US20220402637A1

US20220402637A1 - Apparatus for realising a biodegradable packaging of a product for the preparation of a beverage

Info

Publication number: US20220402637A1
Application number: US17/627,995
Authority: US
Inventors: Valerio TAGLIOLI
Original assignee: Lovitalia Srl
Current assignee: Lovitalia Srl
Priority date: 2019-07-18
Filing date: 2020-07-15
Publication date: 2022-12-22
Also published as: WO2021009685A1; EP3999428A1; IT201900012228A1

Abstract

An apparatus for realising a biodegradable packaging of a product for preparation of beverages includes a first feeder group and a second feeder group. The first feeder group is of a first film made of a biodegradable material, in particular a film of polylactic acid (PLA), and a first rotary carousel, configured, together with a series of work stations associated to the first carousel, to realise a pod made of PLA, containing internally thereof a product for preparation of a beverage. The second feeder group is of a second film made of a biodegradable material, in particular a film of Ecoralene, and a second rotary carousel, configured, together with a series of work stations associated to the second carousel, to realise an Ecoralene cladding of the pod to obtain a biodegradable packaging of a product for preparation of a beverage.

Description

FIELD OF THE INVENTION

The present invention relates to the technical sector concerning the packaging of products for the preparation of hot and/or cold beverages, such as for example coffee, tea, malted drinks, herbal teas, infusions, etc.

DESCRIPTION OF THE PRIOR ART

Products for the preparation of beverages are usually in a granular, powder, lyophilised or ground form, or finely chopped herbs, so they are usually predisposed internally of relative packaging which have to be sealed to safeguard the properties, taste and flavours thereof.
The sealed packages are then inserted by the user into special automatic machines for dispensing the beverage.
Various types and packages are known that are utilised for containing the products for the preparation of beverages.
A particular type of packaging for preparation of a beverage comprises a pod, containing the product for preparation of the beverage, which is closed and sealed inside an external cladding.
The pod is made of a biodegradable material, such as for example polylactic acid (PLA), and comprises a hollow body, having a base, for example circular, and lateral walls, for example a cylindrical wall, internally of which the product for the preparation of the beverage is predisposed, and a closing cover applied and fixed to the body.
The pod, thus-formed, before being clad with a cladding material to obtain the final package, can then be compressed and compacted, for example with the use of a sonotrode.
The cladding materials used for cladding the pod, and for the realising of the final package, are instead of the non-biodegradable type, such as for example a multilayer aluminium sheet.
A known method for realising a packaging of products for preparation of beverages comprises, first, realising the pod using a biodegradable material, and then cladding the pod using a non-biodegradable material, thus cladding the pod using a non-biodegradable material.
To realise the pod, a first sheet is unwound and cut from a first reel of a film of io biodegradable material, such as for example PLA (polylactic acid) and then a second sheet is unwound and cut from a second reel of a film of biodegradable material, such as for example PLA (polylactic acid).
Cuts are made in the first sheet of biodegradable material in such a way as to obtain a series of first pieces of biodegradable material; for example the cuts are made in such a way as to obtain a series of first pieces having a circular shape.
The cuts are made in such a way that the first pieces of biodegradable material have a diameter that is such that, for each thereof, by folding an external circular portion with respect to an internal circular portion, a hollow body can be obtained that has a base wall and a lateral cylindrical wall.
Cuts are made in the second sheet of biodegradable material in such a way as to obtain a series of second pieces of biodegradable material having a circular shape having a sufficient diameter for being applied to close the hollow bodies obtained following the folding of the first pieces.
Once the first pieces of biodegradable material have been folded to form the hollow bodies, a step of filling the hollow bodies is carried out with the products for the preparation of beverages, and then a step of application of the second pieces of biodegradable material to close the hollow bodies, and lastly a step of fixing, for example by heat-welding, the second pieces to the hollow bodies. In this way pods are obtained that contain internally thereof a product for preparation of a beverage.
A final step may be carried out in which the pods are compacted to compress, by compacting, the product for the preparation of the beverage. At the same time, or following the above-described steps, a first sheet of cladding is unwound and cut from a first reel of a film of non-biodegradable material (such as for example an aluminium multi-layer material) and a second sheet of cladding is in turn unwound and cut from a second reel of a film of non-biodegradable material (such as for example an aluminium multi-layer material). The two sheets of non-biodegradable material are used to realise the cladding of the pod in the following way.
A first sheet of cladding is positioned above the centring organs, which define predetermined positions in which the pods must be positioned above the first sheet of cladding.
The pods are positioned above the first sheet of cladding, at the predetermined positions defined by the centring organs, and then the second sheet of cladding is positioned above the pods.
A plurality of heat-forming and heat-welding operations are then carried out on each of the pods interposed between the two sheets of cladding material. In particular, the heat-welding is carried out in such a way that the parts of the two sheets of cladding that are located above and below the pods are heat-welded to one another to form a heat-welded portion that surrounds the pods.
The two sheets are then subjected to cutting operations in such a way as to carry out circular cuts externally of the heat-welded circular portions, thus obtaining the final circular-shaped packagings which enclose internally thereof the pods containing the products for the preparation of a beverage.
The above-described operations for realising the packaging of the products for the preparation of beverages do not create any particular issues, in particular the carrying out of the steps of heat-forming, heat-welding and cutting of the two cladding sheets in non-biodegradable material, as they are sufficiently rigid not to be subject to deformations during the operations of heat-welding and cutting.
The final packages obtained therefore have a substantially uniform shape, with the pod substantially perfectly centred, with the outlines well-defined and therefore appealing from the aesthetic point of view.
In recent times, for various reasons, primarily to guarantee an ecological elimination of the packages once they have been used for the preparation of beverages, the need to have packages of products for the preparation of beverages that are entirely biodegradable has become increasingly pressing, i.e. packages where not only the pod but also the cladding of the pod are made of biodegradable material.
A type of biodegradable material that can be used as a cladding for the pods is constituted by Ecoralene, i.e. a coupled film based on biodegradable material and compostable materials.
In particular Ecoralene is constituted by a high-barrier outer film based on compostable biodegradable cellulose and by an inner film based on a biopolymer of vegetable origin that is biodegradable and compostable. However problems have emerged related to the above-described steps of heat-welding and cutting when using sheets of Ecoralene for realising the cladding of the pods.
In fact, the tensions that are created on the sheets of Ecoralene, during the heat-welding step can cause a relative displacement between the portions of the two sheets, which must be reciprocally heat-welded, and the pods interposed between them, and thus can lead to obtaining non-optimal final packages, as the pods will not be perfectly centred.
Further, the tension to which the sheets of Ecoralene are subjected, following the application of heat during heat-welding, are of various natures as concern the outer film and the inner film, and therefore can lead to creasing and streaking, with a consequent impact on the aesthetic appeal of the final packages.

