US20100101682A1

US20100101682A1 - Method and apparatus for reducing product breakage in a packaging machine

Info

Publication number: US20100101682A1
Application number: US12/260,423
Authority: US
Inventors: Keith Alan Barber; Rudolph L. Bazaldua; Stephen Michael Callahan
Original assignee: Frito Lay North America Inc
Current assignee: Frito Lay North America Inc
Priority date: 2008-10-29
Filing date: 2008-10-29
Publication date: 2010-04-29
Also published as: WO2010053646A2; WO2010053646A3

Abstract

A method for reducing product breakage while filling a product into a package and apparatus for accomplishing the same. The invention describes reducing the momentum of product falling through a filling apparatus to reduce collisions of the product with other product and with the apparatus, thus reducing breakage. The vertical momentum, in one embodiment is transferred to horizontal momentum by imparting a swirling motion onto the product via swirling vanes located on the funnels. Because the product swirls in a controlled direction, collisions and breakage is effectively reduced. In another embodiment, the product encounters bumpers which absorb a portion of the products momentum and which prevent damaging collisions.

Description

BACKGROUND OF THE INVENTION

1. Technical Field
The present invention relates to a method and apparatus for reducing product breakage in a packaging machine.
2. Description of Related Art
Breakage is a problem with virtually any process wherein a package is filled with product, such as a food product. Often, the amount of breakage is dependent on the fragility of a product. Typically homogenous products are less likely to experience breakage as they often comprise less “weak points” which exhibit a tendency to break. The product geometry also affects the tendency of the product to break. Regardless of the product, however, the extent of the breakage is dependent on the process used to package the product.
There are a variety of methods and apparatuses employed to deliver product into a package which are known in the prior art. Many comprise a series of tunnels or chutes which guide and direct the product into a package 107.
FIG. 1 is a side profile of a filling apparatus. A product is typically weighed and measured in some sort of weighing device. FIG. 1 illustrates a statistical or combinational weigher 101. These statistical weighers 101 are well known in the art and precisely measure an amount of the product. A computer then determines a precise combination of individual weighers to achieve a desired weight of product. These statistical weighers 101 are very precise and limit the amount of waste or overfill for a packaged product.
Product from the statistical weighers 101 is typically transferred into a series of funnels and tubes until it has finally reached its packaging bag 107. These funnels and tubes vary in diameter and size. Often the funnels are separated by a distance of 3 feet or more in which the product can accumulate significant vertical velocity. The chutes can be funnels, as illustrated in FIG. 1, or they can be straight walled tubes.
Referring again to FIG. 1, after the product is dumped from statistical weigher 101, it typically flows via gravity through the rest of the filling apparatus. It first encounters the first funnel 102. Some of the product hits the first funnel 102 along its sides and is directed to the second funnel 103. The second funnel 103 is depicted as being located in close proximity to the first funnel 102, but this is not a necessity. There can be a significant distance either between the two funnels or along the entire apparatus wherein the product free falls and accumulates a significant velocity. After the product flows through the first funnel 102, and to the second funnel 103, the product is directed through the exit of the second funnel 103. After the product exits the second funnel 103, it enters the third funnel 104. In the embodiment shown, the third funnel 104 is connected to and is above a product tube 105. The product tube 105 as depicted is a straight walled tube although it may also be a cone. In the product tube, product is transferred from the third funnel 104 to the final product conduit 106 located downstream of the product tube 105. As used herein, “downstream” and “upstream” refer to relative points or locations in the process or apparatus. Thus, an event taking place downstream occurs later in the process and follows events which took place upstream.
The final product conduit 106 used may comprise a variety of means for depositing a product into a package 107. As illustrated, the final product conduit 106 comprises a simple funnel. However, the prior art discloses that the conduit 106 may include sophisticated moving parts such as jaws which are used to simultaneously fill and form the package. Often the packaging machines comprise an absorber which allows product to be softly received into the package. In other words, the package is held in place in such a way as to absorb a portion of the product momentum and reduce breakage. Regardless, typically a conduit 106 is employed to deposit the product into the package.
Unfortunately, when employing a filling apparatus such as the one discussed, the product often becomes broken at some point after the statistical weighers 101. Accordingly, when a consumer opens the package there is often several broken product pieces as well as a volume of crumbs or scraps of product accumulated in the bottom of the package. This is obviously objectionable for a variety of reasons. First, it is almost always desirable to have a whole product. For example if the product is a chip, a chip is desirable as the consumer may be dipping the chip. Further, breakage is undesirable because the broken product tends to collect at the bottom of the package, giving the appearance of a less full bag. A package comprising whole product pieces appears fuller to the consumer and thus more desirable. Accordingly, it is desirable to find an apparatus or a method wherein the product breakage is eliminated or reduced. Further, it is desirable to have a method or apparatus which results in a package which has the appearance of being fuller when opened. It is desirable that any method or apparatus not severely limit the speed in which bags can be made and filled. Furthermore, because many packages involve a vertical, form, fill and seal machine, it is desirable that this product be flexible enough for use on such a machine, preferably with only minor modification.

