GB2417229A

GB2417229A - Automated packaging in tubular material

Info

Publication number: GB2417229A
Application number: GB0418512A
Authority: GB
Inventors: Andrew Martyn Lockyer
Original assignee: Individual
Current assignee: Individual
Priority date: 2004-08-19
Filing date: 2004-08-19
Publication date: 2006-02-22
Anticipated expiration: 2024-08-19
Also published as: GB0418512D0; GB2417229B; WO2006018637A1

Abstract

Apparatus (30) for the automated packaging of products, such as blocks of cheese (21) is provided. The apparatus (30) removes a length of packaging material from a continuous length of flexible, pre-formed tubular material at the packaging site. The apparatus (30) closes one end of the length of packaging material to form a bag (50) and thereafter prepares the bag for receiving product (21) through its open end. Product is filled into the newly formed bag and the open end is closed to envelope the product. A method for the automated packaging of a product and a cheese block packaging installation (10) is also provided. Preparation of the bag to receive product may comprise distending its open end. After filling, the open end may be closed by vacuum sealing.

Description

METHOD AND APPARATUS FOR USE IN THE AUTOMATED

PACKAGING OF PRODUCTS

The present invention relates generally to the packaging of products and specifically to the automated packaging of product in order to increase efficiency and to reduce the requirement for direct intervention by an operator.

There are many systems available for automatic forming of a package and filling it with product, in a so-called form-fil1 operation. For example, US 5,514,029 proposes the use of two layers of film which are joined together with longitudinal and lateral seals to form a bag for a semiliquid product. Document EP 685391 describes the use of a roll of flat film which is formed into a tube. However, in both cases the formation of the bag at the site of packing is relatively complex and is not suitable for all types of products, especially solid or formed products.

It is also known to provide pre-formed bags on a roll or individually supplied which can be manually applied to a packaging machine ready to receive product.

However, this system necessarily increases labour input and handling of the packaging material by an operator, which is undesirable. In addition the size of the bag cannot be controlled at the site of packaging.

The present invention seeks to address the problems with known packaging systems.

According to the first aspect of the present invention there is provided a method for use in the automated packaging of product, comprising the steps of. providing a continuous length of pre-formed flexible tubular packaging material; removing a length of tubular packaging material from the continuous length; closing one end of the removed length of tubular packaging material to form a bag; and preparing the bag for receiving product through the open end.

The present invention is therefore based on the realisation that efficiency improvement and cost savings can be achieved by providing an automated packaging process in which the starting material is a continuous length of flexible packaging material which has been formed into a tube, and in which a bag is prepared from the tubuliform packaging material at the site of packaging immediately prior to filling product into the bag.

Because the packaging material from which the bag is formed is pre-formed into a tube, the number of seals required subsequently to seal the bag is minimised as longitudinal seals are not required. The tubuliform material may be formed, for example, by extrusion or by sealing two sheets of material together along their longitudinal edges.

Because the steps of forming the bag and preparing it for receiving product are automated, manual intervention in the process is removed which has efficiency benefits and reduces the amount of handling of the packaging material required.

The method may further comprise the step of filling product into the newly formed bag through the open end. The filling step may therefore comprise part of the present invention or may be a separate operation performed subsequent to the steps of'the present invention.

The method may further comprise the step of closing the open end of the filled bag to envelope the product. In many cases it will be necessary to close the bag following hlling with product, in particular in cases where the product must be sealed within the bag to protect the product. The closing step may comprise a sealing step in which the open end of the bag is sealed. Alternatively the closing step may comprise a pre-closing or pre-sealing step in which the open end is prepared for closing and/or sealing.

The means for preparing the bag for receiving product may comprise bag opening means which form an open mouth at the end of the tube remote from the closed end. Forming an open mouth could facilitate insertion of product into the bag.

The way in which the bag is opened and the dimensions of the open mouth formed could be chosen to suit the product to be inserted.

The steps of removing the length of tubular material from the continuous length and closing one end of the removed length may be performed simultaneously. For example, a simultaneous heat seal and cutting step may be performed which produces a separated and sealed end.

The open end of the bag may be sealed by vacuum sealing following product insertion. The filled bag is evacuated and a seal is applied to the end of the evacuated bag to provide a vacuum environment for the product in the bag.

The open end of the bag may be prepared for closing by flattening the open end of the bag following receipt of product. Depending on the method for closing the bag, it may be advantageous to present a flattened end. For example, vacuum sealing apparatus often requires a flattened end on which to work.