SUMMARY OF THE INVENTION

The aim of the present invention is therefore to provide a new method for realising an apparatus for realising a biodegradable packaging of products for preparation of beverages, able to obviate the drawbacks of the prior art described in the foregoing.
In particular, an aim of the invention is to provide an apparatus which enables realising packages of products for the preparation of beverages which, following use, are entirely biodegradable, concerning both the pod and the relative cladding, and which at the same time provide an optimal shape from both the structural and the aesthetic point of view.
Further, an aim of the present invention is to provide an apparatus able to realise biodegradable packages containing a varied type of products for preparation of beverages, such as products in powder, granular, lyophilised or ground products, or in the form of chopped herbs, and therefore biodegradable packages utilisable for preparing various types of beverages, and not only coffee, tea, but also herbal teas, infusions, etc.
The above aims are attained in accordance with the contents of the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The characteristics of a preferred embodiment of the apparatus for realising a biodegradable packaging of products for preparation of beverages, proposed by the present invention, will be described in the following with reference to the appended tables of drawings, in which:

FIG. 1 is a schematic plan view of the apparatus of the invention in its entirety;

figures from 2A to 2H are schematic views of a first feeder and cutting group, for cutting at least a first circular piece and a second circular piece from a first film of biodegradable material, in particular polylactic acid (PLA), utilisable by the apparatus for realising a pod containing a product for preparation of a beverage;

figures from 3A to 3H illustrate, in relative schematic views, a second feeder and cutting group, for cutting at least a third circular piece and a fourth circular piece from a second film of biodegradable material, in particular Ecoralene, utilisable by the apparatus for realising a cladding of a pod containing a product for preparation of a beverage for obtaining the final package;

FIG. 4 illustrates detail K1 of FIG. 1 in larger scale better to evidence the characteristics of some significant components of the apparatus of the invention;

figures from 4A to 4E illustrate, in relative schematic views, collection of the first circular piece made of PLA and the second circular piece made of PLA from a first feeder and cutting group and the transfer thereof on the components illustrated in FIG. 4 , at a work station of the apparatus;

figures from 5A to 50 illustrate, in relative schematic views, a possible operating sequence for folding the first circular piece made of PLA and the formation of a hollow body for containing a product for preparation of a beverage at a work station of the apparatus of the apparatus, in which FIG. 5C schematically illustrates in a plan view, and a frontal view in section components of the apparatus used for folding the first circular piece made of PLA and the formation of the hollow body, FIG. 5F illustrates a particular step of the folding of the first circular piece made of PLA, FIG. 51 illustrates the shape of the hollow body in a folding step of the first circular piece made of PLA and FIG. 50 illustrates the final shape obtained for the hollow body;

figures from 6A to 6D illustrate, in relative schematic views, a possible operating sequence for inserting and dosing a product for preparation of a beverage internally of the hollow body obtained from the folding of the first circular piece made of PLA at a work station of the apparatus;

figures from 7A to 7B illustrate, in respective schematic views, a possible operating sequence for carrying out an eventual precompression of the product inserted into the hollow body;

figures from 8A to 8H illustrate, in respective schematic views, a possible operating sequence that can be carried out for folding by pleating of the upper portion of the lateral wall of the hollow body above the product contained in the hollow body so as to form a pleated crown above the product and for application, with spot pre-welding, of the second circular piece made of PLA above the pleated crown to form a closing cover and close the hollow body and to obtain a pod containing the product for preparation of a beverage, at a work station of the apparatus, in which FIG. 8C schematically illustrates and in a perspective view a component used for carrying out the spot pre-welding, FIG. 8G illustrates, in a perspective view the hollow body containing the product for preparing the beverage with the pleated crown folded above the product, while FIG. 8H illustrates the pod obtained;

figures from 9A to 9B, and from 9C to 9D illustrate, in respective schematic views, two possible ways of carrying out an eventual compacting of the pod;

FIG. 10A illustrates detail K2 of FIG. 1 in larger scale in order better to evidence the characteristics of some significant components of the apparatus of the invention;

figures from 10B to 10E illustrate, in relative schematic views, the collecting of the third circular piece made of Ecoralene and the fourth circular piece made of Ecoralene from the second feeder and cutting group and the transfer thereof with extrusion onto the components illustrated in FIG. 10A, at a work station of the apparatus;

figures from 11A to 11B illustrate, in relative schematic views, the steps of heat-forming the third circular piece made of Ecoralene and the fourth circular piece made of Ecoralene to form a first valve-shaped element and a second valve-shaped element, at a work station of the apparatus;

figures from 12A to 12D illustrate, in relative schematic views, the steps of transferring the pod and positioning the pod in the first valve-shaped element and the positioning of the second valve-shaped element above the first valve-shaped element to cover the pod, at a work station of the apparatus;

figures from 13A to 13B illustrate, in relative schematic views, steps for carrying out a spot pre-welding between the first valve-shaped element and the second valve-shaped element, at a work station of the apparatus, while FIGS. 13C and 13D show components of the apparatus used for the pre-welding operations;

figures from 14A to 14D and from 14E to 14H illustrate, in respective schematic views, two possible ways of carrying out a ring welding between the first valve-shaped element and the second valve-shaped element, in order to seal them to one another and seal the pod internally thereof, at a work station of the apparatus, in which in figures from 14A to 14D the ring welding is carried out internally of a controlled-atmosphere environment with a preparative aspirating of oxygen and injection of inert gas;

figures from 15A to 15B illustrate, in respective schematic views, steps for carrying out a final heat-welding between the first valve-shaped element and the second valve-shaped element so as to obtain a biodegradable packaging sealed internally containing the pod with the product for preparation of a beverage for obtaining a beverage, at a work station of the apparatus; FIG. 15C illustrates, in a schematic plan view, a step of checking the biodegradable packaging;

figures from 16A to 16E illustrate, in respective schematic views, gripping steps of the biodegradable packaging and transfer of the biodegradable packaging above an outlet conveyor means, at a work station of the apparatus;

FIG. 17 illustrates, in a schematic perspective view, a work station of the apparatus at which any working residues of the parts made of PLA are aspirated and the cleaning operations of the significant components as in FIG. 4 are carried out;

FIG. 18 illustrates, in a schematic perspective view, a further work station of the apparatus at which any defective biodegradable packages not transferred onto the outlet conveyor means are collected and cleaning operations of the significant components of FIG. 10A.