SUMMARY OF INVENTION

An apparatus and method for reducing product breakage while filling a product into a package is provided. The invention describes reducing the momentum of product falling through a filling apparatus to reduce collisions of the product with other product and with the apparatus, thus reducing breakage. In one embodiment, the apparatus comprises at least one funnel, a steering funnel, which comprises steering vanes. These steering vanes, located on the face of the funnel, impart a swirling motion upon the product dropped within the funnel. Thus, a swirling motion is imparted onto the product which reduces the vertical momentum of the product and which reduces the number and strength of the collisions.
In another embodiment, the apparatus comprises a funnel and a product conduit used for depositing the product into the package located downstream of the funnel. A bumper which is in substantially the same vertical plane as the exit end of the tunnel is suspended somewhere above the lower end of the product conduit but below the exit end of the funnel. As product falls through the funnel it encounters the bumper. The bumper is flexible to absorb momentum without itself causing breakage. Because of the reduced momentum, the strength of the collisions is reduced which likewise reduces the product breakage.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will be best understood by reference to the following detailed description of illustrative embodiments when read in conjunction with the accompanying drawings, wherein:

FIG. 1 is a side profile of a filling apparatus;

FIG. 2 is a perspective view of one funnel employed in one embodiment of the instant invention utilizing steering vanes;

FIG. 3 is a side profile of a filling apparatus employing one embodiment of the instant invention;

FIG. 4 is a perspective view of one funnel employing triangularly shaped steering vanes; and

FIG. 5 is a perspective view of one embodiment utilizing bumpers.