Once the open end is flattened it may be held in this position by joining opposing surfaces of the end together. For example, opposing surfaces of the flattened open end may be joined by spot welds, adhesive or even temporary clips.

The open end may be flattened by separating two opposed points of a tubular end from each other to cause the material therebetween to flatten.

The step of removing the length of tubular material from the continuous length may comprise a cutting step or other suitable step for parting the length from the continuous length. Any suitable method for separating the length of material could be used, including a knife or a hot wire depending on the nature of the material.

The end of the removed length of tubular material may be closed by heat sealing.

However, any suitable method for closing the end could be used.

Whilst not essential, a predetermined length of tubular material may be removed from the continuous length of material so that a bag of predetermined dimensions can be formed. It is particularly important for some applications that the product is a tight fit within the bag, and a bag of predetermined dimensions is important for this to be possible.

The continuous length of pre-formed flexible tubular packaging material may be in the form of a roll of material. Material in a roll configuration is easy to transport and it is easy for the material to be unrolled as lengths of material are required for I O bags.

The continuous length of pre-formed flexible tubular packaging material may be in the form of a flattened tube, which may be gusseted. A flattened tubular construction means that the material does not take up a large amount of space prior to formation into bags.

The method of the present invention may be adapted for a food product.

Accordingly the pre-formed flexible tubular packaging material would be formed from food-grade and approved material. An automated packaging method is particularly advantageous for the packing of food product because manual involvement is minimised and contamination risks are reduced.

The food product may be a block of cheese, such as a 5kg, lOkg or 20kg block of cheese. Blocks of cheese are typically packaged and sealed for long-term storage or maturation. A pre-formed tubular packaging material is ideal for packaging blocks of cheese because the number of seals required to seal the product in a bag are minimised, which reduces the risk of damaging the product. In addition, a reduction in the number of seals required at the site of packaging reduces the risks of faulty seals which would lead to leakage following vacuum sealing.

lurthermore, a tube can easily provide a bag of required and repeatable dimensions so that the bag can be tight around the block.

The continuous length of pre-formed flexible tubular packaging material may be formed from a plastic material.

According to a further aspect of the present invention there is provided apparatus for use in the automated packaging of product, comprising; means for removing a length of tubular packaging material from a continuous length of flexible pre- formed tubular packaging material; means for closing one end of the length of tubular packaging material to form a bag; and means for preparing the bag for receiving the product through the open end.

Apparatus embodying the present invention therefore uses a continuous length of flexible pre-formed tubular packaging material as its starting material and accommodates the continuous length within its structure. Because the apparatus provides for automated packaging, manual intervention is not required and levels of efficiency can be improved over known systems in which pre-formed bags are not formed at the site of packaging and are transported to the packaging site and manually applied to a packaging apparatus to f ll products.

There may be further provided means for filling product into the newly formed bag through the open end. Once the bag has been prepared for use therefore the apparatus of the present invention may also insert product into the bag.

There may further be provided means tor closing the open end of the filled product in order to envelope the product within the bag. The closing operation may comprise a sealing step in which the open end is sealed. Alternatively the closing step may comprise a pre-closing or pre- sealing step in which the open end is prepared for closing and/or sealing.

There may be further provided bag opening means for preparing the bag for receiving products. For example, suction could be applied to the exterior faces of opposing sides of a flattened tubular structure in order to pull them apart to provide an open mouth.

The apparatus may be arranged so that the means for removing the length of material from a continuous length and the means for closing one end of the removed length act simultaneously. For example, a combined heat sealing and cutting station may be provided for by the apparatus.

The open end of the bag may be closed following product receipt by vacuum sealing means. The vacuum sealing means may form part of the present apparatus or the filled bag may be transported from the filling site to a separate vacuum sealing system.

There may further be provided means for flattening the open end of the bag following receipt of product in order to prepare it for closing. This may involve joining opposing surfaces of the open end of the tube together in order to hold the end flat, such as by spot welding the opposing surfaces together.

The means for flattening the open end of the bag may comprise some means of separating two diametrically opposed points of the tubular end from each other, in order to cause the material therebetween to flatten. This may involve two finger- like projections entering the open end of the bag and then being moved apart so that they push on the inner faces of the opposed points of the tubular end, causing it to flatten.

The apparatus may allow for a predetermined length of material to be removed.

