US20200115081A1 - Pallet bag gathering apparatus and process for use - Google Patents
Pallet bag gathering apparatus and process for use Download PDFInfo
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- US20200115081A1 US20200115081A1 US16/512,372 US201916512372A US2020115081A1 US 20200115081 A1 US20200115081 A1 US 20200115081A1 US 201916512372 A US201916512372 A US 201916512372A US 2020115081 A1 US2020115081 A1 US 2020115081A1
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- pallet
- bag
- gathering
- gathering frame
- pallet bag
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B35/00—Supplying, feeding, arranging or orientating articles to be packaged
- B65B35/30—Arranging and feeding articles in groups
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D81/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
- B65D81/18—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents providing specific environment for contents, e.g. temperature above or below ambient
- B65D81/20—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents providing specific environment for contents, e.g. temperature above or below ambient under vacuum or superatmospheric pressure, or in a special atmosphere, e.g. of inert gas
- B65D81/2069—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents providing specific environment for contents, e.g. temperature above or below ambient under vacuum or superatmospheric pressure, or in a special atmosphere, e.g. of inert gas in a special atmosphere
- B65D81/2084—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents providing specific environment for contents, e.g. temperature above or below ambient under vacuum or superatmospheric pressure, or in a special atmosphere, e.g. of inert gas in a special atmosphere in a flexible container
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B9/00—Enclosing successive articles, or quantities of material, e.g. liquids or semiliquids, in flat, folded, or tubular webs of flexible sheet material; Subdividing filled flexible tubes to form packages
- B65B9/10—Enclosing successive articles, or quantities of material, in preformed tubular webs, or in webs formed into tubes around filling nozzles, e.g. extruded tubular webs
- B65B9/13—Enclosing successive articles, or quantities of material, in preformed tubular webs, or in webs formed into tubes around filling nozzles, e.g. extruded tubular webs the preformed tubular webs being supplied in a flattened state
- B65B9/135—Enclosing successive articles, or quantities of material, in preformed tubular webs, or in webs formed into tubes around filling nozzles, e.g. extruded tubular webs the preformed tubular webs being supplied in a flattened state for palletised loads
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D33/00—Details of, or accessories for, sacks or bags
- B65D33/002—Rolls, strips or like assemblies of bags
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D33/00—Details of, or accessories for, sacks or bags
- B65D33/01—Ventilation or drainage of bags
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D71/00—Bundles of articles held together by packaging elements for convenience of storage or transport, e.g. portable segregating carrier for plural receptacles such as beer cans or pop bottles; Bales of material
- B65D71/0088—Palletisable loads, i.e. loads intended to be transported by means of a fork-lift truck
- B65D71/0092—Palletisable loads, i.e. loads intended to be transported by means of a fork-lift truck provided with one or more rigid supports, at least one dimension of the supports corresponding to a dimension of the load, e.g. skids
- B65D71/0096—Palletisable loads, i.e. loads intended to be transported by means of a fork-lift truck provided with one or more rigid supports, at least one dimension of the supports corresponding to a dimension of the load, e.g. skids the dimensions of the supports corresponding to the periphery of the load, e.g. pallets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D81/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
- B65D81/24—Adaptations for preventing deterioration or decay of contents; Applications to the container or packaging material of food preservatives, fungicides, pesticides or animal repellants
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D85/00—Containers, packaging elements or packages, specially adapted for particular articles or materials
- B65D85/30—Containers, packaging elements or packages, specially adapted for particular articles or materials for articles particularly sensitive to damage by shock or pressure
- B65D85/34—Containers, packaging elements or packages, specially adapted for particular articles or materials for articles particularly sensitive to damage by shock or pressure for fruit, e.g. apples, oranges or tomatoes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B11/00—Wrapping, e.g. partially or wholly enclosing, articles or quantities of material, in strips, sheets or blanks, of flexible material
- B65B11/58—Applying two or more wrappers, e.g. in succession
- B65B11/585—Applying two or more wrappers, e.g. in succession to stacked articles, e.g. pallettised loads
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B25/00—Packaging other articles presenting special problems
- B65B25/02—Packaging agricultural or horticultural products
- B65B25/04—Packaging fruit or vegetables
- B65B25/041—Packaging fruit or vegetables combined with their conservation
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D2571/00—Bundles of articles held together by packaging elements for convenience of storage or transport, e.g. portable segregating carrier for plural receptacles such as beer cans, pop bottles; Bales of material
- B65D2571/00006—Palletisable loads, i.e. loads intended to be transported by means of a fork-lift truck
- B65D2571/00012—Bundles surrounded by a film
Definitions
- This invention relates to the packaging of respiring and non-respiring biological materials, particularly various berries.
- This invention is useful in packaging any and all fresh fruit and vegetables.
- it is useful in increasing the speed of the packing operation, reduces worker fatigue, increases reproducibility, decreases errors, and allows for automation of the packaging process for a variety of pallet sized packaging of biological materials.
- Respiring and non-respiring biological materials e.g. fruits and vegetables, consume oxygen (O 2 ) and produce carbon dioxide (CO 2 ) at rates which depend upon the stage of their development, the atmosphere surrounding them and the temperature.