DETAILED DESCRIPTION

Several embodiments of Applicants' invention will now be described with reference to the drawings. Unless otherwise noted, like elements will be identified by identical numbers throughout all figures.
Generally, this invention relates to a method and apparatus for preventing breakage during packaging. A goal is to reduce breakage by reducing the high velocity of the product and more specifically by elimination of the high momentum product-to-product collisions as well as the high momentum product-to-apparatus collisions. The invention can suitably be used on a standard vertical form, fill, and seal machines known well in the art. However, the invention is not limited to vertical form, fill, and seal machines, as the instant invention can be utilized on virtually any packaging apparatus. Referring back to FIG. 1, Applicants have determined that many of the collisions which result in breakage occur at two places: an impact point 108 located near the junction of the product tube 105 and the third funnel 104, and a second impact point located near the junction of the product tube 105 and the final product conduit 106. It should be noted that while the impact point is discussed as being a single point for simplicity, it is actually an impact zone. The impact typically occurs somewhere within the defined zone. Regarding the impact point 108 located near the top of the product tube 105, it can be appreciated that product which slopes down the sides of the second funnel 103 can be directed to the impact point 108 resulting in significant breakage. Likewise, product sliding down the straight sides of the product tube 105 can collide with the junction of the fourth funnel 106 resulting in further product breakage. This collision with the junction of the product conduit 106 can be magnified if, for example, the product tube 105 is round whereas the product conduit 106 is square, oval, rectangular, or some other shape. Thus, product which is riding down the sides of the product tube 105 may break near the junction of the square edges, for example, around the product conduit 106. Thus, Applicants have identified two impact points located on the apparatus which contribute to product breakage and which can be avoided. It should be noted that another impact point is the final product stopping point located in the floor of the package. Thus, the floor of the package is yet another impact point. As will be discussed below, the instant invention reduces the vertical momentum of the falling product. The reduced vertical momentum in turn reduces the intensity of the collision between the product and the floor of the package. Accordingly, the invention also reduces breakage of the product as it is being deposited into its package.
It should be noted that while Applicants generally refer to the filling apparatus of FIG. 1, this is done for clarity purposes only and should not be deemed limiting. The instant invention is suitable for use on a variety of systems including systems with at least one funnel as well as systems with a series of various funnels, tubes, drops, etc. used to package a product. Furthermore, while the product tube 105 is depicted as being physically connected to the third funnel 104, in other embodiments the two are not directly connected. So is the case with the other equipment discussed herein as well. Thus, if equipment is discussed or depicted as being connected, it is to be understood that the instant invention is not so limited as the equipment does not have to be physically connected.
Referring now to FIG. 2, FIG. 2 is a perspective view of one funnel employed in one embodiment of the instant invention employing steering vanes. Applicants have found a novel and non-obvious method of injecting a swirling motion to the product to reduce breakage. As will be discussed below, the swirling motion reduces the strength of the collisions at the impact point 108 and consequently reduces breakage. Further, as the product swirls in a similar direction as opposed to sliding down opposite sides of a funnel in opposing directions, the product-to-product collisions are likewise decreased. In FIG. 2, the steering vanes 201 which impart the swirling motion to the product are illustrated. As used herein, “steering vanes” refer to physical protrusions from the inside face of the funnel which impart a swirling motion to product dropped in said funnel. These physical protrusions may be affixed to an existing funnel or the funnel may be molded or formed so as to exhibit these physical protrusions. The steering vanes may comprise a curvature which imparts a swirling motion, or the steering vanes may be straight vanes which are angled relative to the vertical direction which likewise imparts a swirling motion. Thus, there are a variety of orientations of the steering vanes which impart a swirling motion including curved, straight, and bent. Bent, as used herein refers to a straight orientation which comprises one or more angled segments. Further, as will be discussed, these steering vanes can comprise a variety of cross-sectional shapes. For example, in one embodiment the steering vanes comprise a rounded cross-section. A rounded cross-section is meant to include any circular cross-section as well as any cross-section with rounded edges, corners, or sides. Applicants have found in some embodiments the rounded cross-section is gentle on the product and tends to be self cleaning. In another embodiment, discussed in more detail below, the steering vanes comprise triangular shaped steering vanes. In still another embodiment, the steering vanes comprise triangular shaped vanes wherein either the corners of the triangle are rounded, or the sides of the triangle are rounded or both. Those skilled in the art will appreciate that different cross-sectional shapes will be advantageous for different products.
While FIG. 2 illustrates the steering vanes 201 being located on a funnel with sloped sides, a straight walled chute may also be utilized. Accordingly, as used herein, a “funnel” refers to an object which controls the flow of product; “funnel” includes a funnel with sloped sides and an entrance end which has a larger diameter than the exit end but also includes a tube with straight walls.
