NZ207705A - Automatic fruit packing from graded bulk supply to pocketed trays - Google Patents

Description

2077(95 N.Z. No. 207705 30 March 1984 NEW ZEALAND Patents Act 1953 COMPLETE SPECIFICATION IMPROVEMENTS IN AND RELATING TO AUTOMATED FRUIT PACKING APPARATUS I, LESLIE DOUGLAS HAMLIN, a New Zealand citizen of No. 1 R.D., Matawero, Gisborne, New Zealand, do hereby declare the invention for which I pray that a Patent may be granted to me, and the method by which it is to be performed, to be particularly described in and by the following statement:- 207705 This invention relates to an apparatus for use in the automated packaging of fruit into trays, and in particular, for the automated packaging of kiwifruit into kiwifruit trays.

The kiwifruit industry is currently vigorous with ever-increasing volumes of kiwifruit being produced. The majority of this fruit is destined for the export market and thus there is a need for efficient handling of the fruit after harvest. To be suitable for export, kiwifruit must be packaged in suitable trays. Such trays usually comprise a wooden outer box within which is a protective film liner. A plix tray (plix is a trade name - a plix tray is a moulded plastics tray) is disposed on the liner within the wooden box, the plix tray being especially moulded into a regular array of pockets to accommodate the fruit. To date, the fruit, subsequent to grading, is packed into the trays completely by hand. This is usually performed by a chain of packers each performing a specific operation in the packing of the trays. Typical of fruit production, the kiwifruit harvest season is relatively short thus resulting in a very large volume of fruit requiring to be processed in a relatively short time period. It can therefore be seen that the packing of a large amount of fruit into trays is a labour-intensive operation, and growers often experience great difficulty in obtaining the necessary labour for a short period. Additionally, working on ct packing chain can be very hard work and problems are experienced in ensuring that packers maintain an efficient packing rate throughout a shift. 207765 The aim of the present invention is to provide an automated apparatus for facilitating the packing of fruit into trays thus alleviating the aforementioned difficulties.

According to a first aspect of the invention, there is provided an apparatus for continuously packing fruit into trays, said trays comprising an outer shallow box provided with a liner film and an inner tray in the form of a moulding with an array of fruit pockets therein, said apparatus comprising a frame assembly mounting a sequence of stations, a first station comprising a first fruit conveying means at least the entry of which is disposed to receive fruit from a bulk fruit supply, a second station comprising a regulated endless fruit conveying belt having moulded pockets on the surface thereof to a pattern corresponding to that of said inner tray, one end of said belt being so disposed with respect to said first fruit conveying means as to receive fruit in said pockets, and the other end of said belt defining a discharge end, a tray conveying means disposed to pass a tray thereon below the said other end of the belt, and synchronised in speed with respect to said belt so as to permit gravity discharge of fruit contained in pockets of said belt to corresponding pockets of said tray as said tray and belt progress.

In further describing the invention by way of preferred embodiments reference will be made to the accompanying drawings in which 207705 k H Figure 1 is a oahomroatie side elevation of the automated apparatus, Figure 2 is a plan view of the fruit conveying belt, Figure 3 is a side elevation of Figure 2, and Figure 4 is a schematic side elevation of a second embodiment of "ft* automated apparatus.

Referring to Figure 1 of the drawings, the automated apparatus is preferably mounted on a simple frame 10 comprising a fabrication of box section steel components. As can be seen the frame 10 mounts a regulated chain drive 11 which conveys a tray T along a linear path in the direction of arrow A. The drive for the chain (as may be for all components of the apparatus) is expediently via a suitable mechanical supply, preferably electrically operated, however, a hydraulic drive may alternatively be used. All sensors are preferably pneumatic. The graded kiwifruit are held in a large bin B located above a fruit conveying means comprising a regulated feed belt 12 which delivers fruit to a specially shaped conveying belt 13.

Referring to Figure 2 of the drawings the belt 13 is made of a conventional material and has riveted thereto, a fibroglaoo liner having moulded therein an array of pockets 14 each locating an 207705 ffti# individual kiwifruit K. The pattern of pockets corresponds to that of the plix P of a kiwifruit tray. Such a plix is usually six rows of six pockets, however, that shown in Figure 2 is a belt for use with a 33 fruit per tray and is of a staggered arrangement. Other such plixes accommodate up to 46 fruit per tray. The size of each pocket 14 is thus varied depending on the grade of fruit. Accordingly it has been found convenient to provide a range of belts 13 having different specifications to accommodate the differing grades of fruit and plix patterns.