DESCRIPTION OF PREFERRED EMBODIMENTS

With reference to the appended tables of drawings, reference numeral (100) denotes the apparatus for realising a biodegradable packaging of a product for preparation of beverages, object of the present invention, in its entirety.
FIG. 1 illustrates, in a plan view, the overall layout of the apparatus (100) for which some significant components have been illustrated, while the relative work stations for carrying out the various steps of realising a pod (A) made of a biodegradable material, containing a product for preparation of a beverage, such as polylactic acid (PLA), and a cladding thereof with a biodegradable material, such as Ecoralene, have been illustrated only schematically by relative numbered rectangles.
The special characteristics of the various work stations of the apparatus have instead been illustrated in detail in the remaining figures. With reference to FIG. 1 , the apparatus (100) of the invention, in a general aspect thereof, comprises the following combination of characteristics.
It comprises:
a first feeder group (A1) of a first film made of a biodegradable material, in particular polylactic acid (PLA), and a first rotary carousel (G1), destined, together with a series of work stations associated to the first carousel (G1), to realise a pod made of polylactic acid (PLA), containing internally thereof a product (P) for preparation of a beverage;
a second feeder group (A2) of a second film made of a biodegradable material, in particular Ecoralene, and a second rotary carousel (G2), destined, together with a series of work stations associated to the second carousel (G2), to realise an Ecoralene cladding of the pod to obtain a biodegradable packaging of a product for preparation of a beverage.
In greater detail, the first feeder group (A1) is configured for and directed at unwinding a first film (M1) of biodegradable material, in particular, as mentioned, a first film made of polylactic acid, from a first reel (B1) of biodegradable material and for cutting the first film (M1) so as to obtain a first sheet (F1), and comprising first cutting means (T1) configured and activatable to cut the first sheet (F1) so as to obtain at least a first circular piece (S1) and at least a second circular piece (S2), wherein the at least a first circular piece (S1) has a greater diameter than the at least a second circular piece (S2) and has dimensions that are such as to enable the relative folding thereof in order to form a hollow body (C) having a circular base (CB) and a lateral wall (CL).
The first feeder group (A1) is configured in such a way as to position the first circular piece (S1) and the second circular piece (S2) cut in the first sheet (F1) at a first collecting position (C1) (for example figures from 2A to 2H illustrate a possible preferred but not exclusive embodiment of the first feeder group (A1) which, as it is not exclusive, will be described in more detail in the following part of the present description, once the essential aspects of the invention have been revealed).
The first rotary carousel (G1) is configured in such a way as to be activatable in rotation about a first vertical rotation axis (V1), comprising a first series of plates (1) angularly arranged with respect to one another about the first vertical axis of rotation (V1), wherein each plate (1) comprises a first support (11), comprising suction holes (12), configured to receive and retain, by suction, the first circular piece (S1), and a second support (13), comprising suction holes (14), configured to receive and retain, by suction, the second circular piece (S2).
In greater detail, the first support (11) (see for example FIG. 4 ) is conformed in such a way as to centrally comprise a cylindrical housing (15) having a diameter smaller than the diameter of the first circular piece (S1), and so as to comprise a plate (17) provided with suction holes (18), predisposed internally of the cylindrical housing (15) so as to be translatable vertically with respect to the cylindrical housing (15), between a raised position and a lowered position.
The first carousel (G1) is arranged with respect to the first feeder group (A1) and is activatable in angular rotation about the first vertical axis of rotation (V1) according to successive angular rotations so that, at each angular rotation, a plate (1) at a time of the first series of plates (1) is positioned in a first angular position (Z1) situated at the first collecting position (C1) wherein the first feeder group (A1) positions the first circular piece (S1) and the second circular piece (S2), so that the first circular piece (S1) can be collected from the first feeder group (A1) and positioned on the first support (11), with the plate (17) in a raised position at the upper end of the cylindrical housing (15), which retain the first circular piece (S1) by suction, and the second circular piece (S2) can be collected from the first feeder group (A1) and positioned on the second support (13) which retains it by suction (for example figures from 4A to 4E illustrate a possible preferred but not exclusive embodiment of transfer of the first and second piece, which, as it is not exclusive, will be described in more detail in the following part of the present description).
The first carousel (G1) is activatable in angular rotation about the first vertical axis of rotation (V1) in successive angular rotations so as to position, at each angular rotation, the plate (1) of the first carousel (G1) with the first circular piece (S1) and the second circular piece (S2) paused in successive angular positions at relative work stations which are configured in such a way that the following operations are carried out in succession at them:
an internal circular portion of the first circular piece (S1) is pushed into the cylindrical housing (15), together with the lowering of the plate (17), so as to fold an external circular portion with respect to the internal circular portion and form a hollow body (C) having a circular base (CB), defined by the internal circular portion, and a lateral wall (CL) defined by the external circular portion folded with respect to the internal circular portion (for example figures from 5A to 50 illustrate a possible preferred but not exclusive folding mode of the first circular piece for forming the hollow body which, as it is not exclusive, will be described in more detail in the following part of the present description);
a product (P) for preparation of a beverage is inserted and dosed in the hollow body (C) so as to fill a part of the volume of the hollow body in such a way that an upper portion (S) of the lateral wall (CL) of the hollow body (C) is free and not occupied by the product (P) (see for example figures from 6A to 6D); the upper portion (S) of the lateral wall (CL) of the hollow body (C) is bent by means of pleating with respect to the lateral wall (CL) of the hollow body (C) to form a pleated crown (PS) above the product (P) contained in the hollow body (C) and the second circular piece (S2) is collected from the second support (13) and positioned above the pleated crown (PS), carrying out a welding, to form a closing cover (CC) and close the hollow body (C) in such a way as to obtain a pod (D) containing the product (P) for preparation of a beverage (for example figures from 8A to 8H illustrate a possible preferred but not exclusive embodiment of carrying out the folding by pleating of the upper portion (S) of the lateral wall (CL) of the hollow body (C) so as to form a pleated crown above the product, which, as it is not exclusive, will be described in more detail in the following part of the present description once the salient and essential aspects of the invention have been revealed).
In turn, the second feeder group (A2) is configured for unwinding a second film (M2) of biodegradable material, in particular, as mentioned, a second film made of Ecoralene, from a second reel (B2) of biodegradable material and for cutting the second film (M2) so as to obtain a second sheet (F2) and comprises second cutting means (T2) configured and activatable to cut the second sheet (F2) so as to obtain at least a third circular piece (S3) and at least a fourth circular piece (S4), wherein the at least third circular piece (S3) and the at least fourth circular piece (S4) have a diameter that is substantially identical to one another and which is of greater dimensions than the diameter of the pod (D) obtained on the plate (1) of the first series of plates (1) of the first carousel (G1).
The second feeder group (A2) is configured in such a way as to position the third circular piece (S3) and the fourth circular piece (S4) cut in the second sheet (F2) at a second collecting position (C2) (for example figures from 3A to 3H illustrate a possible preferred but not exclusive embodiment of the second feeder group (A2) which, as it is not exclusive, will be described in more detail in the following part of the present description, once all the essential aspects of the invention have been revealed).
The second rotary carousel (G2) is arranged flanked to the first carousel (G1) and is configured in such a way as to be activatable in rotation about a second vertical axis of rotation (V2), and comprises a second series of plates (2) angularly arranged with respect to one another about the second vertical axis of rotation (V2), wherein each plate (2) of the second series of plates (2) of the second carousel (G2) comprises a first half-shell (21), provided with suction holes (22), and a second half-shell (23), provided with suction holes (24), hinged to one another and configured in such a way as to be activatable between a splayed position (D1), in which they are splayed with respect to one another, and a superposed position (D2), wherein they are superposed on one another and closed to one another.