The steering vanes 201 illustrated in FIG. 2 are “perpendicular wall” steering vanes. As used herein “perpendicular wall steering vanes” are steering vanes which rise substantially vertically from the surface of the funnel in the shape of a wall and which create a physical barrier between adjacent lanes, keeping product from one lane from reaching the adjacent lane. Thus, the perpendicular wall steering vane is substantially perpendicular to the surface of the funnel. In some embodiments, perpendicular wall steering vanes are preferable when the product length is less than the distance between adjacent vanes. As used herein “product length” refers to the maximum length of a product measured from any direction. In one embodiment, the ratio of spacing between adjacent steering vanes to product length is between about 10:1 to about 0.5:1, wherein the spacing between adjacent steering vanes is measured at its shortest point. While the effectiveness of a given steering vane is dependent on the product length, there are a variety of other factors including product shape, uniformity, and locking ability which likewise affect the effectiveness. The locking ability of a product refers to the ability of the product to lock and engage with other products to form a large connected mass. Thus, the orientation, height, shape, etc. of a steering vane is highly dependent on the product to be packaged. For example, round and uniform products typically do not lock with one another. As another example, long, skinny, and uniform product often aligns like cards in a deck. In so aligning, such products have successfully been packaged in steering vanes wherein the product length is greater than the spacing between adjacent perpendicular wall steering vanes. Contrariwise, some products, such as curved potato chips, tend to lock together and form single mass or large clusters of product. The single mass becomes lodged and slows or stops the flow of product if not properly separated and directed. This will be discussed in detail below.
The steering vanes 201 impart a swirling motion to the product. This is contrasted to the prior art wherein the product follows the slope of the funnel and is directed in the most directly vertical path wherein there is great velocity in the vertical or Y direction and comparatively little velocity in the horizontal or X direction. The steering vanes 201 impart a swirling motion to the product wherein a portion of the vertical momentum is transferred into horizontal momentum, and more specifically into a rotational or helical momentum as the product swirls. The height, length, and orientation of the steering vanes 201 can be adjusted to achieve a desired swirling motion. As can be appreciated, as the swirling motion is increased, the vertical velocity is decreased. As a result, the throughput of product per unit time through the second funnel 103, and consequently through the entire filling process is decreased. This has a direct effect on the number of packages which can be filled in a given time. Thus, those skilled in the art will appreciate that a given product can be optimized for optimal throughput in terms of bags per unit time and acceptable breakage.
In the depicted embodiment the steering vanes 201 extend beyond the exit end of the funnel. This provides an opportunity to provide an increased swirling motion to the product. In another embodiment the steering vanes 201 extend only for the length of the funnel, whereas in other embodiments the steering vanes 201 do not extend for the entire length of the funnel. In still other embodiments the steering vanes 201 begin straight but later curve, while in other embodiments the steering vanes 201 begin curved but later straighten. Often such embodiments are used to accommodate existing equipment which cannot be replaced or modified. Those skilled in the art will appreciate that process, apparatus, and product circumstances may dictate minor changes in the location, orientation, geometry, length, etc. of the steering vanes 201. Thus, the many variables surrounding the steering vanes 201 may be adjusted to optimize a variety of parameters in a process including breakage and product throughput.
In FIG. 2, the steering vanes are illustrated as being located on the second funnel 103. A funnel comprising steering vanes is referred to as a steering funnel. Consequently, as illustrated in FIG. 2, the second funnel 103 is a steering funnel. A filling apparatus of the instant invention comprises at least one steering funnel, but it may comprise several steering funnels. Furthermore, the steering funnel may be located at virtually any location in the filling apparatus. For example, the steering vanes 201 may alternatively be located on the first funnel 102 or the third funnel 104, or both. In one embodiment, when multiple steering funnels are used each steering funnel imparts the same swirling direction. Thus, if an upstream steering funnel imparts a counter-clockwise swirl, then the downstream steering funnel likewise imparts a counter-clockwise swirl. The steering vanes 201 have little to no effect on the flow of the product upstream of their location. This is one reason why the steering vanes 201 are depicted as being located on the second funnel 103 wherein they will have a significant effect on the flow of the product downstream. In one embodiment, Applicants have found the location of the steering vanes 201 on the second funnel 103 to be preferable, as they have found that in some embodiments product has more contact with the outer wall in the second funnel 103 than the first funnel 102. Thus, in such embodiments because there is more product contact with the side walls of the funnel 103, the flow of the product can be better controlled compared to a funnel which has minimal product contact with its side walls.