- O 2 oxygen
- CO 2 carbon dioxide
- MAP modified atmosphere packaging
- the objective is to produce a desired atmosphere around respiring and non-respiring materials by placing them in a sealed container whose permeability to O 2 and CO 2 and CO 2 is correlated with (i) the partial pressures of O 2 and CO 2 in the air outside the package, and (ii) the temperature, to produce a desired atmosphere within the container and (iii) the gas permeation properties of the chosen package materials and components.
- the container includes an atmosphere control member having a high permeability to O 2 and CO 2 .
- controlled atmosphere packaging the objective is to produce a desired atmosphere around respiring and non-respiring materials by displacing some or all of the air within a container by one or more gases, e.g. nitrogen, O 2 , CO 2 and ethylene, in desired proportions.
- gases e.g. nitrogen, O 2 , CO 2 and ethylene.
- the preferred packaging atmosphere for fresh respiring and non-respiring fruit or vegetables often depends on the age of the fruit or vegetables and the changes (if any) which are desired. Generally, for example, the preferred O 2 content during storage of unripe fruits is lower than the preferred O 2 content during subsequent ripening at a higher temperature. This fact causes problems for both MAP and CAP. For example, in MAP, although the O 2 permability of the container generally increases with temperature (especially if it contains an atmosphere control member comprising a crystalline polymer having an appropriate melting point, as disclosed in U.S. Pat. No. 6,376,032 and International Publication No. WO 00/04787), the increase is often insufficient to avoid the need for significant compromise between the preferred atmospheres at different stages. In CAP, it is theoretically possible to monitor the packaging atmosphere and to change it as often as is necessary to maintain the preferred level of O 2 (and other gases).
- U.S. Pat. No. 5,799,495 discloses a system in which biologically respiring and non-respiring material, e.g. fruit, is transported and ripened in a sealed container, and is first surrounded by a first atmosphere and thereafter by a second atmosphere, the second atmosphere containing more oxygen than the first.
- the atmospheres are controlled by injection of appropriate gases directly into the container.
- pallet packaging For the transportation of berries, for example, it is typically desirable to use pallet packaging to generate a controlled or modified atmosphere inside the pallet to extend shelf-life of produce, minimize microbial growth, maintain color, and maintain freshness.
- Strawberries are hand-picked in the field, placed into plastic clam shell enclosures that are then placed into cardboard trays and cardboard trays are stacked onto a wooden pallet to a height of about 100-120 inches containing about 1000 lbs. of berries.
- the pallet of packaged berries is transported to a cooler and the temperature reduced to about 32° F.
- the cooled pallet is then placed by forklift onto a structurally robust metal support and transfer mechanism at which time jaws or clamps encircle the cardboard trays of berries, lifts up the trays as one unit and workers put a combination of cardboard and plastic sheeting onto the pallet and then the trays of berries are lowered back onto the pallet. Workers then staple or tack the about 6 inch flap of plastic sheet that extends beyond the pallet edges to the trays of berries.
- a pallet bag is lowered onto the pallet from above to overlap with the tacked up sheet. Tape (about 6 inch wide) is then used to seal the pallet bag to the sheet while the, for example, 1000 lb. pallet spins on the support system.
- a slit or hole is made in the side of the pallet bag and a probe inserted that can remove some of the inside air and replace with carbon dioxide to a target concentration. See, U.S. Pat. No. 7,770,366, which is incorporated herein by reference in its entirety.
- the load of biological materials e.g., berries
- the pallet must be prepared with a pallet load bag that can be lifted around the load and sealed to establish the packaging environment for the materials.
- the typical approach is to manually gather the bag to place around the pallet for subsequent raising and sealing around the load of materials. This manual process is time-consuming, subject to non-repeatability errors, and prevents an automated overall packaging approach.
- the embodiments of the present invention address this problem by adding critical automation to improve the speed and quality of the process, addressing the aforementioned problems.
- the first area of the invention includes the following aspects.
- a first aspect of the invention includes a pallet bag gathering apparatus having a plurality of roller wheels designed to advance a pallet bag onto an adjustable frame capable of duplicating the dimensions of the pallet to be used in the automated pallet bag packaging system.
- the apparatus can be used to gather pallet bags of any dimensions but is particularly useful when it is designed to gather and compress pallet bags with the following properties:
- the pallet bag gathering apparatus has the following features:
- the guide arms are initially in a release position wherein the guide wheels are not in contact with the gathering frame but the guide stop is in contact with the gathering frame proximate to the top portion of the gathering frame.
- the guide arm pivots at the guide stop such that the guide wheels are not in contact with the gathering frame.
- a pallet bag is dispensed from the bag rolls and the top opening of the pallet bag is fed under the guide wheels, at which time the guide arm is made to pivot to a position where it is in contact with the outside portion of the pallet bag, wherein the inside portion of the pallet bag is pressed against the gathering frame by the guide wheels.
- Said guide arms may be from about 1 foot to about 2 feet in length preferably, though the preferred length can be determined as needed to accommodate the gathered pallet bag.