The first half-shell (21) and the second half-shell (23) (visible for example in greater detail in FIGS. 10A in which they are in the splayed position (F1) thereof) have dimensions such as to be able to receive internally thereof respectively the third circular piece (S3) and the fourth circular piece (S4), and to retain them by suction.
Further, the second carousel (G2) is arranged with respect to the second feeder group (A2) and is activatable in angular rotation about the second vertical axis of rotation (V2) according to successive angular rotations so that, at each angular rotation, a plate (2) at a time of the second series of plates (2), with the first half-shell (21) and the second half-shell (23) in the splayed position (D1), is positioned in a first angular position (U1) situated at the second collecting position (C2) wherein the second feeder group (A2) positions the third circular piece (S3) and the fourth circular piece (S4), so that the third circular piece (S3) can be collected from the second feeder group (A2) and then pushed and positioned in the first half-shell (21) to form a first valve-shaped element (25), which is retained by suction in the first half-shell (21), and the fourth circular piece (S4) can be collected from the second feeder group (A2) and then pushed and positioned in the second half-shell (23) to form a second valve-shaped element (26), which is retained by suction in the second half-shell (23) (for example figures from 10B to 10E illustrate a possible preferred but not exclusive embodiment of transfer of the third and fourth piece, which, as it is not exclusive, will be described in more detail in the following part of the present description).
The second carousel (G2) is also thus activatable in rotation about the second vertical axis of rotation (V2) with an angular rotation such as to position the plate (2), with the first valve-shaped element (25) retained by suction in the first half-shell (21) and the second valve-shaped element (26) retained by suction in the second half-shell (23), in a successive angular position at a work station in which the first valve-shaped element (25) is heat-formed internally of the first half-shell (21), into a shape such that it comprises an annular peripheral portion (27) and a first seat (28) such as to be able to accommodate a lower part of the pod (D) formed on the plate (1) of the first carousel (G1), and the second valve-shaped element (26) is heat-formed internally of the second half-shell (23), into a shape such that it comprises an annular peripheral portion (29) and a second seat (30) such as to be able to accommodate the upper part of the pod (D) formed on the plate (1) of the first carousel (G1) (see for example FIGS. 11A and 11B).
The apparatus (100) is configured in such a way that, the first carousel (G1), with the relative plate (1) of the first series of plates (1) which bears the pod (D), and the second carousel (G2), with the relative plate (2) of the second series of plates (2) bearing the two heat-formed valve-shaped elements (25, 26) retained by suction by the two half-shells (21, 23), being activatable in rotation according to relative angular rotations so as to position the plate (1), with the pod (D), and the plate (2), with the two valve-shaped elements (25, 26), in respective successive angular positions opposite one another (see for example FIG. 12A). In this way, the pod (D) can be collected and positioned from the first plate (1) in the first seat (28) of the first valve-shaped element (25) retained by aspiration by the first half-shell (21) of the second plate (2), with a lower part of the pod (D) in the first seat (28), and the second half-shell (23) can thus be activated into the superposed position (D2), so as to superpose on the first half-shell (21), and position the second valve-shaped element (26), retained thereby by suction, above the first valve-shaped element (25) and with an upper part of the pod (D) being accommodated in the second seat (30) of the second valve-shaped element (26), and so that the annular peripheral portion (29) of the second valve-shaped element (26) superposes on the annular peripheral portion (27) of the first valve-shaped element (25) (for example figures from 12B to 12D illustrate a possible preferred but not exclusive embodiment of transfer of the pod (D) which, as it is not exclusive, will be described in more detail in the following part of the present description).
Further the second carousel (G2) is thus consequently activatable in angular rotation about the second vertical axis of rotation (V2) according to successive angular rotations so as to position, at each angular rotation, the plate (2) of the second series of plates (2) with the two half-shells (21, 23) in the superposed position (D2), and the two valve-shaped elements (25, 26), superposed on one another and internally containing the pod (D), in successive angular positions at relative work stations which are configured in such a way that at which, in succession, the following operations are carried out:
the second half-shell (23), once the suction action has been deactivated so as to release the second valve-shaped element (26), is returned into the splayed position (D1) from the first half-shell (21), and the first valve-shaped element (25) and the second valve-shaped element (26) are heat-welded at the relative annular peripheral portions (27, 29) superposed on one another in such a way as to seal the pod (D) internally thereof and obtain a sealed biodegradable packaging (F) of a product (P) for preparation of a beverage (see for example FIGS. 15A and 15B);
the sealed biodegradable packaging (F) containing a product (P) for preparation of a beverage is collected from the plate (2) of the second series of plates (2) of the second carousel (G2) and transferred onto a conveyor means (31) (see for example figures from 16A to 16E).
Owing to this special combination of characteristics, the apparatus (100) of the invention has a first carousel and relative work stations specially predisposed to realise a pod containing a product for preparation of a beverage from a first sheet cut from a first film of biodegradable material, such as polylactic acid, which is unwound by a single first reel, in particular from a first circular piece a second circular piece cut in the first sheet.
At the same time, with the second carousel and with the relative associated work stations mentioned in the foregoing, the apparatus utilises a second sheet of biodegradable material, such as Ecoralene, which is cut from a second film unwound from a second reel, so as to obtain a third circular piece and a fourth circular piece which are used to create the cladding of the pod.
In this way, the third circular piece and the fourth circular piece already have the suitable dimensions to be used as cladding for wrapping the pod, and can be subjected, independently of one another, to the operations of heat-forming so as to obtain the two valve-shaped elements having a suitable shape to receive, in the relative seats, corresponding portions of the pod.
The fact of having to heat-form the third circular piece and the fourth circular piece in the two valve-shaped elements, previously to the coupling thereof with the pod, enables carrying out the heat-forming in an effective and precise way and giving the two valve-shaped elements relative suitable shapes which, once coupled, will define the final cladding of the pod, and thus the shape of the final package.
Further, when the two valve-shaped elements are superposed on one another to close the pod internally thereof, owing to the special shape they are given during the independent heat-forming, they will have only the relative annular portions that superpose on one another, and therefore a very precise and defined area, at which the operations of heat-welding and sealing can be carried out, with no repercussion on the pod contained internally thereof, in the two seats of the two valve-shaped elements, nor on the shape of the two valve-shaped elements.
Therefore, with the apparatus (100) of the present invention it is possible to obtain a final package that is entirely made of a biodegradable material, both for the material of the pod and the material of the cladding, and will have a well-defined shape as regards the relative edge, which will be perfectly circular (circular edges of the third and fourth circular piece, superposed on one another) with two containing caps of the pod formed by the two seats of the two valve-shaped elements.
In a first preferred aspect, the apparatus (100) can be configured to comprise the combination of the work stations described in the following:
a first collecting work station (P1), for gripping the first circular piece (S1) and the second circular piece (S2);
a second folding and heat-forming work station (P2) for folding and heat-forming of the first circular piece (S1) in a hollow body (C) having a base wall (CB) and a lateral wall (CL);
a third dosing work station (P3), for dosing a product (P) for preparation of a beverage in the hollow body (C);