These belts 13 may be readily interchanged on the apparatus.

Each belt is provided with a space between every sixth of pockets to correspond to the space between following trays as each plix tray is provided with six rows of pockets.

Because of the shape of the pocket it is found that kiwifruit more or less locate themselves in a correct alignment, however, the apparatus provides additional means to ensure that this occurs efficiently, as will be described in detail hereinafter.

In order to even the distribution of fruit as they are transferred from the feed belt 12 to belt 13, the fruit pass over a vibrating slide 14 located between the respective belts. This could be substituted by a singulator device as is well known in the industry.

Referring to Figure 1 and Figure 3 of the drawings the fruit is discharged from the belt 13 to the corresponding pockets in the touj 207705 plix of the tray by simply tipping off the edge of the belt, a row at a time, as the belt 13 rotates. Thus the speed of the belt 13 and tray chain drive 11 and the relative positions of the rows of pockets on the belt 13 and the corresponding pockets in the plix are synchronised so that the fruit drop directly at the correct spacing into the plix as the belt and tray progress. As mentioned above, when a tray is completely filled, the gap between the last row of pockets and the first row of the following tray is compensated for by spacing provided in the belt 13.

To ensure a smooth non-bounce location of the fruit into the pockets of the plix and to facilitate orientation therein, a roller 15 is provided adjacent the row of plix being filled. Roller 15 is of a very soft resilient material such as sponge rubber so as not to damage the fruit. The roller is preferably mounted on a spindle and may be radially split so that each pocket in the row may be independently dampened.

Subsequent to complete filling of each row of the tray, the tray is conveyed by the chain drive under appropriate means to fold over the liner film sheet located between the plix P and the tray T. It is mentioned that the tray and plix are arranged with a film liner therebetween such that the film has an extended portion 19a on the leading end of the tray and a short flap 19b on the trailing end. As the tray is conveyed it passes under a 207705 a* bar 18 which folds the portion 19a over the fruit. The tray is further conveyed over a fan arrangement 20 which blows trailing flap 19b over the leading flap 19a prior to tucking as will be described hereinafter. Subsequent to this operation the tray is conveyed to a settling station mounting a vibrating mechanism 16. This mechanism 16 expediently takes the form of a gantry 17 mounted on frame 10 which supports a spring mounted platen coupled to a foam plastics pad which in use bears directly (over the liner) onto the fruit in the tray. As the tray is conveyed along the frame it activates a pneumatic sensor which causes a platen to engage the under surface of the tray and raise it into engagement with the vibrating pad. The vibrating pad causes the fruit to lie in uniform orientation in the pockets of the plix. An alternative arrangement is the substitution of the station for a series of rollers over which the tray passes to impart the necessary vibration to the fruit.

The tray is then conveyed to a tucking station 21. As the tray proceeds it activates a sensor which causes a platen 22 to raise the tray into engagement with arrangement 21 mounted on frame 10 overhead of the platen 22 on which the tray is supported. Arrangement 21 essentially comprises a pair of reciprocating elements which engage the liner on the lateral peripheral portions of the inside of the tray to thereby tension and tuck the liner into the tray which will thus form a protective covering over the fruit. 207705 Subsequent to the tucking operation the tray is conveyed to a lidder 23 which essentially i6 a simple arrangement for placing a o*ite> cardboard lid from a bulk supply the tray. The lidder has once again an overhead pneumatically operated arrangement mounted on frame 10. Forward movement of the tray triggers an appropriate sensor to activate the arrangement.

Subsequent to the lidding operation the tray is conveyed to an unloading station 24 for manual removal and stacking.

In use the apparatus is designed to be worked with six attendants. These may be stationed as follows, namely one at the bulk supply of fruit, one either side of the tray filling station, one at the tray tucking station and one at each of the lidding stations and unloading stations. As previously mentioned the bulk storage holds pre-graded fruit and thus the apparatus is designed to pack in a single run a desired grade of fruit. Accordingly a suitable fruit conveying belt 13 is chosen to suit the size of fruit and the plix tray arrangement. In operation, a portion of the fruit in the bulk supply B is unloaded onto the feed conveyor 12 which is regulated by means of a foot controlled switch to ensure that the conveying belt 13 is not flooded with fruit. The vibrating plate 14 serves to evenly distribute the fruit so that they will locate uniformly across and into the pockets of belt 13. - 8 - V *A\ 1 SDECJ986& 207705 The trays T complete with liner film and plix tray are continuously supplied to the conveying chain 11 by means of an inclined chute and proceed along to eventually emerge below the discharge end of belt 13. As mentioned belt 13 and chain conveying means are synchronised so that each row of pockets holding fruit and pockets in the tray plix correspond. The padded roller 15 ensures that the majority of fruit is retained in the plix, however, any doubling up of fruit or blank spaces may easily be rectified by one of the attendants.

