32 may comprise rotary knives.

This invention also provides a method for producing and packaging pods with infusion products comprising the steps of:

- feeding a first continuous strip S1 ;

- dosing a product on the first continuous strip S1 in such a way to form a plurality of single portions of dosed product arranged along a plurality of side-by-side lines;

- feeding a second continuous strip S2 on the first continuous strip S1 having the dosed portions of product;

- closing the first S1 and second S2 continuous strips to form a continuous band N of pods comprising a plurality of pods arranged along a plurality of side-by-side lines advancing along an advancement plane P;

- cutting the continuous band N to form single pods 1 ;

- inserting the pods 1 into a package;

- closing the pods 1 into a package.

The method according to the invention also comprises the following steps:

- folding a packaging strip 9 along a folding line forming a continuous U- shaped pocket by overlapping two portions of the packaging strip 9, so as to create an opening opposite the folding line;

- substantially simultaneously gripping, by a plurality of grippers 10, a corresponding plurality of single pods 1 arranged along a common row;

- releasing the gripped pods 1 inside the folded packaging strip 9 one at a time by an angular rotation of each gripper 10 of the plurality of grippers 10.

A machine structured as described above therefore achieves the preset aims thanks to a structure of the station for receiving and evacuating the pods obtained with continuous mobile grippers which are able to simultaneously pick up two or more pods feeding out from the production line (moving in a stepwise fashion) and carry the pods into the packaging strip according to a predetermined sequence.

These operations for picking up and subsequently positioning the pods are performed at a height substantially equal to the working height of the stations for forming the pods, with the advantages of reducing station operating spaces as well as reducing the number of steps and the handling of the pods compared to prior art solutions.

The grippers are structured in such a way that they can be adapted to any differences in production of the bands forming the pods which may be different (in terms of the number of pods in the rows formed on the band).

Claims

1 . Machine for producing and packaging pods (1 ) comprising: a first feeding station (2) configure to feed a first continuous strip (S1 ); a dosing station (3) configured to dose a product on the first continuous strip (S1) in such a way to form a plurality of single portions of dosed product arranged along a plurality of side-by-side lines; a second feeding station (4) configured to feed a second continuous strip (S2) to be disposed on top of the first continuous strip (S1) having the dosed portions of product; a joining station (5) configured to seal the first (S1) and the second (S2) continuous strips together to form a continuous band (N) comprising a plurality of pods arranged along a plurality of adjacent lines advancing on an advancement plane (P); a cutting station (6) configured to cut single pods (1 ) from the continuous band (N); a receiving/evacuating station (7) configured to receive and evacuate the single pods (1 ); a packaging station (8) configured to pack the pods (1 ); characterized in that the receiving/evacuating station (7) comprises: a plurality of grippers (10) rotating around a rotation axis (Z) and laying on a rotation plane parallel to the advancement plane (P); each gripper (10) being configured for gripping and releasing one single pod (1 ) at a time; a folding station (11 ) configured to fold a packaging strip (9) along a folding line forming a continuous U-shaped pocket by overlapping two portions of the packaging strip (9), so as to create an opening opposite to the folding line; the folded packaging strip (9) being made to advance by advancement means (12) along a plane coplanar to the rotation plane of the plurality of grippers (10); and a handling and control unit (13) connected to the grippers (10) and configured to allow the plurality of grippers (10) to substantially simultaneously grip a corresponding plurality of single pods (1 ) arranged a common row and exiting from the cutting station (6), and subsequently to release the gripped pods (1 ) inside the folded packaging strip (9) one at a time by an angular rotation of each gripper (10) of said plurality of grippers (10).

2. Machine according to claim 1 , wherein each gripper (10) is slidingly mounted to a respective arm (14).

3. Machine according to claim 1 or 2, wherein the handling and control unit (13) comprises a cam track (15) on which the plurality of grippers (10) slide; the cam track (15) developing along an arc of circumference shaped and configured to bring each gripper (10) from a minimum distance to a maximum distance from the rotation axis (Z) so as to allow each gripper (10) to move along several transition positions and at least a release position of the single pod (1 ) inside the folded packaging strip (9).

4. Machine according to any of the preceding claims, wherein the handling and control unit (13) further comprises a translation head (16) for translating each gripper (10) in correspondence with an exiting zone of the pods (1 ) downstream the cutting station (6); the translation head (16) having an actuator unit (17) configured to intercept each gripper (10) so as to move each gripper (10) at the exiting zone of the pods (1 ) in such a manner to protrude the gripper (10) for gripping the pod (1 ), and retract the gripper (10) when the pod (1 ) has been gripped, and subsequently to protrude the gripper (10) for releasing the gripped pod (1 ) inside the folded packaging strip (9).