a fourth folding and closing work station (P4) for folding an upper portion (S) of the lateral wall (CL) of the hollow body (C) above the product (P) and the application of the second circular piece (S2) to close the hollow body (C) and form the pod (D) containing the product (P) for preparation of a beverage;
a fifth collecting work station (P5), for gripping the third circular piece (S3) and the fourth circular piece (S4);
a sixth heat-forming work station (P6), for heat-forming the third circular piece (S3) in a first valve-shaped element (25) and the heat-forming of the fourth circular piece (S4) in a second valve-shaped element (26);
a seventh collecting and transferring work station (P7), wherein the pod (D) is collected and positioned in the first valve-shaped element (25) and the second valve-shaped element (26) is positioned above the first valve-shaped element (26) for closing the pod (D) there-between;
an eighth heat-welding and sealing station (P8), for the heat-welding and reciprocal sealing of the valve-shaped elements (25, 26) in order to obtain a biodegradable packaging (F) of a product for preparation of a beverage; a ninth outfeed work station (P9), for gripping the biodegradable packaging (F) and for transfer thereof onto a conveyor means (31).
In detail, the various work stations described in the foregoing are arranged and configured in the following way.
The first collecting work station (P1) is situated at the first collecting position (C1) wherein the first feeder group (A1) positions the first circular piece (S1) and the second circular piece (S2) and at the first angular position (Z1) wherein the plate (1) of the first series of plates (1) is positioned by the first carousel (G1), so as to collect the first circular piece (S1) and the second circular piece (S2).
The first collecting work station (P1) comprises collecting means (3) (described in greater detail in the following part of the description) which are configured and activatable to collect the first circular piece (S1) and the second circular piece (S2) from the first feeder group (A1) and to position the first circular piece (S1) on the first support (11) of the plate (1), so that the first circular piece (S1) is centred with respect to the cylindrical housing (15) so that an internal circular portion of the first piece (S1) is at the cylindrical housing (15) and resting on the plate (17), the plate being positioned in a raised position with respect to the cylindrical housing (15) at the upper end of the cylindrical housing (15), and an external circular portion of the first circular piece (S1) is external of the cylindrical housing (15), and in such a way that the first support (11) and the plate (17) can retain the first circular piece (S1) by suction, and in order to position the second circular piece (S2) on the second support (13) of the plate (1), so that the second support (13) can retain the second circular piece (S2) by suction (see for example figures from 4A to 4E).
The second folding and heat-forming work station (P2)is situated at a second angular position (Z2) wherein the plate (1) of the first carousel (G1), with the first circular piece (S1) and the second circular piece (S2) being retained by suction by the first support (11) and the second support (13), is positioned following an angular rotation of the first carousel (G1) (FIG. 5G).
The second folding and heat-forming work station (P2) comprises first folding and heat-welding means (4) (described in detail in the following) which are configured and activatable in synchrony with the lowering of the plate (17) with respect to the cylindrical housing (15) of the first support (11) towards a relative lowered position, so as to push the internal circular portion of the first circular piece (S1) into the cylindrical housing (15) so as to fold an external circular portion with respect to the internal circular portion and form a hollow body (C) having a circular base (CB), defined by the internal circular portion, and a lateral wall (CL) defined by the external circular portion folded with respect to the internal circular portion (see figures from 5B to 50).
The third dosing work station (P3) is situated at a third angular position (Z3) wherein the plate (1) of the first carousel (G1), with the hollow body (C) in the cylindrical housing (15) of the first support (11) filled with the product (P) for preparation of a beverage and the second circular piece (S2) retained by suction by the second support (13), is positioned following an angular rotation of the first carousel (G1) (FIG. 6A).
The third dosing work station (P3) comprises dosing means (5) which are configured for dosing a product (P) for preparation of a beverage in the hollow body (C) so as to fill a part of the volume of the hollow body (C) in such a way that an upper portion (S) of the lateral wall (CL) of the hollow body (C) is free and not occupied by the product (P).
For example, in particular, in this third dosing work station (P3), the dosing means (5) can be in a fixed position, while the plate (17) can be movable upwards, with respect to the cylindrical housing (15) of the first support (11) in which the hollow body (C) is positioned, to raise an upper part of the hollow body (C) beyond the cylindrical housing (15) and to position it at the dosing means (5), to facilitate the filling and dosing operations of the hollow body with a relative product for preparation of a beverage (see FIGS. 6B, and 6D).
The dosing means (5) can be configured in such a way as to be able to receive and dose various types of products for preparation of beverages, such as products in powder, granular, lyophilised or ground products, or in the form of chopped herbs.
For example, the dosing means (5) can be coupled to infeeding and dispensing products (not illustrated) for preparation of a beverage by infusion configured so as to be able to mix different types of herbs with one another, also following personal requests by each single user desiring a particular combination or mix of herbs for preparing a relative herbal tea or infusion.
The fourth folding and closing work station (P4) is situated at a fourth angular position (Z4) wherein the plate (1) of the first carousel (G1), with the hollow body (C) in the cylindrical housing (15) of the first support (11) filled with the product (P) for preparation of a beverage and the second circular piece (S2) retained by suction by the second support (13), is positioned following an angular rotation of the first carousel (G1).
The fourth folding and closing work station (P4) comprises second folding means (6) which are configured and activatable so as to be able to fold the upper portion (S) of the lateral wall (CL) of the hollow body (C) with respect to the lateral wall (CL) by means of pleating, to form a pleated crown (PS) above the product (P) contained in the hollow body (C) (see for example FIGS. 8A, 8B, 8D, 8G).
The fourth folding and closing work station (P4) further comprises gripping and welding means (7) which are configured to grip the second circular piece (S2) from the second support (13) and to position the second circular piece (S2) above the pleated crown (PS), carrying out a welding to form a closing cover (CC) and close the hollow body (C) in such a way as to obtain a pod (D) containing the product (P) for product (P) for preparation of a beverage (see for example FIGS. 8C, 8E, 8F and 8H).
A preferred embodiment of the second folding means (6) will be described in greater detail in the following part of the description.
The fifth collecting work station (P5) is situated at the second collecting position (C2), wherein the second feeder group (A2) positions the third circular piece (S3) and the fourth circular piece (S4) and at the first angular position (U1) wherein the plate (2) of the second series of plates (2) is positioned by the second carousel (G2), with the first half-shell (21) and the second half-shell (23) in the relative splayed position (D1).
The fifth collecting work station (P5), comprises second collecting means (8) io configured and activatable to collect the third circular piece (S3) and the fourth circular piece (S4) from the second feeder group (A2) and to position the third circular piece (S3) in the first half-shell (21), pushing the third circular piece (S3) into the first half-shell (21) so that the third circular piece (S3) adheres to the walls of the first half-shell (21) and is retained by suction by the first half-shell (21), forming a first valve-shaped element (25), and to position the fourth circular piece (S4) in the second half-shell (23), pushing the fourth circular piece (S4) into the second half-shell (23) so that the fourth circular piece (S4) adheres to the walls of the second half-shell (23) and is retained by suction by the second half-shell (23), forming a second valve-shaped element (26) (see for example figures from 10B to 10E).
The sixth heat-forming work station (P6) is situated at a second angular position (U2) wherein the plate (2) of the second carousel (G2), with the first valve-shaped element (25) retained by suction in the first half-shell (21) and with the second valve-shaped element (26), retained by suction in the second half-shell (23), is positioned following an angular rotation of the second carousel (G2) (FIG. 11A).
The sixth heat-forming work station (P6) comprises heat-forming means (9) (for example heated punches) which are configured and activatable to insert in the first half-shell (21) and the second half-shell (23) and go into contact with the first valve-shaped element (25) and the second valve-shaped element (26) (FIG. 11B).