- the guide arms have a space between the guide wheel and the guide stop that is approximately rectangular in shape with a width of approximately the diameter of the guide wheel, which may be about 3 inches to about 6 inches and a length from about 1 foot to about 2 feet. This space is used to collect the gathered pallet bag.
- gathering process can be initiated either manually or automatically by sensing the pallet bag has been fed to a point beyond the contact point of the guide wheels to the gathering frame.
- the guide wheels move in a direction to feed the pallet bag into the space between the guide wheel and the guide stop on the gathering frame.
- the gathering process in a preferred embodiment takes less than about twenty seconds, preferably less than ten seconds.
- the guide wheels may be pivoted away from the gathering frame such that the wheels are no longer in contact with the outside surface of the pallet bag.
- the gathered pallet bag may then be lowered from the gathering frame and preferably placed on a pallet in preparation for moving the pallet with the gathered pallet bag to a station of an automated pallet bag packaging system to receive a load of biological materials for packaging within the pallet bag.
- the pallet bags may be gathered, removed and stacked for use in the automated pallet bag packaging system.
- the pallet gathering apparatus is integrated into the pallet bag packaging system such that a gathered bag is automatically deposited on a pallet for loading biological materials on such pallet, extending the pallet bag over the biological materials, and sealing the bag.
- FIG. 1 is a depiction of a top-diagonal view of the pallet bag gathering apparatus.
- FIG. 2 is a depiction of a rear view of the pallet bag gathering apparatus.
- FIG. 3 is a depiction of a top down view of the pallet bag gathering apparatus.
- FIG. 4 is a depiction of a side view of the pallet bag gathering apparatus.
- components A, B and C can consist of (i.e. contain only) components A, Band C, or can contain not only components A, Band C but also one or more other components.
- the defined steps can be carried out in any order or simultaneously (except where the context excludes that possibility), and the method can include one or more other steps which are carried out before any of the defined steps, between two of the defined steps, or after all the defined steps (except where the context excludes that possibility).
- sealing can be, but sometimes is not, hermetic sealing, due to poor heat seal operation, poor taping or poor closure.
- a seal made by conventional methods often is not a hermetic seal, and has the advantage that it permits equilibration of the pressures inside and outside the bag. If the container is sealed hermetically, it will generally be desirable to include one or more pinholes in the container, to achieve such equilibration and or through appropriate choice of ACM, for example BreathWay membranes alone or in combination with other ACMs. If two Breatheway ACMs are used, for example, one can avoid the need for pinholes even when hermetically sealed.
- the sealing could be designed to permit a controlled amount of direct exchange between the packaging atmosphere and the atmosphere surrounding the container.
- the Pallet bag may be a standard thickness, for example about 2 to about 8 mil, more preferably about 3 to about 4 mil and may be composed of any plastic material, low density polyethylene (LDPE) is a preferred plastic (since by using a mechanical locking device no heat sealing is needed—but heat sealing may be applied) but any plastic monolayer, plastic laminates or multicomponent laminates or blends may be used for example, PE, PP, PET, thermoplastic elastomer, stretch plastic, Nylon, paper/plastic laminates, and the like. Other bag materials and thicknesses may be used. However, it is desirable that the upper portions of the wall material should be sufficiently flexible to be used with the mechanical seal preferably used in the pallet packaging system herein.
- LDPE low density polyethylene
- Suitable flexible material for the bag may be PE, PP, Nylon, polyester, recycled or repurposed plastic, low cost paper/plastic laminates, and other laminates.
- Preferred materials include LDPE, Linear low density polyethylene (LLDPE), ultra low density polyethylene (ULDPE).
- LLDPE Linear low density polyethylene
- ULDPE ultra low density polyethylene
- a stretch plastic may be preferred.
- the pallet bag material contains one or more specialty additives, including additives having one or more of the following properties: anti-microbial; anti-fungal; photobiodegradable; oxo-photobiodegradable; UV blocker; anti-drag; anti-scratch; print enhancer; anti-static; anti-fog; pro-release; and pest repellant (e.g., ant, rodent).
- the material may optionally contain metallic silver particles, zeolites, organic micro-particles, titanium dioxide, and silica, as well as other additives to aid in the process and promotion of packaged biological materials.
- the pallet bag material may be selected based on cost or moisture vapor transmission rate (MVTR) properties or puncture resistance or other reasons.
- atmosphere control technology for example a BREATHEWAY® membrane or microperforations as appropriate.
- the pallet packaging system uses a BREATHEWAY® membrane, as described in other Apio/Landec patents and patent applications, including U.S. Pat. Nos. 5,254,354; 6,376,032; 6,548,132, and 7,329,452, each of which is incorporated by reference in its entirety.
- Use of the membrane technology allows effective atmosphere control of oxygen and carbon dioxide for extension of shelf-life, taste, freshness, and other benefits, such as appearance.
- the pallet bag/cover may optionally have a ‘valve” mechanism built into the bag that may be a one-way or two-way valve to assist in the speed and efficiency of removing the air in the bag and replacing with CO 2 which may eliminate the need to cut and then retape the bag after CO 2 injection.