Accordingly the predetermined length could be unrolled, lifted or pulled as appropriate. By doing so a bag of predetermined dimensions can be formed. The continuous length of pre-formed flexible tubular packaging material may be provided in the form of a roll of material. A roll of material is easy to transport, and unrolling a predetermined length of material from a roll is easy as the exposed end of the roll is simply pulled to a required position relative to a cutter or the like.

The continuous length of pre-formed flexible tubular packaging material may be in the form of a flattened tube, which may be gusseted to provide additional packaging volume.

The apparatus may be adapted for packaging a food product and as such the use of food-approved packaging material would be essential, as would the ability to provide apparatus which is easy to clean and keep free from contamination.

The apparatus may be adapted for packaging a block of cheese, in which case minimum manual intervention would be an advantage, as would preparing bags of a predetermined size so that the blocks of cheese could fit tightly within the bag.

Vacuum sealing of a filled bag is the preferred method for sealing blocks of cheese and so an apparatus in which the open end of the filled bag is prepared for vacuum sealing by flattening the end would be advantageous.

The continuous length of packaging material may be formed from a plastics material such as polyethylene.

The present invention also provides a packaging system using the method described above.

The present invention also provides a packaging system incorporating the apparatus described above.

According to a further aspect of the present invention there is provided a cheese block packaging installation apparatus comprising or including the apparatus as described above.

The present invention will now be more particularly described, by way of example, with reference to the accompanying drawings, in which: Figure I is a perspective view of a cheese block packaging installation according to the present invention; Figure 2a is a perspective view of the packaging apparatus of Figure 1; Figure 2b is a perspective view of part of the packaging apparatus of Figure 2a with a gripping member shown in a first position; Figure 2c is a perspective view of the apparatus of Figure 2b shown following movement of a gripping member to a second position to unroll a length of packaging material; Figure 2d is a perspective view of the apparatus of Figure 2c shown with a bag opening member in a closed position; Figure 2e is a perspective view of the apparatus ol Figure 2d shown following movement of the gripping member back to its first position and movement of a heat sealing/cutting member to a second, contacting position; Figure 2f is a perspective view of the apparatus of Figure 2e in which the bag opening member has moved to an open position and moved over a bag tray member; Figure 2g is a perspective view of the apparatus of Figure 2f in which the bag opening member has been withdrawn and the bag tray member has moved upwards with the bag ready to receive a block of cheese.

Figure 3a is a front view of the mouth of a bag formed according to the present invention; Figure 3b is a plan view of the mouth of Figure 3a shown with bag flattening fingers inserted; Figure 3c is a front view of the mouth of Figures 3a and 3b following flattening and scaling in position; and Figure 3d is a section of a filled bag having a flattened mouth as shown in Figure 3c.

Referring first to Figure I there is shown a packaging installation generally indicated 10. The installation 10 includes a cheese block forming tower 20, a cheese block packaging apparatus 30 and a conveyor belt 60.

The cheese block forming tower 20 is usually 5m to tom in height and contains a body of cheese to be packaged. Cheese at the bottom of the tower 20 is cut by a knife (not shown) to form a block 21 which is in line with an outlet 22.

The cheese block 21 is pushed out of the bottom of the tower 20 by a piston (not shown) and into a bag 50 which is prepared and positioned ready to receive the block 21 by the apparatus 30. In use the block 21 is pushed into the open mouth of the bag 50. The filled bag 50 is then transported on the conveyor belt 60 to a vacuum sealing station (not shown) where the open mouth of the bag 50 is sealed.

The apparatus 30 is located entirely below the conveyor belt 60 and thus does not interfere in any way with access to the cheese block tower 20.

Referring now to Figure 2a there is shown the apparatus 30 in more detail isolated from the cheese packaging installation 10.

As shown in Figure 2a and described in greater detail with reference to Figures 2b to 2g, the basic components of the apparatus 30 are: a roller 31 which receives a roll of packaging material 32; a gripping member 36; a heat sealing/cutting member 43; a bag opening member 38; and a bag tray member 46.

Referring now also to Figure 2b the apparatus 30 includes a cylindrical roller 31 which rotatably receives a roll of packaging material 32. The roll 32 comprises a roll of pre-formed flexible tubular packaging material formed from a five layer laminate material in which the two outer layers are polyethylene and intermediate sealing layers are formed on the outer layers to bond the polyethylene layers to a central layer of nylon, which provides an oxygen barrier. The material is approximately 100pm thick, with the nylon layer comprising about 40,um of the thickness. The material from the roll 32 is passed around tensioning rollers 33, 34, and the free end 41 of the roll is held by a gripping member 36 in a position designated A. In Figure 2c the gripping member 36 has moved from position A to position B and in doing so has unrolled a length of material 37 from the roll 32. The distance between position A and position B therefore represents the length of a packaging bag to be formed, and is adjustable. The length of the bag is therefore set before the product is loaded.