The heat-forming means (9) are conformed so as to heat-form the first valve-shaped element (25) so that the first valve-shaped element (25) comprises an annular peripheral portion (27) and a first seat (28) such as to be able to accommodate a lower part of the pod (D) formed in the fourth folding and closing io work station (P4) on the plate (1) of the first carousel (G1), and so as to heat-form the second valve-shaped element (26) so that the second valve-shaped element (26) comprises an annular peripheral portion (29) and a second seat (30) such as to be able to accommodate the upper part of the pod (D) formed in the fourth folding and closing work station (P4) on the plate (1) of the first carousel (G1). Advantageously, with the apparatus (100) of the invention, the third circular piece
(S3) made of Ecoralene and the fourth circular piece (S4) made of Ecoralene, in the fifth work station (P5), are both positioned by means of the second collecting means (8), with the high-barrier outer film resting on the two half-shells (21, 23). In this way, the heat-forming operation, by means of the heat-forming means (9), zo in the sixth work station (P6), takes place, for both, at the inner film, so that the third piece and the fourth piece can be subjected to the same stresses and can undergo a same corresponding deformation, which leads to the formation of the two valve-shaped elements having a same shape.
The seventh collecting and transferring work station (P7) of the pod (D), is situated at a fifth angular position (Z5) in which the plate (1) of the first carousel (G1), with the pod (D) containing the product (P) for preparation of a beverage formed in the fourth folding and closing work station (P4), is positioned following an angular rotation of the first carousel (G1) and at a third angular position (U3) in which the plate (2) of the second carousel (G2), with the first valve-shaped element (25) heat-formed and retained by suction in the first half-shell (21) and the second valve-shaped element (26), heat-formed and retained by suction in the second half-shell (23), is positioned following an angular rotation of the second carousel (G2) so that it is opposite the plate (1) of the first carousel (G1) (FIG. 12A).
The seventh collecting and transferring work station (P7) comprises collecting and transfer means (10) that are configured and activatable to collect the pod (D) and transfer and position the pod (D) in the first seat (28) of the first valve-shaped element (25) so that a lower part of the pod (D) is accommodated in the first seat (28) (figures from 12B to 12D).
For example, the collecting and transfer means (10) can comprise a suction gripping element (101) conformed in such a way as to have a seat profiled complementarily to an upper portion of the pod and provided with holes (102) that are activatable in suction, to grip the pod (D) by aspiration. To facilitate the grip of the pod (D), the plate (17) present in the cylindrical housing (15) of the first support (11) can be raised into a raised position with respect to the zo cylindrical housing (15) so as to raise the pod beyond the first support (11) (FIG. 12B).
Guide means (103) are present to guide the movement of the gripping element (101) above the first half-shell (21) of the plate (2) positioned at the second carousel (G2) in the relative third angular position (U3).
The second half-shell (23) is thus subsequently activated into the superposed position (D2), so as to superpose on the first half-shell (21), and position the second valve-shaped element (26), retained thereby by suction, above the first valve-shaped element (25) and with an upper part of the pod (D) being accommodated in the second seat (30) of the second valve-shaped element (26), and so that the annular peripheral portion (29) of the second valve-shaped element (26) superposes on the annular peripheral portion (27) of the first valve-shaped element (25).
The eighth heat-welding and sealing station (P8) is situated at a fourth angular position (U4) in which the plate (2) of the second carousel (G2), with the two valve-shaped elements (25, 26), superposed on one another and internally containing the pod (D), is positioned following a further angular rotation of the second carousel (G2) (FIG. 15A).
The eighth heat-welding and sealing station (P8) comprises heat-forming and sealing means (19) which are configured and activatable, once the second half-shell (23) is returned into the splayed position (D1) with respect to the first half-shell (21), to heat-weld the first valve-shaped element (25) and the second valve-shaped element (26) at the relative annular peripheral portions (27, 29) superposed on one another in such a way as to seal the pod (D) internally thereof and obtain a sealed biodegradable packaging (F) of a product for preparation of a beverage (FIG. 15B).
Lastly, the ninth outfeed work station (P9) is situated at a fifth angular position (U5) wherein the plate (2) of the second carousel (G2), with the biodegradable packaging (F) sealed, obtained in the eighth heat-welding and sealing work station (P8), is positioned following a further angular rotation of the second carousel (G2) (FIG. 16A).
The ninth outfeed work station (P9) comprises second collecting and transfer means (32), which are configured and activatable to collect the biodegradable packaging (F) and transfer and position the biodegradable packaging (F) on the conveyor means (31) (see figures from 16B to 16E).
The apparatus (100) of the invention can be predisposed and configured in such a way as to also comprise other preferred work stations destined to carry out further particular machining during the steps of realising both the pod and the cladding thereof.
In a preferred aspect, the apparatus (100) can be configured in such a way as to comprise a compression work station (P10), which is associated to the first carousel (G1) between the third dosing work station (P3) and the fourth folding and closing work station (P4), at a first intermediate angular position (Z6) (position visible in FIG. 1 ), between the third angular position (Z3) and the fourth angular position (Z4), wherein the plate (1) of the first carousel (G1), with the hollow body (C) filled with the product (P) for preparation of a beverage, supported by the plate (17) formed in the cylindrical housing (15) of the first support (11) and the second circular piece (S2) retained by suction by the second support (13), is positioned following an angular rotation of the first carousel (G1).
The compression work station (P10) comprises compression means (33) (for example a vertically-movable pusher element) which are configured and activatable to be lowered towards the plate (1) and insert in the hollow body (C) and push downwards, rotating about a vertical axis of rotation, the product (P) for preparation of a beverage contained in the hollow body (C) so as to compress it, reducing the volume thereof (see FIGS. 7A, 7B).
In a further preferred aspect, the apparatus (100) can be configured in such a way as to comprise a compacting and sealing work station (P11), associated to the first carousel (G1) between the fourth folding and closing work station (P4) and the seventh collecting and transferring work station (P7), at a second intermediate angular position (Z7) (visible in FIG. 1 ), between the fourth angular position (Z4) and the fifth angular position (Z5), wherein the plate (1) of the first carousel (G1), with the pod (D) containing the product for preparation of a beverage supported by the plate (17) of the first support (11), is positioned following an angular rotation of the first carousel (G1).
The compacting and sealing work station (P11) comprises compacting and sealing means (34) which are configured and activatable to be lowered towards the plate (1), in synchrony with the raising of the plate (17) into the raised position to raise the pod (D) beyond the cylindrical housing (15) of the first support (11), so as to be able to abut the pod (D) and compact the pod (D), reducing the overall volume there, and seal it completely.
In a first embodiment, the compacting and sealing means (34) comprise a sonotrode (340) which is configured in such a way as to be vertically activatable and be lowered towards the plate (1) and abut the pod (D), raised by the plate (17) beyond the cylindrical housing (15) of the first support (11), in order to compact the pod (D), completely sealing it (see FIGS. 9A, and 9B).
On the basis of another possible embodiment, the compacting and sealing means (34) comprise a vertically-movable pusher element (341), provided with a welding cartridge (342) (see FIGS. 9C, and 9D).
In a further preferred aspect, the apparatus (100) can comprise a first cleaning station (P12), associated to the first carousel (G1), between the seventh collecting and transferring work station (P7) of the pod (D) and the first collecting work station (P1), at a third intermediate angular position (Z8) (visible in FIG. 1 ), between the fifth angular position (Z5) and the first angular position (Z1), wherein the plate (1) of the first carousel (G1) is positioned after the pod (D) has been transferred onto the plate (2) of the second carousel (G2), and so that any eventual working waste can be removed and the first support (11), with the relative suction holes (12), the plate (17), with the relative suction holes (18) and the second support (13), with the relative suction holes (14), can be subjected to cleaning operations (FIG. 17 ).