As discussed, the steering vanes 201 give the product a swirling motion. Thus, as product is dumped from statistical weighers 101 into the first funnel 102 and into the second funnel 103, the product begins to swirl. It should be noted that while statistical weighers 101 are discussed in one embodiment the instant invention is not so limited. The instant invention may successfully be employed in virtually any weigher including volumetric weighers, single bucket drops, and continuous product streams.
Because the product begins to swirl, when it encounters the third funnel 104 along with product tube 105, not all of the momentum is concentrated on the impact point 108. Instead the product swirls in a circular direction down the tube. This slightly decreases throughput and greatly reduces breakage at the impact point 108.
FIG. 3 is a side profile of a filling apparatus employing one embodiment of the instant invention. FIG. 3 illustrates the steering vanes 201 located on the second funnel 103. Again, as previously described, the steering vanes 201 can be located on virtually any funnel or chute. FIG. 3 also illustrates another embodiment which further reduces breakage. As previously discussed, Applicants have found that breakage primarily occurs in two spots on the apparatus: the impact point 108 or zone located near the top of the product tube 105, and the impact point located near the intersection of the bottom of the product tube 105 and the product conduit 106. Thus, in the embodiment as illustrated in FIG. 3, the straight walled product tube 105 of FIG. 1 is replaced with a product tube 105 comprising sloped sides. Thus, instead of a straight walled product tube which often directs product straight down to a collision point, the improvement comprises the use of a slanted walled tube or funnel. In this fashion, the lower end of the product tube, may fit within the final product conduit 106 which helps direct the product away from the impact points. Thus, this improvement removes the previous impact point previously located near the junction of the straight walled product tube 105 and the product conduit 106 which further decreases breakage.
Likewise, Applicants offer another improvement to reduce the effect of the impact point located near the junction of the product tube 105 and the product conduit 106. As discussed above, often the product tube 105 has a circular cross section whereas the product conduit 106 often has a square cross section. To decrease the effect of the transition from a round cross section to a square transition, in one embodiment the cross section of the product tube 105 gradually transitions to a square cross section at the junction with the product conduit 106. Likewise, in other embodiments the product conduit 106 gradually transitions to a circular cross section at the junction with the product tube. Such changes reduce the possible impact points which can result because of the change in cross sections.
As will be discussed below, the speed of packaging is a function of several factors including, but not limited to, the product type, uniformity of product, density of the product, geometry of the product, length and orientation of the steering vanes, product spread, as well as the acceptable product breakage. With regard to one flat and uniform, cracker-like product, bag rates of about 1 to about 60 bags per minute have been achieved. Again, however, the bag rates are product dependent, thus these examples should not be deemed limiting as higher bag rates can be achieved as discussed below. In another embodiment bags have rates of 1 to about 60 bags per minute. In another embodiment, the bags have rates of about 30 to about 60 bags per minute. In still another embodiment, the bags have rates of about 50 and about 60 bags per minute. As previously described, the steering vanes 201 give the product a swirl motion which decreases the vertical velocity of product down through the series of funnels. Accordingly, in a given series of funnels, the steering vanes 201 will result in a larger residence time than if the steering vanes 201 are not used. As used herein “residence time” refers to the time a product spends in a given funnel or series of funnels. Further, the steering vanes 201 cause the product to spread out further along the series of tunnels than if the product was allowed to fall directly through the series of funnels. Accordingly, the use of steering vanes 201 increases the amount of product scatter. As used herein “product scatter” is the time from when the first product enters the package 107 and the last product enters the package 107. Thus, a method which comprises little product scatter is one wherein all of the product enters the package at roughly the same time. As stated above, the use of steering vanes 201 typically increases the amount of product scatter. This results from the fact that the total distance between the first and last product is increased as a result of the steering vanes 201. The amount of product scatter dictates the number of maximum packages per minute which can be filled; increased scatter means more time must be dedicated to filling an individual package with product. Accordingly, for a given product scatter there is a maximum number of packages per minute which may be filled. Those skilled in the art will appreciate that the product scatter for a given product is a function of the length, orientation, etc. of a steering vane 201, as well as the density, uniformity, geometry, and other variables of the product. Thus, the product scatter, and consequently, the maximum bags per minute is a function of the steering vane 201 employed and the product being packaged.
Table 1 below illustrates the reduced breakage which results from using the steering vanes of the instant invention. The data was taken on a filling apparatus similar to that described in FIGS. 1 and 3 above. The Control used a funnel which lacked steering vanes, whereas the subsequent runs had perpendicular wall steering vanes located in the second funnel. The product employed was flat and uniform cracker-like product.