In Figure 2d a bag opening member 38 is introduced. The opening member 38 comprises upper and lower opening members 38a, 38b comprising bars 39a, 39b each having five spaced suction cups 40. In use the upper and lower bars 38a, 38b are moved towards each other so that the suction cups 40 engage the end 41 of the length of packaging material 37. The suction cups 40 fit between slots 42 formed in the gripping member 36.

In Figure 2e the gripping member 36 has released the length of material 37 and returned to position A before gripping the packaging material again. With the length of material 37 held firmly between the bag opening member 38 and the gripping member 36, heat sealing bars 43a, 43b forming part of a heat sealing/cutting member 43 are brought together at the end 44 of the length of material 37 to heat seal the end 44. Simultaneously the end 44 of the length of material 37 is cut by a blade 45 integrated into the heat sealing bar 43a to form a bag 50.

In Figure 2f the bag opening bars 38a, 38b have been moved to their original, open position to open the end 41 of the bag to form a mouth. The bag opening member 38 then travels to position C in which the open mouth 41Of the bag passes over a bag tray 46 comprising upper and lower tray members 46a, 46b.

The bag tray members 46a, 46b are moved apart to stretch the bag mouth 41 to a required size and to engage the inner face of the bag mouth 41.

The bag opening member 38 now releases the end 41 of the bag and returns to position B in its open configuration with the upper and lower members 38a,38b spaced ready to receive a new length of packaging material.

The bag tray members 46a, 46b are now raised to the upper position shown in Figure 2g in which they are in line with the cheese block 21 so that the block 21 can be pushed into the prepared bag 50 through the bag tray 46. The apparatus 30 has therefore provided for the automated formation of a bag and loading of the bag ready to receive product.

As the cheese block 21 is pushed into the bag 50, the bag 50 is pushed off the bag tray 46 so that the filled bag 50 is pushed onto the conveyor 60. The block 21 is therefore f fled into the bag 50 immediately after formation of the bag 50.

The bag tray members 46a, 46b are then moved back towards each other and moved back down below the level of the conveyor 60 to a lower position ready to receive a new bag.

Referring now to Figure 3a there is shown a front view of the bag following filling with the block of cheese. The mouth 41 is in a generally elliptical shape.

Referring now to Figure 3b there is shown a bag flattening apparatus which can be used to flatten the open mouth 41 of the bag following filling with a block of cheese. The apparatus comprises two elongate fingers 70, 71 which are inserted into the open mouth 41 of the bag and then moved apart in the direction of the arrows D. Accordingly the material between the points engaged by the fingers 70, 71 flattens.

In Figure 3c the flattened end 41 of the mouth is shown and is held in place by two spot welds 75, 76. The spot welds 75, 76 hold the mouth 41 flat so that it is ready for a vacuum sealing step by conventional vacuum sealing apparatus (not shown) to complete the form-fill-seal operation.

Referring now to Figure 3d the bag 50 is shown filled with a cheese block 21 and prepared for vacuum sealing by flattening of the mouth 41 as described above.

Claims

1. A method for use in the automated packaging of product, comprising the steps of: - providing a continuous length of pre-formed flexible tubular packaging material; - removing a length of tubular packaging material from the continuous length; closing one end of the removed length of tubular packaging material to form a bag; and - preparing the bag for receiving product through the open end.

2. A method as claimed in Claim 1, further comprising the step of filling product into the newly formed bag through the open end.

3. A method as claimed in Claim 2, further comprising the step of closing the open end of the filled bag to envelope the product.

4. A method as claimed in any of Claims 1 to 3, in which the means for preparing the bag comprise bag opening means which form an open mouth.

5. A method as claimed in any preceding claim, in which the steps of removing a length of material and closing one end of the removed length are performed simultaneously.

6. A method as claimed in any preceding claim, in which the open end of the bag is closed by vacuum sealing.

7. A method as claimed in any preceding claim, in which the open end of the bag is prepared for closing by flattening the open end of the bag following receipt of product.