- a ‘valve” mechanism built into the bag that may be a one-way or two-way valve to assist in the speed and efficiency of removing the air in the bag and replacing with CO 2 which may eliminate the need to cut and then retape the bag after CO 2 injection.
- the pallet bag may optionally be a custom designed bag which, when opened and placed over the pallet will have a flat top to lie smoothly over the top layer of product trays. This bag design will not leave any hanging ears, which otherwise require taping and add extra labor, cost and time.
- a preferred pallet bag may be designed to fit a unit load of 48′′ ⁇ 40′′ (Standard Grocery Manufacturers Association (GMA) pallet) with varying heights and will come in a roll form.
- GMA Standard Grocery Manufacturers Association
- the pallet bag may be designed for use with a sea pallet, which commonly has a size of 1200 mm ⁇ 1000 mm.
- the pallet bag may be sized for a European pallet of 800 mm ⁇ 1200 mm used in some parts of Europe.
- the pallet bags in one aspect, form part of the present invention and can be used to drive efficiency, lower costs, and to render a clean looking finished pallet with the right atmosphere.
- a fully automated system is used from using film in the shape of a long tube that can be automatically cut to size for a custom pallet height, with the top heat sealed and holes cut over which may be placed ACM membranes, such as BreatheWay® membranes, or microperforations for atmosphere control.
- FIGS. 1-4 show features of the pallet bag gathering apparatus.
- the depiction of the pallet bag gathering apparatus 100 shows guide arm 120 with feeder wheels 121 and guide stops 122 .
- the guide arm 120 pivots away from the gathering frame 110 prior to feeding the pallet bag from the pallet bag rolls 150 .
- the pallet bag rolls may be of different lengths and circumferences depending on the containers that will be packaged within the pallet bag.
- Controller 130 is used to program the process of feeding the pallet bag from roller 150 between the feeder wheels 121 and the gathering frame 110 to the void space between the feeder wheels 121 and the guide stops 122 .
- the pallet bag feeder 140 may be automatically programmed to feed the pallet bag to the gathering frame 110 and may be programmed to automatically detach the pallet bag from the roll when the bottom of the bag proceeds beyond a set point.
- this alternative view from behind the pallet bag gathering apparatus 200 shows the controller 230 and the plurality of pallet bag rolls 250 loaded on spools for distribution therefrom to the gathering frame.
- this alternative view from above the pallet bag gathering apparatus 300 shows the top of the controller, the pallet bag rolls 350 , the pallet bag feeder 340 , the gathering frame 310 and the guide arm 120 .
- this alternative view from the side of the pallet bag gathering apparatus 400 shows the pallet bag feeder 440 , the gathering frame 410 , the feeder wheels 411 , and the guide stops 412 .
Abstract
Description
- This application claims the benefit of U.S. Provisional Patent Application No. 62/698,796, filed on Jul. 16, 2018 and relates to U.S. application Ser. No. 15/604,629, filed May 24, 2017, U.S. Provisional Application No. 62/340,966, filed May 24, 2016, and the following commonly assigned applications, including application Ser. No. 13/368,216, filed Feb. 7, 2012. Application Ser. No. 13/368,216, filed Feb. 7, 2012 is a continuation of Ser. No. 09/858,190, filed May 15, 2001, now U.S. Pat. No. 8,110,232. Ser. No. 09/858,190 is also related to claims priority under 37 CFR 1.78(a)(5) from Provisional Application Ser. No. 60/325,762, filed May 26, 2000, which resulted from the conversion of application Ser. No. 09/580,379, into a provisional application under 37 CFR 1.53(c)(2). This application is also related to (1) application Ser. No. 09/989,682, filed Nov. 20, 2001, now U.S. Pat. No. 7,601,374, which is a continuation-in-part of Ser. No. 09/858,190, (2) application Ser. No. 12/553,852 filed Sep. 3, 2009, now U.S. Pat. No. 8,092,848, which is a divisional of Ser. No. 09/989,682, and co-filed applications from U.S. Provisional Patent Application Nos. 62/698,908, 62/698,923, and 62/701,364. The entire disclosure of each of those patents and applications is incorporated herein by reference for all purposes.
- This invention relates to the packaging of respiring and non-respiring biological materials, particularly various berries. This invention is useful in packaging any and all fresh fruit and vegetables. In particular, it is useful in increasing the speed of the packing operation, reduces worker fatigue, increases reproducibility, decreases errors, and allows for automation of the packaging process for a variety of pallet sized packaging of biological materials.