TABLE 1

Product Breakage

Control - 50	50 bags Per
Bags per	Minute with	60 bags per minute
minute	Steering Vanes	with Steering Vanes

Whole pieces (%)	65	87	91
(average)
Partial pieces (%)	24	8	5
(average)
Scrap (%)	11	5	4
(average)

The above table illustrates the effectiveness of implementing steering vanes on one product type. Whole pieces are pieces which have not been broken. It can be seen that the percentage of whole pieces increases substantially when using steering vanes. As discussed above, this is desirable as a consumer typically desires a whole product. Partial pieces are those pieces which have been broken and are larger than half of the product. The percentage of partial pieces decreased when utilizing Applicant's steering vanes. Likewise, the percentage of scrap, or broken pieces smaller than half of the product, also dramatically decreased. Again, Table 1 illustrates that a substantial reduction in breakage results by adding steering vanes.
Applicants note that a variety of products may be utilized in the apparatus described herein. Those skilled in the art will appreciate the subtle nuances that require adjustment to account for the product changes. As discussed, the size of the product may dictate the length, curvature, etc. of a steering vane 201. As can be appreciated, because the steering vanes often start at the larger outer diameter of a funnel and finish at the smaller outer diameter at the bottom of the funnel, the distance between steering vanes 201 is typically greater at the top of a funnel than at the bottom of the funnel. As discussed, it can be appreciated that for certain products the gap between steering vanes 201 at the bottom of the funnel is preferably larger than the product being packaged. However, as stated above, this limitation is highly product dependent as some products may become broken, damaged, or lodged if the distance between steering vanes is smaller than the product being packaged whereas in other products this is not as large of an issue. As stated above, uniform and discrete product can generally tolerate smaller gaps. Generally, the non-uniform products are the products which require larger gaps. In such products, utilizing smaller gaps may result in increased bridging. Bridging, as used herein, refers to product becoming lodged or stuck in a restricted position. Product which becomes lodged can then cause other product to become lodged forming bridges of lodged product. Even if the product does not become lodged between steering vanes 201, the product may be slowed because of the narrow gap which is likewise undesirable as it decreases the maximum possible bag rate.
Applicants have discovered another embodiment to alleviate the problems associated with bridging. FIG. 4 is a perspective view of one funnel employing triangularly shaped steering vanes. The depicted embodiment is typically ideal for non-uniform products with locking or linking ability which would likely otherwise become lodged in the perpendicular wall steering vanes 201 as illustrated in FIG. 2. The triangularly shaped steering vanes 401 comprise two sloped edges rather than a perpendicular dividing wall as in the steering vanes 201 illustrated in FIG. 2. Thus, whereas the perpendicular wall steering vanes 201 of FIG. 2 typically forces product to remain in the designated lane, the triangularly shaped steering vanes 401 allow the product to rise upon its sloped edges. For example, a product which is greater in length than the distance between edges of adjacent vanes 401, or even greater than the distance between centerlines of adjacent vanes 401 may be utilized in the funnel 102 of FIG. 4. When such a product reaches the exit of the second funnel 102 wherein the distance between edges of adjacent vanes 401 is at its smallest, the product is allowed to rise up on one of the sloped edges of the triangular steering vane 401 allowing the product more room. Thus, the product is not confined to the distance between vanes 401. This is helpful in that the pinch points which could otherwise slow or stop product flow are eliminated. Likewise, regardless of product length, non-uniform product which tends to link and form a large mass which may plug the perpendicular wall steering vanes are able to rise up on one of the edges allowing the product and the mass more room, which consequently, reduces bridging. In one embodiment, the ratio of spacing between adjacent triangularly shaped steering vanes to product length is between about 10:1 to about 0.5:1, wherein the spacing between adjacent steering vanes is measured from the center line of each vane at its shortest point. For the reasons discussed above, Applicants have found the embodiment comprising triangularly shaped steering vanes 401 to be particularly well suited for potato or tortilla chips which comprise a longer product length and non-uniform geometry.
Furthermore, triangularly shaped steering vanes may be well suited in embodiments wherein the small diameter of the funnel is set at a maximum for processing reasons. For example, if the exit diameter of a funnel exactly matches the diameter of a product tube which cannot be replaced, then the funnel exit diameter cannot be changed. In such situations, a pinch point problem cannot simply be solved by replacing the funnel with a larger diameter funnel as is possible in other scenarios. Instead, the user may employ triangularly shaped steering vanes 401 which decrease the effect of a pinch point without adjusting the diameter size of the funnel. While both perpendicular wall steering vanes 201 and triangular steering vanes 401 have been described, those skilled in the art will appreciate that other steering vane geometries may be desirable for a given product and/or apparatus including for example, semi-circle cross sections.
Now that a filling apparatus has been described, a method of reducing product breakage will be discussed. The method comprises the steps of introducing product into a filling apparatus, imparting a swirling motion onto the product, and filling said product into a package, wherein the imparting step comprises using at least one funnel which comprises steering vanes. This advantageous method can be performed on most existing filling apparatuses by replacing at least one pre-existing funnel with a steering funnel comprising steering vanes. Thus, with only minor equipment changes the breakage of a product can be significantly reduced. Additionally, the method and apparatus discussed herein requires no moving parts on the steering funnel. This is advantageous in that it reduces capital costs and limits the opportunity for mechanical failure.
Referring now to FIG. 5, FIG. 5 is a perspective view of one embodiment utilizing bumpers. As used herein, “bumpers” refers to a flexible item which partially absorbs the momentum of a product and reduces product breakage. This embodiment, along with the other embodiments discussed, aim to reduce breakage by decreasing the effect of collision points located throughout the series of chutes or funnels. In addition, this embodiment aims to reduce the strength and effect of collisions that the product has with itself, thus decreasing product breakage. The embodiment illustrated in FIG. 5 does not use steering vanes, but instead uses bumpers 502. As with the steering vanes previously described, the bumpers 502 can be located in virtually any funnel, however, as illustrated, the bumpers 502 are partially located within the third funnel 104.