The filled tray is conveyed along the frame to be operated on by the subsequent stations. The appropriate attendants ensure that any mishaps are appropriately rectified.

Referring to Figure 4 of the drawings a second embodiment is shown. The various stations are similarly mounted on a simple frame 50. The fruit are conveyed from a bulk supply to conveyor belt 51 by a roller conveyor 52. Belt 51 is similar to belt 13 of the previous embodiment, however, it is horizontally disposed.

The tray chain drive is, however, reversed (arrow B) to that of the previous embodiment, but the tray is similarly filled by the fruit tipping off the edge of the belt 51. However, in this embodiment a guide 53 is provided to hold the fruit in the pockets as they turn around the radiused portion of the path of travel. The guide 53 expediently comprises rows of brushes fixed 207705 to the inside of a curved holder disposed adjacent to the radiused portion of the belt 51.

This embodiment in its simplest form is not provided with any of the additional stations of the previous embodiment. The remaining operations are expediently carried out by hand by the attendant operators. In alternative embodiments further stations such as a tucking station are included.

It has been found that the present automated apparatus of the first embodiment can easily pack twenty trays per minute utilising a total of six attendants. In comparison, it is a conservative estimate that a total of twenty-nine staff would be required to maintain this output in a completely manually operated packing line. It will therefore be appreciated that the present invention provides a very considerable saving in labour requirements and associated savings in overhead costs.

It will be appreciated that at least some of the subsequent stations in the apparatus could be substituted with manual labour and in particular the lidding station, and that alternative provisions for much of the hardware could be effected without departing from the scope of the invention ^ OS defined 10 ■POIIcAaJI^ .

Claims (12)

207705 WHAT I CLAIM IS:-

1. An apparatus for continuously packing fruit into trays, said trays comprising an outer shallow box provided with a liner film and an inner tray in the form of a moulding with an array of fruit pockets therein, said apparatus comprising a frame assembly mounting a sequence of stations, a first station comprising a first fruit conveying means at least the entry of which is disposed to receive fruit from a bulk fruit supply, a second station comprising a regulated endless fruit conveying belt having moulded pockets on the surface thereof to a pattern corresponding to that of said inner tray, one end of said belt being so disposed with respect to said first fruit conveying means as to receive fruit in said pockets, and the other end of said belt defining a discharge end, a tray conveying means disposed to pass a tray thereon below the said other end of the belt, and synchronised in speed with respect to said belt so as to permit gravity discharge of fruit contained in pockets of said belt to corresponding pockets of said tray as said tray and belt progress.

2. Apparatus as claimed in claim 1 further comprising a locating/dampening device disposed adjacent said dischargetof »- 6o'»d Ibelt to facilitate the location and settling of fruit in the pockets of said tray. 11 1SDECI986® 207705

3. Apparatus as claimed in claim 2 wherein said locating/dampening device comprises a curved guide consisting of rows of brushes mounted inside a semi-circular housing, said device disposed at the discharge end such that said brushes contact fruit at the commencement of the gravity discharge.

4. Apparatus as claimed in claim 2 wherein said locating/dampening device comprises a soft resilient roller disposed adjacent the row of trays being filled.

5. Apparatus as claimed in any one of the preceding claims wherein the endless fruit conveying belt is demountable and capable of substitution with any of a range of alternative belts accommodating various fruit sizes and/or inner tray configurations.

6. Apparatus as claimed in any one of the preceding claims wherein the endless belt is provided with a spacing at regular intervals to allow for-a gaps between following trays.

7. Apparatus as claimed in any one of the preceding claims including a further station provided with vibrating means to vibrate a tray conveyed thereon to facilitate settling of the fruit in the tray pockets.

8. Apparatus as claimed in any one of the preceding claims including a further station provided with liner Jtucking means.1 12 207705

9. Apparatus as claimed in any one of the preceding claims including a further station provided with a lidder to cap said boxes.

10. Apparatus as claimed in any one of the preceding claims wherein said sequence of stations follows a linear path.

11. Apparatus as claimed in any one of the preceding claims when said belt drive and tray drive are chain driven.

12. Apparatus substantially as herein described with reference to and as illustrated by the accompanying drawings. LESLIE DOUGLAS HAMLIN By His Attorneys HENRY HUGHES LIMITED