- Respiring and non-respiring biological materials, e.g. fruits and vegetables, consume oxygen (O2) and produce carbon dioxide (CO2) at rates which depend upon the stage of their development, the atmosphere surrounding them and the temperature. In modified atmosphere packaging (MAP), the objective is to produce a desired atmosphere around respiring and non-respiring materials by placing them in a sealed container whose permeability to O2 and CO2 and CO2 is correlated with (i) the partial pressures of O2 and CO2 in the air outside the package, and (ii) the temperature, to produce a desired atmosphere within the container and (iii) the gas permeation properties of the chosen package materials and components. In many cases, the container includes an atmosphere control member having a high permeability to O2 and CO2. In controlled atmosphere packaging (CAP), the objective is to produce a desired atmosphere around respiring and non-respiring materials by displacing some or all of the air within a container by one or more gases, e.g. nitrogen, O2, CO2 and ethylene, in desired proportions. Reference may be made, for example, to U.S. Pat. No. 3,360,380 (Bedrosian), U.S. Pat. No. 3,450,542 (Badran), U.S. Pat. No. 3,450,544 (Badran et al.), U.S. Pat. No. 3,798,333 (Cummin et al), U.S. Pat. No. 3,924,010 (Erb), U.S. Pat. No. 4,003,728 (Rath), U.S. Pat. No. 4,734,324 (Hill), U.S. Pat. No. 4,779,524 (Wade), U.S. Pat. No. 4,830,863 (Jones), U.S. Pat. No. 4,842,875 (Anderson), U.S. Pat. No. 4,879,078 (Antoon), U.S. Pat. No. 4,910,032 (Antoon), U.S. Pat. No. 4,923,703 (Antoon), U.S. Pat. No. 4,987,745 (Harris), U.S. Pat. No. 5,041,290 (Wallace et al.) U.S. Pat. No. 5,045,331 (Antoon), U.S. Pat. No. 5,063,753 (Woodruff), U.S. Pat. No. 5,160,768 (Antoon), U.S. Pat. No. 5,254,354 (Stewart), U.S. Pat. No. 5,333,394 (Herdeman), U.S. Pat. No. 5,433,335 (Raudalus et al.), U.S. Pat. No. 5,460,841 (Herdeman), U.S. Pat. No. 5,556,658 (Raudalus et al.), U.S. Pat. No. 5,658,607 (Herdeman), U.S. Pat. No. 6,013,293 (De Moor) and U.S. Pat. No. 6,376,032 (Clarke et al), International Publication Nos. WO 94/12040 (Fresh Western) and WO 00/04787 (Landec), and European Patent Applications Nos. 0,351,115 and 0,351,116 (Courtaulds). The disclosure of each of these patents and publications is incorporated herein by reference in its entirety for all purposes.
- The preferred packaging atmosphere for fresh respiring and non-respiring fruit or vegetables often depends on the age of the fruit or vegetables and the changes (if any) which are desired. Generally, for example, the preferred O2 content during storage of unripe fruits is lower than the preferred O2 content during subsequent ripening at a higher temperature. This fact causes problems for both MAP and CAP. For example, in MAP, although the O2 permability of the container generally increases with temperature (especially if it contains an atmosphere control member comprising a crystalline polymer having an appropriate melting point, as disclosed in U.S. Pat. No. 6,376,032 and International Publication No. WO 00/04787), the increase is often insufficient to avoid the need for significant compromise between the preferred atmospheres at different stages. In CAP, it is theoretically possible to monitor the packaging atmosphere and to change it as often as is necessary to maintain the preferred level of O2 (and other gases).
- But this is difficult and expensive, and often impractical. For example, U.S. Pat. No. 5,799,495 discloses a system in which biologically respiring and non-respiring material, e.g. fruit, is transported and ripened in a sealed container, and is first surrounded by a first atmosphere and thereafter by a second atmosphere, the second atmosphere containing more oxygen than the first. The atmospheres are controlled by injection of appropriate gases directly into the container.
- For the transportation of berries, for example, it is typically desirable to use pallet packaging to generate a controlled or modified atmosphere inside the pallet to extend shelf-life of produce, minimize microbial growth, maintain color, and maintain freshness.
- Currently, Strawberries are hand-picked in the field, placed into plastic clam shell enclosures that are then placed into cardboard trays and cardboard trays are stacked onto a wooden pallet to a height of about 100-120 inches containing about 1000 lbs. of berries. The pallet of packaged berries is transported to a cooler and the temperature reduced to about 32° F.
- The cooled pallet is then placed by forklift onto a structurally robust metal support and transfer mechanism at which time jaws or clamps encircle the cardboard trays of berries, lifts up the trays as one unit and workers put a combination of cardboard and plastic sheeting onto the pallet and then the trays of berries are lowered back onto the pallet. Workers then staple or tack the about 6 inch flap of plastic sheet that extends beyond the pallet edges to the trays of berries. A pallet bag is lowered onto the pallet from above to overlap with the tacked up sheet. Tape (about 6 inch wide) is then used to seal the pallet bag to the sheet while the, for example, 1000 lb. pallet spins on the support system. A slit or hole is made in the side of the pallet bag and a probe inserted that can remove some of the inside air and replace with carbon dioxide to a target concentration. See, U.S. Pat. No. 7,770,366, which is incorporated herein by reference in its entirety.
- However, there are several problems with the prior system, including:
-
- i. The plastic sheet between the pallet and berry trays cannot be applied in the field because the plastic sheet is often damaged during transport leading to leaks in the bag;
- ii. The prior system is slow and subject to human error since it requires so many manual steps to apply the current bag system;
- iii. The prior system requires a large footprint within the cooler since the overall system must be structurally strong enough to hold, move, raise, rotate and manipulate a 1000 lb. pallet with structural strength to spare while providing a safe work environment to works manually applying the packaging to the pallet;
- iv. The prior system has a high failure rate, as defined by pallet bags not maintaining the target atmosphere due to manual error resulting in rips, tears, leaks at the seal where the bag and bottom sheet meet and are taped, etc. In particular the taped seal is a source of significant leak failure;
- v. The prior system, equipment, and slow manual process time lead to a slow system;
- vi. The prior system is prone to worker health issues due toworkers bending over, stapling sheet, lifting, and other labor-intensive involvement; and
- vii. Without the use of the BreathWay® membrane, the current system can develop high CO2 levels that lead to off-odor, off-taste and a short shelf-life.