As depicted, the free floating bumper 502 is secured by the floating securing device 501. In one embodiment, the floating securing device 501 is secured to the combinational weighers 101. In such an embodiment, the floating securing device 501 typically passes through at least one funnel upstream of the free floating bumper 502. Thus, referring back to FIG. 1, the floating securing device 501 extends or is attached to a securing means including wire, string, bar, or the like, from a point on the combinational weigher 101, through the first funnel 102, through the second funnel 103, and into the third funnel 104. Those skilled in the art will appreciate different ways of positioning the bumpers 502 within the funnel 104.
As depicted, the third funnel 104 has a receiving end and an exit end. The receiving end is the top end of the funnel and, as shown, comprises a larger diameter. The exit end is the bottom end of the funnel and, as shown, comprises a smaller diameter than the receiving end. Again, funnels without sloped walls may also be utilized in this invention. The exit end of the third funnel 104, in the embodiment depicted, is connected to the top end of the product tube 105. It should be noted that in other embodiments the exit end of the funnel 104 is not directly connected to the top end of the product tube 105 but is simply located above it.
It can be appreciated that after product exits the second funnel 103, it will impact bumper 502 and will lose momentum. In this manner, breakage is reduced or eliminated because the collision which could otherwise take place at impact point 108 is eliminated. Additionally, the bumper 502 prevents product from colliding with itself, further decreasing breakage. As discussed above, without a bumper, product from substantially opposite sides of the funnel are directed to each other wherein they collide and break.
The bumper 502 can be located in a plurality of advantageous positions. In each of these positions, the bumper 502 is in the substantially same vertical plane as the product tube 105 and the exit end of the funnel 103. Further, in many embodiments, the bumper 502 is located upstream of the bottom end of the final product conduit 106; the bumper 502 does not extend past the bottom end of the final product conduit 106. If the bumper 502 extends past the final product conduit 106, it may interfere with the filling of the package with product. For this reason, in some embodiments the bumper does not extend beyond the bottom of the product tube 105 so as to keep from interfering with the filling of the product.
As illustrated, the bumper 502 is below the exit of the second funnel 103, below the receiving end of the third funnel 104, but above the exit of the third funnel 104. This location will prevent product simultaneously deposited on opposite sides of the second funnel 103 from colliding with itself. As discussed, this reduces breakage. Furthermore, because the product exiting the second funnel 103 encounters the bumpers 502 and consequently has reduced momentum, the strength of any incidental collisions with the impact point 108 is decreased. It should be noted that while the entire bumper 502 is illustrated as being beneath the exit of the second funnel 103, in other embodiments just a portion of the bumper 502 will extend beyond the exit of the second funnel 103.
In another embodiment, the bumper 502 extends below and beyond the exit end of the third funnel 104. This position presents a physical barrier which prevents product from colliding with the impact point 108. Thus, referring to FIG. 5, a bumper 502 extending below the exit end of the third funnel will prevent product from sliding down the right side of the second funnel 103 and being projected to the impact point 108 located on the left exit end of the third funnel. Again, the bumper 502 acts as a physical barrier which, because of its location below the exit end of the third funnel 104, prevents damaging collisions with the impact points 108. It should be noted that because the product tube 105 is connected to the third product tube 104, as depicted the bumper 502 extends within the product tube 105. Those skilled in the art will appreciate that placement of the bumpers 502 is dependent on a variety of factors including funnel pitch, product momentum, distance between funnels, etc.
Because the extent of the product contact with the bumpers 502 effects the maximum throughput, in one embodiment, the ratio of the inner diameter of the product tube 105 to the outer diameter of the bumper 502 is between about 5:1 to about 1.1:1. The outer diameter of the bumper 502 is measured as the mean diameter of the bumper. With these ratios, the product has sufficient room to be absorbed by the bumper 502 without undesirably slowing or stopping the flow of product through the product tube 105. It should be noted that the bumper size is typically dependent on product size, shape, density, as well as bumper flexibility.
In one embodiment, the bumper 502 comprises individual strands of pliable material which absorb the momentum of the product which falls upon the bumper. The number, size, and strength of these strands depend on the size, density, etc. of the product being packaged, but Applicants have found that thin plastic strands have performed successfully. The strands may also be from a nylon sheet, engineered plastics, rubbers, and other flexible material.
It should be noted that while the strands 502 of the figures are “flared” or “curled,” the instant invention is not so limited. In other embodiments the strands are not flared but are instead straight or substantially shape. Those skilled in the art will appreciate that the geometry of the strands can be optimized for optimal handling of product with depending on the product shape, density, size, etc.
An alternative to the bumper 502 comprising individual strands is a bumper 502 comprising a soft pillow structure (not depicted). In such an embodiment, the product encounters the bumper 502 and a portion of the momentum is absorbed by the pillow structure of the bumper 502. Thus, the pillow structured bumper 502 works similar to the embodiment comprising individual strands except rather than a pliable strand individually absorbing a portion of the momentum of the product falling from the upstream funnel, the entire body of the pillow structured bumper 502 absorbs the momentum. Those skilled in the art will appreciate how to optimize the bumper 502 to absorb sufficient momentum to prevent breakage without slowing or stopping the flow of the product unnecessarily. The pillow structured bumper 502 may be filled with air or another cushion. Further, the bumper 502 may comprise either a filled or hollow tube structure. Regardless of the embodiment, the bumper 502 reduces the momentum of the product and accordingly reduces breakage of the product before it is filled into a package. Advantageously, in one embodiment the bumpers 502 require no mechanical energy to operate which reduces the operating costs of the apparatus.
To reduce product breakage in a filing apparatus product is first introduced into a funnel. A portion of the product momentum is then absorbed by a bumper which is in substantially the same vertical plane as the upstream funnel, and wherein at least a portion of the bumper is located below the exit end of the funnel. Thus, a novel and non-obvious method for reducing the breakage of a product in packaging has been described.
While the invention has been particularly shown and described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention.