In a further particularly preferred aspect, the apparatus (100) can be configured in such a way as to comprise a first pre-welding station (P13), associated to the second carousel (G2), between the seventh collecting and transferring work station (P7) and the eighth heat-welding and sealing work station (P8), at a first intermediate angular position (U6), (visible in FIG. 1 and in FIG. 13A) between the third angular position (U3) and the fourth angular position (U4), wherein the plate (2) of the second carousel (G2), with the two half-shells (21, 23) in the superposed position (D2) thereof with the two valve-shaped elements (25, 26), superposed on one another and internally containing the pod (D), is positioned following an angular rotation of the second carousel (G2).
The first pre-welding station (P13) comprises spot welding means (35) which are conformed in such a way as to comprise a movable element (350) (FIG. 13C), vertically-movable, which is provided with heated contact rods (351). The movable element (350) is configured and activatable to be vertically lowered towards the second half-shell (23), closed above the first half-shell (21), so that the heated contact rods (351) pass through through-holes (230) realised in the second half-shell (23) (FIG. 13D) so that the heated contact rods (351) reach into contact with the superposed annular portions (27, 29) of the valve-shaped elements (25, 26), in order to carry out the reciprocal welding in the contact points with the heated contact rods (351) (FIG. 13B).
This is particularly advantageous, as the second half-shell (23), once the suction action has been deactivated, can be safely returned into the splayed position (D1) from the first half-shell, with the certainty that the second valve-shaped element (26) will be correctly positioned above the first valve-shaped element (25) (still retained by suction by the first half-shell (21)) due to the presence of the weld spots between the relative annular superposed portions.
On the basis of a further particularly preferred aspect, for the purpose of obtaining a final package that is perfectly closed and sealed, the apparatus (100) can be configured in such a way as to comprise a second pre-welding station (P14), associated to the second carousel (G2), between the first pre-welding station work station (P13) and the eighth heat-welding and sealing work station (P8), at a second intermediate angular position (U7) (visible in FIG. 1 ), between the first intermediate angular position (U6) and the fourth angular position (U4), wherein the plate (2) of the second carousel (G2), with the two half-shells (21, 23) in the superposed position (D2) thereof and the two valve-shaped elements (25, 26), superposed on one another and internally containing the pod (D) and pre-welded to one another with weld spots at the relative annular portions (27, 29), is positioned following an angular rotation of the second carousel (G2). The second pre-welding station (P14) comprises a ring heat welding element (36) which is configured and activatable in order to be vertically translatable and lowerable towards the plate (2), once the second half-shell (23), with the suction action deactivated to release the second valve-shaped element (26), is moved into the splayed position (D1) with respect to the first half-shell (21), in order to abut the superposed annular portions (27, 29) of the two valve-shaped elements (25, 26) and carry out a ring welding thereof (figures from 14E to 14H).
In a preferred embodiment, the ring welding using the ring heat welding element (36) can be carried out in a controlled-atmosphere environment (G) (see for example figures from 14A to 14D).
In this case, the ring welding is carried out following the partial raising of the second half-shell (23) from the first half-shell (21) so as to expose the mutually-superposed two valve-shaped elements (25, 26), and pre-welded to one another with weld spots at the relative annular portions (27, 29), and internally containing the pod (D), to the controlled-atmosphere environment, and subsequently to an aspiration of oxygen from the controlled-atmosphere environment (G), in order to remove the residual oxygen inside the two valve-shaped elements (25, 26), and to an injection of inert gas (for example nitrogen) into the controlled-atmosphere environment (G), so that the inert gas inserts between the two valve-shaped elements (25, 26).
In this case, for these operations, the second pre-welding station (P14) comprises a bell element (37) configured and activatable in vertical translation so as to be lowered and positioned on the plate (2) of the second carousel (G2) so as to create a controlled-atmosphere environment (G) which contains the two half-shells (21, 23) closed in the superposed position (D2) thereof, and containing the two valve-shaped elements (25, 26), superposed on one another, pre-welded to one another with weld spots in the relative annular portions (27, 29), and internally containing the pod (D) (FIG. 14A).
In particular, the bell element (37) is provided with a first conduit (370), connected to an oxygen aspiration source, and communicating with the inside of the bell element (37), and a second conduit (371), connected to an inert gas injection source and communicating with the inside of the bell element (37), the ring heat welding element (36) being mounted on the bell element (37) vertically movable with respect to the bell element (37) so as to be lowered towards the plate (2), against the recall action of elastic means (360).
In this way, the second half-shell (23) can be partly raised with respect to the first half-shell (21), exposing the two valve-shaped elements in the parts of the relative annular superposed portions between the reciprocal weld spots, to the controlled-atmosphere environment in the bell element, thus enabling aspiration of oxygen internally thereof and injection of inert gas (FIG. 14C).
In a further preferred aspect, the apparatus (100) can be configured in such a way as to comprise detecting means (38) (for example optical detecting means or photocells), which are predisposed so as to detect the height and integrity of the biodegradable packaging (F) borne by the plate (2) of the second series of plates (2) of the second carousel (G2) during the passage of the plate (2) between the eighth heat-welding and sealing work station (P8) and the ninth outfeed work station (P9) (see for example FIG. 15C). In this way, the apparatus (100) will have available information on the presence of zo any packages (F*) that are defective or have a different height with respect to a predetermined height, so as to keep the second collecting and transfer means (32) inactive in the ninth outfeed work station (P), so that the defective packages (F*) remain on the second plate (2).
In those cases, the apparatus (100) will also comprise a second cleaning station (P15), which is associated to the second carousel (G2), between the ninth outfeed work station (P9) and the fifth collecting work station (P5), at a third intermediate angular position (U8) (visible in FIG. 1 ), between the fifth angular position (U5) and the first angular position (U1), wherein the plate (2) of the second carousel (G2) is positioned following an angular rotation of the second carousel (2).
In this second cleaning station (P15) (FIG. 18 ) the possibly defective packages (F*) which have remained on the second plate (2) can be removed (for example by means of the use of suitable suction gripping means, not illustrated) and the first half-shell (21), with the relative suction holes (22), and the second half-shell (23), with the relative suction holes (24), can be subjected to cleaning operations. The following is a description of the constructional peculiarities of some significant components in some of the work stations described in general terms in the foregoing.
According to the preferred embodiment illustrated in figures from 4A to 4E, the collecting means (3) of the first collecting work station (P1) comprise a suction plate (300) mounted by means of relative rods (302) on a support frame (301) that is rotatable about a horizontal axis of rotation. The rods (302) are mounted translatably with respect to the frame (301) in order to enable the suction plate (300) to be translated distancingly or nearingly from or to the frame (301).
In this way, the suction plate (300) can be positioned in a vertical configuration (FIGS. 4A, and 4B) so as to be able to grip by suction the first circular piece (S1) and the second circular piece (S2) cut in the first sheet (F1), made of polylactic acid and arranged vertically in the first collecting position (P1) by the first feeder group (A1).
The suction plate (300), once the first circular piece and the second circular piece have been collected, following the rotation of the frame (301) about the horizontal axis of rotation, can thus be positioned in a horizontal configuration (FIGS. 4D, and 4E), and then, by means of the translation of the rods (302) with respect to the frame (301), can be lowered towards the first support (11) and the second support (13) of the first plate (1), positioned by the first carousel (G1) in the first angular position (Z1), in order to release thereon the first and the second circular piece.
In particular, a significant aspect of the apparatus (100) of the invention is constituted by the special conformation of the first support (11) of the first plate (1) of the first carousel (G1), used for folding the first circular piece made of polylactic acid and the formation of the hollow body of the pod.