- Some of these problems are addressed using a single-bag system with the use of a designed gas permeable membrane, such as the BreathWay® membrane described in patents cited and incorporated herein by reference in their entirety and by automating the system such as in U.S. application Ser. No. 15/604,629 and the co-filed U.S. Provisional applications titled “Pallet Bag” and “Automated Process and Apparatus for Packaging Biological Materials,” which are incorporated herein by reference in their entirety.
- However, in an embodiment of that system the load of biological materials (e.g., berries), is placed on a pallet wherein the pallet must be prepared with a pallet load bag that can be lifted around the load and sealed to establish the packaging environment for the materials. From the prior art methods of packaging other pallet loads of such materials, the typical approach is to manually gather the bag to place around the pallet for subsequent raising and sealing around the load of materials. This manual process is time-consuming, subject to non-repeatability errors, and prevents an automated overall packaging approach.
- The embodiments of the present invention address this problem by adding critical automation to improve the speed and quality of the process, addressing the aforementioned problems.
- The first area of the invention includes the following aspects.
- A first aspect of the invention includes a pallet bag gathering apparatus having a plurality of roller wheels designed to advance a pallet bag onto an adjustable frame capable of duplicating the dimensions of the pallet to be used in the automated pallet bag packaging system. The apparatus can be used to gather pallet bags of any dimensions but is particularly useful when it is designed to gather and compress pallet bags with the following properties:
-
- i. The length of the pallet bag for use in the automated gathering apparatus may be about 50 to about 150 inches long, preferably about 113 inches to about 120 inches long;
- ii. The circumference of the pallet bag is from about 150 inches to about 250 inches, preferably about 175- about 200 inches, most preferably about 186 inches in circumference;
- iii. The bag composition is typically polyethylene (PE), generally low density polyethylene (LDPE) which may have additives and features to improve durability;
- iv. The pallet bag typically is gusseted, with the sides folded inward;
- v. The bags may optionally have one or more holes, for example, about 18 inches from the top of the bag, each of the holes being covered by an atmosphere control membrane (ACM), preferably the patented ACMs sold by Landec Corporation under the tradename BreatheWay, such membranes may be the same or different;
- vi. The location of the ACM membranes is on or near the top surface of the pallet bags is preferred and desirable to minimize blockage from load shifting during shipment; and
- vii. The pallet bags and ACMs are designed with dimensions to accommodate each different type of produce due to different respiration rates and quantities.
- In a second aspect the pallet bag gathering apparatus has the following features:
-
- i. A gathering frame that is made of a rigid material such as metal that is from about 150 inches to about 250 inches, preferably about 175- about 200 inches, most preferably about 186 inches in circumference and shaped to fit the pallet bag;
- ii. The gathering frame may be adjustable to accommodate pallet bags of different circumferences;
- iii. The gathering frame has feed wheels that automatically advance the bag over the frame until it is stopped by the guide stops at the ends of the plurality of guide arms;
- iv. The number of guide arms may vary but in one embodiment each side has four guide arms, though two to six may be used alternatively, said guide arms being flexibly attached to the gathering frame wherein each guide arm has a feed wheel at one end and a guide stop at the other end;
- v. The guide arms are flexible with sufficient tension to secure the gathered pallet bag to the gathering frame but flexible enough to allow the pallet bag to pass under the guide wheel into the gathering area;
- vi. The gathering area is the area of the guide arm between the feed wheel and the guide stop, wherein the area must be sufficient to collect the entire length of the pallet bag;
- vii. The guide wheels are controlled by a controller which may operate manually to start when the top of the pallet bag is fed into the guide wheels or preferably programmed to start advancing the bag upon sensing the bag has been fed to substantially all guide wheels and to continue until the end of the pallet bag advances to contact the gathering frame; and
- viii. Optionally, the gathering frame is positioned above a pallet or a pallet is placed below the gathering frame to transfer the gathered pallet bag to the pallet for use in the automated pallet packaging system.
- In a Prior to use the guide arms are initially in a release position wherein the guide wheels are not in contact with the gathering frame but the guide stop is in contact with the gathering frame proximate to the top portion of the gathering frame. In one embodiment the guide arm pivots at the guide stop such that the guide wheels are not in contact with the gathering frame. A pallet bag is dispensed from the bag rolls and the top opening of the pallet bag is fed under the guide wheels, at which time the guide arm is made to pivot to a position where it is in contact with the outside portion of the pallet bag, wherein the inside portion of the pallet bag is pressed against the gathering frame by the guide wheels. Said guide arms may be from about 1 foot to about 2 feet in length preferably, though the preferred length can be determined as needed to accommodate the gathered pallet bag. The guide arms have a space between the guide wheel and the guide stop that is approximately rectangular in shape with a width of approximately the diameter of the guide wheel, which may be about 3 inches to about 6 inches and a length from about 1 foot to about 2 feet. This space is used to collect the gathered pallet bag.