8. A method as claimed in Claim 7, in which the flattened open end is held flattened by joining opposing surfaces of the end together.

9. A method as claimed in Claim 8, in which the opposing surfaces of the flattened open end are joined by spot welds.

10. A method as claimed in any of Claims 7 to 9, in which the open end is flattened by separating two diametrically opposed points of the tubular end from each other to cause the material there between to flatten.

11. A method as claimed in any preceding claim, in which the step of removing the length of tubular material comprises a cutting step.

12. A method as claimed in any preceding claim, in which the end of the removed length of tubular material is closed by heat sealing.

13. A method as claimed in any preceding claim, in which a predetermined length of tubular material is removed from the continuous length to provide a bag of predetermined dimensions.

14. A method as claimed in any preceding claim, in which the continuous length of pre-formed flexible tubular packaging material is provided in the form of a roll of material.

15. A method as claimed in any preceding claim, in which the continuous length of pre-formed flexible tubular packaging material is in the form of a flattened tube.

16. A method as claimed in any preceding claim, in which the continuous length of pre-formed flexible tubular packaging material is gusseted.

17. A method as claimed in any preceding claim, in which the continuous length of pre-formed flexible tubular packaging material is formed from a plastics material.

18. A method as claimed in any preceding claim, in which the method is adapted for a food product.

19. A method as claimed in Claim 18, in which the food product is a block of cheese.

20. Apparatus for use in the automated packaging of product, comprising: - means for removing a length of tubular packaging material from a continuous length of flexible pre-formed tubular packaging material; means for closing one end of the length of tubular packaging material to form a bag; and means for preparing the bag for receiving product through the open end.

21. Apparatus as claimed in Claim 2O, in which there are further provided means for filling product into the newly formed bag through the open end.

22. Apparatus as claimed in Claim 21, in which there are further provided means for closing the open end of the filled bag to envelope the product.

23. Apparatus as claimed in any f Claims 20 to 22, in which there are further provided bag opening means for preparing the bag for receiving product.

24. Apparatus as claimed in any of Claims 20 to 23, in which the means for removing a length of material and the means for closing one end of the removed length act simultaneously.

25. Apparatus as claimed in any of Claims 20 to 24, in which the open end of the bag is closed following product receipt by vacuum sealing means.

26. Apparatus as claimed in any of Claims 20 to 25, in which there are further provided means for flattening the open end of the bag following receipt of product to prepare it for closing.

27. Apparatus as claimed in Claim 26, further comprising means for joining opposing surfaces of the open end together to hold the end flat.

28. Apparatus as claimed in Claim 27, in which the means for joining the opposing surfaces together comprise spot welds.

29. Apparatus as claimed in any of Claims 26 to 28, in which the means for flattening the open end of the bag comprise means for separating two diametrically opposed points of the tubular end from each other to cause the material there between to flatten.

30. Apparatus as claimed in any of Claims 20 to 29, in which the means for removing the tubular material length comprise cutting means.

31. Apparatus as claimed in any of Claims 20 to 30, in which the means for closing one end of the tubular material length comprise heat sealing means.

32. Apparatus as claimed in any of Claims 20 to 31, in which the means for removing a length of tubular packaging material remove a predetermined length to provide a bag of predetermined dimensions.

33. Apparatus as claimed in any of Claims 20 to 32, in which the continuous length of pre-forrned flexible tubular packaging material is provided in the form of a roll of material.

34. Apparatus as claimed in any of Claims 20 to 33, in which the continuous length of pre-formed flexible tubular packaging material is in the form of a flattened tube.

35. Apparatus as claimed in any preceding claim, in which the continuous length of pre-formed flexible tubular packaging material is gusseted.

36. Apparatus as claimed in any of Claims 20 to 35, in which the apparatus is adopted for packaging a food product.

37. Apparatus as claimed in any of Claims 20 to 36, in which the apparatus is adapted for packaging a block of cheese.

38. Apparatus as claimed in any of Claims 20 to 37, in which the continuous length a packaging material is formed from a plastics material.

39. A packaging system incorporating the apparatus of any of Claims 20 to 38.

40. A packaging system using the method of any of Claims I to 19.

41. A cheese block packaging installation apparatus comprising or including the apparatus of any of Claims 20 to 38.

42. A method substantially as hereinbefore described with reference to, and as shown in, the accompanying drawings.

43. Apparatus substantially as hereinbefore described with reference to, and as shown in, the accompanying drawings.