5. Machine according to claim 4 when it depends on claim 3, wherein the translation head (16) interacts with the grippers (10) along a portion of said arc of circumference, the cam track (15) being interrupted along said portion of arc of circumference.

6. Machine according to any of the preceding claims, wherein each gripper (10) comprises: a couple of jaws (18) for gripping the pod (1 ) articulated to a support sleeve (19) and movable from a closed position to grip the pod (1) to an open position to release the pod (1 ); a cylinder (20) axially slidable inside the sleeve (19) and joined to a cam follower (21 ) arranged at one end of the cylinder (20); the cylinder (20) being movable, upon command of the cam follower (21 ), between a first idle position in which the cylinder (20) is moved away from the pair of jaws (18) and a second operating position in which the cylinder (20) is approached to the pair of jaws (18); a control head (22) arranged at an internal end of the cylinder (20) and configured to intercept a pair of prongs (23) protruding from the gripping jaws (18) when the cylinder (20) moves from the first to the second position, and further to bring the pair of jaws (18) from the closed position to the open position.

7. Machine according to any of the preceding claims 2-6, wherein each arm (14) is articulated to a shaft (24) which is kinematically connected to a respective independent drive mechanism (25); each shaft (24) being housed in a turret (26) extending along the rotation axis (Z).

8. Machine according to any of the preceding claims 2-7, wherein each arm (14) comprises a shelf (27) arranged parallel to the rotation plane, said shelf (27) supporting a sliding bushing (28) accommodating the gripper (10).

9. Machine according to any of the preceding claims, wherein the advancement means (12) of the folded packaging strip (9) comprise: a first couple of dragging rollers (29) for dragging the folded packaging strip (9), arranged downstream of the folding station (11 ) of the packaging strip (9), and configured to allow an advancement of the folded packaging strip (9) alongside the cutting station (6); and a second pair of dragging rollers (30), arranged downstream of the first pair of rollers (29), and configured to advance the folded packaging strip (9) accommodating the pods (1 ).

10. Machine according to any of the preceding claims, wherein the packaging station (8) comprises: a station (31 ) configured to close the advancing folded packaging strip (9) accommodating the pods and to form a line of individual packages enclosing a predefined number of pods (1 ); a cutting station (32), arranged downstream of the closing station (31 ), suitable for separating the individual formed packages from each other.

11. Machine according to any of the preceding claims, comprising a forming station (33) configured to create on the first strip (S1), by means of a pusher (34), depressions and arranged upstream of the dosing station (3), so as to allow dosing of product within each created depressions.

12. Receiving and evacuating station (7) for packaging pods (1 ) comprising: a plurality of grippers (10) rotating around a rotating axis (Z) and laying on a rotation plane; each gripper (10) being configured to grip and subsequently release one single pod (1 ); a folding station (11 ) configured to fold a packaging strip (9) along a folding line so as to form a continuous U-shaped pocket by overlapping two portions of packaging strip so as to form an opening opposite to the folding line, the folded packaging strip (9) being made to advance by advancement means (12) along an advancement plane (P) parallel to the rotation plane of the plurality of grippers (10); a handling and control unit (13) connected to the grippers (10) and configured to allow the plurality of grippers (10) to substantially simultaneously grip a corresponding plurality of single pods (1 ) arranged along a common row, and subsequently to release the gripped pods (1 ) inside the folded packaging strip (9) one at a time by an angular rotation of each gripper (10) of said plurality of grippers (10).

13. Method for producing and packaging pods of infusion products comprising the steps of: feeding a first continuous strip (S1 ); dosing a product on the first continuous strip (S1) in such a way to form a plurality of single portions of dosed product arranged along a plurality of side-by-side lines; feeding a second continuous strip (S2) on top of the first continuous strip (S1) having the dosed portions of product; closing together the first (S1) and second (S2) continuous strips to form a continuous band (N) of pods comprising a plurality of pods arranged along a plurality of side-by-side lines advancing along an advancement plane (P); cutting the continuous band (N) to form single pods (1 ); inserting the pods (1 ) into a package; closing the package; characterized in that said method further comprises the following steps: folding a packaging strip (9) along a folding line forming a continuous U- shaped pocket by overlapping two portions of the packaging strip (9), so as to create an opening opposite the folding line; substantially simultaneously gripping, by a plurality of grippers (10), a corresponding plurality of single pods (1 ) arranged along a common row; releasing the gripped pods (1 ) inside the folded packaging strip (9) one at a time by an angular rotation of each gripper (10) of said plurality of grippers (10).