- After the pallet bag is fed under the guide wheels, which may be automatic or manually fed, and the guide wheels are pivoted to contact the outside of the pallet bag, then gathering process can be initiated either manually or automatically by sensing the pallet bag has been fed to a point beyond the contact point of the guide wheels to the gathering frame. The guide wheels move in a direction to feed the pallet bag into the space between the guide wheel and the guide stop on the gathering frame. The gathering process in a preferred embodiment takes less than about twenty seconds, preferably less than ten seconds. When the bottom of the gathered bag is secured against the lower part of the gathering frame, the guide wheels stop either manually or automatically by sensing the resistance of the bag or by sensing the bottom of the bag against the gathering frame. To remove the gathered bag from the gathering frame the guide wheels may be pivoted away from the gathering frame such that the wheels are no longer in contact with the outside surface of the pallet bag. The gathered pallet bag may then be lowered from the gathering frame and preferably placed on a pallet in preparation for moving the pallet with the gathered pallet bag to a station of an automated pallet bag packaging system to receive a load of biological materials for packaging within the pallet bag.
- Alternatively, the pallet bags may be gathered, removed and stacked for use in the automated pallet bag packaging system. Alternatively, the pallet gathering apparatus is integrated into the pallet bag packaging system such that a gathered bag is automatically deposited on a pallet for loading biological materials on such pallet, extending the pallet bag over the biological materials, and sealing the bag.
- The drawings are for illustrative purposes and do not depict every embodiment of the invention.
-
FIG. 1 is a depiction of a top-diagonal view of the pallet bag gathering apparatus. -
FIG. 2 is a depiction of a rear view of the pallet bag gathering apparatus. -
FIG. 3 is a depiction of a top down view of the pallet bag gathering apparatus. -
FIG. 4 is a depiction of a side view of the pallet bag gathering apparatus. - In the Summary of the Invention above and in the Detailed Description of the Invention, the Examples, and the Claims below, reference is made to particular features (including method steps) of the invention. It is to be understood that the embodiments of the invention include all possible combinations of such particular features. For example, where a particular feature is disclosed in the context of a particular aspect or embodiment of the invention, or a particular claim, that feature can also be used, to the extent possible, in combination with and/or in the context of other particular aspects and embodiments of the invention, and in the invention generally.
- The term “comprises” and grammatical equivalents thereof are used herein to mean that other components, ingredients, steps etc. are optionally present. For example, an article “comprising” (or “which comprises”) components A, B and C can consist of (i.e. contain only) components A, Band C, or can contain not only components A, Band C but also one or more other components. Where reference is made herein to a method comprising two or more defined steps, the defined steps can be carried out in any order or simultaneously (except where the context excludes that possibility), and the method can include one or more other steps which are carried out before any of the defined steps, between two of the defined steps, or after all the defined steps (except where the context excludes that possibility).
- Where reference is made herein to sealed packages and sealed containers, and to sealing bags and other containers containing biological materials, it is to be understood that the sealing can be, but sometimes is not, hermetic sealing, due to poor heat seal operation, poor taping or poor closure.
- Conventional methods for sealing bags and other containers can conveniently be used in this invention. Such conventional methods include, for example, the use of a cable tie to seal the neck of a polymeric bag. A seal made by conventional methods often is not a hermetic seal, and has the advantage that it permits equilibration of the pressures inside and outside the bag. If the container is sealed hermetically, it will generally be desirable to include one or more pinholes in the container, to achieve such equilibration and or through appropriate choice of ACM, for example BreathWay membranes alone or in combination with other ACMs. If two Breatheway ACMs are used, for example, one can avoid the need for pinholes even when hermetically sealed.
- The less complete the sealing of the container, the less the influence of the permeability of the container on the packaging atmosphere within it. Thus, even a poor seal may be sufficient, or even desirable, for example when the desired O2 content of the packaging atmosphere lies between the O2 content of the atmosphere surrounding the package and the O2 content of the packaging atmosphere that would result if the seal was a hermetic seal. Under such circumstances, the sealing could be designed to permit a controlled amount of direct exchange between the packaging atmosphere and the atmosphere surrounding the container.
- The Pallet bag may be a standard thickness, for example about 2 to about 8 mil, more preferably about 3 to about 4 mil and may be composed of any plastic material, low density polyethylene (LDPE) is a preferred plastic (since by using a mechanical locking device no heat sealing is needed—but heat sealing may be applied) but any plastic monolayer, plastic laminates or multicomponent laminates or blends may be used for example, PE, PP, PET, thermoplastic elastomer, stretch plastic, Nylon, paper/plastic laminates, and the like. Other bag materials and thicknesses may be used. However, it is desirable that the upper portions of the wall material should be sufficiently flexible to be used with the mechanical seal preferably used in the pallet packaging system herein.