Claims

1. An apparatus for filling a package with product, said apparatus comprising:

at least one steering funnel, said at least one steering funnel comprising at least one steering vane;

a final product conduit located downstream of said at least one steering funnel, said conduit used to deposit said product into said package;

wherein said at least one steering vane comprises sufficient orientation to impart a swirling motion to a product feed entering the steering funnel.

2. The apparatus of claim 1 further comprising a series of funnels.

3. The apparatus of claim 1 wherein at least one of said at least one steering vane is curved.

4. The apparatus of claim 1 wherein at least one of said at least one steering vane is straight.

5. The apparatus of claim 1 further comprising a product tube located above said final product conduit, said product tube being downstream of said steering funnel.

6. The apparatus of claim 5 further comprising a downstream funnel, said downstream funnel comprising a receiving end and an exit end, wherein said downstream funnel is located downstream from said steering funnel, and wherein said product tube is located below the exit end of said downstream funnel.

7. The apparatus of claim 6 further comprising at least one funnel upstream of said at least one steering funnel.

8. The apparatus of claim 6 wherein said product tube has sloped walls.

9. The apparatus of claim 1 wherein at least one of said at least one steering vane is a perpendicular wall steering vane.

10. The apparatus of claim 1 wherein at least one of said at least one steering vane is a triangularly shaped steering vane.

11. The apparatus of claim 1 wherein at least one of said at least one steering vane comprises a rounded cross-section.

12. The apparatus of claim 1 used within a vertical form, fill, and seal machine.

13. The apparatus of claim 1 wherein said product is a snack food.

14. The apparatus of claim 1 wherein said steering funnel comprises no moving parts.

15. A method for reducing product breakage in a filling apparatus, said method comprising:

introducing product into a filling apparatus;

imparting a swirling motion on said product;

filling said product into a package;

wherein said imparting step comprises using at least one funnel comprising at least one steering vane.

16. The method of claim 15 wherein said product comprises a snack food.

17. The method of claim 15 performed on a vertical, form, fill, and seal machine.

18. The method of claim 15 wherein said filling step comprises filling up to about 60 packages per minute.

19. The method of claim 15 wherein said imparting step comprises using at least one perpendicular wall steering vane.

20. The method of claim 15 wherein said imparting step comprises using at least one triangularly shaped steering vanes.

21. The method of claim 15 wherein said imparting step comprises using at least one steering vane comprising a rounded cross-section.

22. The method of claim 15 wherein said filling step further comprises directing product through a product tube, said product tube comprising sloped walls, and wherein said product tube is located downstream of at least one funnel.

23. The method of claim 15 wherein said imparting step requires no moving parts.

24. A package filled with the method of claim 15.

25. An apparatus for filling a package with product, said apparatus comprising:

a first funnel comprising a receiving end and an exit end;

a final product conduit located downstream of said first funnel, said conduit comprising a top end and a bottom end, and wherein said conduit is used to deposit said product into said package; and

a bumper located above the bottom end of said final product conduit, wherein at least a portion of said bumper is located below the exit end of said funnel;

wherein said bumper is located in a position with respect to the final product and the first funnel so as to contact product which falls through the first funnel.

26. The apparatus of claim 25 further comprising a product tube comprising a top end and a bottom end, wherein the exit end of said first funnel is above the top end of said product tube.

27. The apparatus of claim 26 wherein said bumper at least partially extends within said product tube.

28. The apparatus of claim 26 wherein the ratio of the inner diameter of the product tube to the outer diameter of the bumper is between about 5:1 to about 1.1:1.

29. The apparatus of claim 25 wherein said bumper is suspended through and within at least one upstream funnel.

30. The apparatus of claim 25 wherein said bumper comprises strands of pliable material.

31. The apparatus of claim 30 wherein said pliable material is a plastic.

32. The apparatus of claim 25 wherein said bumper comprises a pillow structure.

33. The apparatus of claim 25 wherein said bumper comprises a tube structure.

34. The apparatus of claim 25 further comprising a second funnel comprising a receiving end and an exit end.

35. The apparatus of claim 34 wherein said second funnel is located upstream of said first funnel.

36. The apparatus of claim 34 wherein said second funnel is located downstream of said first funnel.

37. The apparatus of claim 36 further comprising a product tube comprising a top end and a bottom end, wherein the exit end of said second funnel is above the top of said product tube.

38. The apparatus of claim 36 wherein no portion of said bumper extends beyond the exit end of said second funnel.

39. A method for reducing product breakage in a filling apparatus, said method comprising:

introducing product into a funnel, said funnel comprising a receiving end and an exit end;

absorbing a portion of the momentum of the product falling from the funnel with a bumper;

filling said product into a package;

wherein the bumper is in substantially the same vertical plane as the exit end of the funnel; and

wherein at least a portion of the bumper is located below the exit end of said funnel.

40. The method of claim 39 wherein said introducing step comprises introducing a snack food.

41. The method of claim 39 performed on a vertical, form, fill, and seal machine.

42. The method of claim 39 wherein said filling step comprises filling up to about 60 packages per minute with said product.

43. The method of claim 39 wherein said absorbing step requires no additional energy.