- Suitable flexible material for the bag may be PE, PP, Nylon, polyester, recycled or repurposed plastic, low cost paper/plastic laminates, and other laminates. Preferred materials include LDPE, Linear low density polyethylene (LLDPE), ultra low density polyethylene (ULDPE). Depending on the method of applying the bag over the pallet, a stretch plastic may be preferred.
- In one embodiment the pallet bag material contains one or more specialty additives, including additives having one or more of the following properties: anti-microbial; anti-fungal; photobiodegradable; oxo-photobiodegradable; UV blocker; anti-drag; anti-scratch; print enhancer; anti-static; anti-fog; pro-release; and pest repellant (e.g., ant, rodent). The material may optionally contain metallic silver particles, zeolites, organic micro-particles, titanium dioxide, and silica, as well as other additives to aid in the process and promotion of packaged biological materials.
- Because heat sealing may be unnecessary when using a “mechanical seal”, the pallet bag material may be selected based on cost or moisture vapor transmission rate (MVTR) properties or puncture resistance or other reasons. Integral to the pallet packaging system is the use of atmosphere control technology, for example a BREATHEWAY® membrane or microperforations as appropriate. Preferably the pallet packaging system uses a BREATHEWAY® membrane, as described in other Apio/Landec patents and patent applications, including U.S. Pat. Nos. 5,254,354; 6,376,032; 6,548,132, and 7,329,452, each of which is incorporated by reference in its entirety. Use of the membrane technology allows effective atmosphere control of oxygen and carbon dioxide for extension of shelf-life, taste, freshness, and other benefits, such as appearance.
- The pallet bag/cover may optionally have a ‘valve” mechanism built into the bag that may be a one-way or two-way valve to assist in the speed and efficiency of removing the air in the bag and replacing with CO2 which may eliminate the need to cut and then retape the bag after CO2 injection.
- The pallet bag may optionally be a custom designed bag which, when opened and placed over the pallet will have a flat top to lie smoothly over the top layer of product trays. This bag design will not leave any hanging ears, which otherwise require taping and add extra labor, cost and time. A preferred pallet bag may be designed to fit a unit load of 48″×40″ (Standard Grocery Manufacturers Association (GMA) pallet) with varying heights and will come in a roll form. Alternatively, the pallet bag may be designed for use with a sea pallet, which commonly has a size of 1200 mm×1000 mm. Alternatively, the pallet bag may be sized for a European pallet of 800 mm×1200 mm used in some parts of Europe.
- These bags in a roll will allow for easy automation.
- The pallet bags, in one aspect, form part of the present invention and can be used to drive efficiency, lower costs, and to render a clean looking finished pallet with the right atmosphere. In one embodiment, a fully automated system is used from using film in the shape of a long tube that can be automatically cut to size for a custom pallet height, with the top heat sealed and holes cut over which may be placed ACM membranes, such as BreatheWay® membranes, or microperforations for atmosphere control.
-
FIGS. 1-4 show features of the pallet bag gathering apparatus. - Regarding
FIG. 1 , the depiction of the palletbag gathering apparatus 100 shows guidearm 120 withfeeder wheels 121 and guide stops 122. Theguide arm 120 pivots away from thegathering frame 110 prior to feeding the pallet bag from the pallet bag rolls 150. The pallet bag rolls may be of different lengths and circumferences depending on the containers that will be packaged within the pallet bag.Controller 130 is used to program the process of feeding the pallet bag fromroller 150 between thefeeder wheels 121 and thegathering frame 110 to the void space between thefeeder wheels 121 and the guide stops 122. Thepallet bag feeder 140 may be automatically programmed to feed the pallet bag to thegathering frame 110 and may be programmed to automatically detach the pallet bag from the roll when the bottom of the bag proceeds beyond a set point. - Regarding
FIG. 2 , this alternative view from behind the palletbag gathering apparatus 200 shows thecontroller 230 and the plurality of pallet bag rolls 250 loaded on spools for distribution therefrom to the gathering frame. - Regarding
FIG. 3 , this alternative view from above the palletbag gathering apparatus 300 shows the top of the controller, the pallet bag rolls 350, thepallet bag feeder 340, thegathering frame 310 and theguide arm 120. - Regarding
FIG. 4 , this alternative view from the side of the palletbag gathering apparatus 400 shows thepallet bag feeder 440, thegathering frame 410, thefeeder wheels 411, and the guide stops 412. - Persons having ordinary skill in the art will recognize certain modifications, permutations, additions and sub-combinations of the embodiments described herein. It is intended herein to include all such modifications, permutations, additions and sub-combinations.
Claims (12)
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US16/512,372 US20200115081A1 (en) | 2018-07-16 | 2019-07-16 | Pallet bag gathering apparatus and process for use |
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US201862698796P | 2018-07-16 | 2018-07-16 | |
US16/512,372 US20200115081A1 (en) | 2018-07-16 | 2019-07-16 | Pallet bag gathering apparatus and process for use |
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US20200115081A1 true US20200115081A1 (en) | 2020-04-16 |
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US16/512,372 Abandoned US20200115081A1 (en) | 2018-07-16 | 2019-07-16 | Pallet bag gathering apparatus and process for use |
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