The first support (11) is conformed (such as for example visible in FIGS. 4, 4A, 5A, 5D) so as to comprise radial seats (16) arranged radially with respect to the cylindrical housing (15) and is mounted on the plate (1) in such a way as to be activatable in rotation about a vertical axis of rotation that is axial to the cylindrical housing (15).
This special shape of the first support (11) is strictly correlated to the particular shape and structure of the first folding and heat-welding means (4) of the second folding and heat-forming work station (P2), which enable realising a particular folding of the first circular piece (S1) and obtaining a hollow body (C) with a reinforced lateral wall.
The first folding and heat-welding means (4) (see in detail, for example, figures from 5A to 5E) are configured and structured in such a way as to comprise: a first pusher element (41) and a second pusher element (42) which cooperate with one another for the folding of the first circular piece (S1).
The first pusher element (41), heatable by means of a resistance, has a cylindrical shape and is activatable in vertical translation to be lowered towards the plate (1) in order to abut the internal circular portion of the first circular piece (S1) and push it into the cylindrical housing (15) of the first support (11), so that the external circular portion of the first circular piece on (S1), external with respect to the cylindrical housing (15) and to the internal circular portion, is folded with respect to the internal circular portion forming the hollow body (C) with the base wall (CB) and the lateral wall (CL).
The second pusher element (42) is conformed and configured in such a way as to comprise a series of radial paddles (43), activatable in vertical translation, so as to be lowered in synchrony with the first pusher element (41) towards the plate (1), so that the series of radial paddles (43) abut radial portions of the external circular portion of the first circular piece (S1) and push the radial portions into the radial seats (16) of the cylindrical housing (15).
In this way, during the folding of the first circular piece (S1) in the cylindrical housing (15), radial tabs (161) are formed, in the radial seats (16) of the cylindrical housing (15), which project externally of the lateral wall (CL) of the hollow body (C) (see for example FIG. 5F which illustrates an initial step of the folding of the first circular piece (S1) (and FIG. 5I which illustrates the shape obtained for the hollow body (C) at the end of the folding step of the first circular piece (S1)).
The second pusher element (42) is thus activatable in raising vertical translation with respect to the radial seats (16) of the cylindrical housing (15) (see FIG. 5M) so as to disengage from the cylindrical housing (15) so that the first support (11), with the first pusher element (41) maintained in the cylindrical housing (15) in contact with the hollow body (C) and heated by the resistance, can be activated in rotation about the vertical axis of rotation that is axial with respect to the cylindrical housing (15) so as to fold the radial tabs (161) projecting externally from the lateral wall (CL) of the hollow body (C) and to heat-form the hollow body (see for example FIG. 5N in which the rotation of the first support (1) is illustrated, with the first pusher element omitted for greater clarity of view). Lastly, the first pusher element (41) is activatable in vertical translation in order to be distanced from the cylindrical housing (15) and in order to disengage from the hollow body (C).
FIG. 5O illustrates the final shape obtained for the hollow body at the second folding and heat-forming work station (P2).
A further special and advantageous aspect of the apparatus (100) of the invention relates to the special conformation and structure of the second folding means (6) in the fourth folding and closing work station (P4) of the pod (D).
The second folding means (6) are in fact configured and structured in such a way as to comprise a series of blades (61) hinged to one another and reciprocally arranged in such a way as to form between them a central opening (62) (see for example FIG. 8A), having a greater diameter than the diameter of the hollow body (C) obtained in the second folding and heat-forming work station (P2); the blades (61) are activatable in reciprocal rotation with respect to one another in order to be able to narrow the central opening (62).
In this way, when the plate (1) is positioned by the first carousel (G1) in the fourth angular position (Z4) at the fourth folding and closing work station (P4) with the hollow body (C) formed in the cylindrical housing (15) of the first support (11) and containing the product (P) for preparation of a beverage, the plate (17) is activatable in vertical translation in order to be raised with respect to the cylindrical housing (15) and to raise and position the hollow body (C) so that the upper portion (S) of the lateral wall (CL) of the hollow body (C) not occupied and free of the product (P) inserts in the central opening (62) present between the blades (61) (see FIG. 8B).
The blades (61) are then activatable in rotation with respect to one another, about the relative hinge points, so as to narrow the central opening (62) (FIG. 8D) in order to abut the upper portion (S) and fold the upper portion (S) with respect to the lateral wall (CL) of the hollow body (C), carrying out a folding with pleating and forming a pleated crown (PS) above the product (P) contained in the hollow body (C) (see in particular FIG. 8G).
Owing to the presence of the pleated crown (PS), formed as described in the foregoing, it will be easier to position the second circular piece (S2) to close the hollow body (C), as it can position the second circular piece resting on the pleated crown (PS) and forming the closing cover (CC) of the hollow body (C) to form the pod (D).
Further, in this way, for the gripping and welding means (7) it will be easier to be able to position and heat-weld the second circular piece (S2) on the pleated crown (PS).
For example, the gripping and welding means (7) can comprise a suction gripping member (700), having a circular suction gripping surface, with a suction hole arranged centrally, and provided, peripherally, with projecting teeth (701) that are heatable by means of a cartridge so as to carry out heat-welding spots between the second circular piece (S2) and the pleated crown (PS), once the second circular piece (S2) is positioned on the pleated crown (PS).
The hollow body (C) containing the product (P) for preparation of a beverage is thus perfectly closed by means of a correct and centred positioning of the closing cover (CC).
In the preferred embodiment illustrated in the figures, the second collecting means (8) in the fifth collecting work station (P5) (see figures from 10B to 10E) comprise a second suction plate (80) on which are mounted, translatably with respect to the second suction plate (80), a pair of pusher elements (81, 82).
The second suction plate (80) is movable from a first position, at the second collecting position (C2) wherein the second feeder group (A2) positions the third circular piece (S3) and the fourth circular piece (S4), wherein the second suction plate (80) collects, by suction, the third circular piece (S3) and the fourth circular piece (S4) (FIG. 10B), at a second position above the first half-shell (21) and the second half-shell (23) of the plate (2) positioned by the second carousel (G2) in the first angular position (U1), so as to position the third circular piece (S3) above the first half-shell (21) and the fourth circular piece (S4) above the second half-shell (23) (FIG. 10D).
The pair of pusher elements (81, 82), following the deactivation of the aspiration of the second suction plate (80), are then translatable with respect to the second suction plate (80), to push the third circular piece (S3) into the first half-shell (21), so that the third circular piece (S3) adheres to the walls of the first half-shell (21) and is retained by suction by the first half-shell (21), forming a first valve-shaped element (25) by extrusion, and to push the fourth circular piece (S4) into the second half-shell (23) so that the fourth circular piece (S4) adheres to the walls of the second half-shell (23) and is retained by suction by the second half-shell (23), forming a second valve-shaped element (26) by extrusion. Owing to the presence of the pair of pusher elements (81, 82), which push the third circular piece and the fourth circular piece in the relative half-shells, it is possible to mechanically deform the two circular pieces, giving them a first shape, being a valve shape, which will then be stabilised by heat-forming in the following heat-welding sixth work station (P6).
In the preferred embodiment illustrated in the figures, the second collecting and transfer means (32) in the ninth outfeed work station (P9) comprise a suction gripping member (320) movable from a first position, wherein the suction gripping member (320) is positionable above the plate (2), positioned by the second carousel (G2) in the fifth angular position (U5), at the first half-shell (21) which bears the biodegradable packaging (F), so as to collect, by suction, the biodegradable packaging (F), at a second position, wherein it is above the conveyor means (31), in order to release the biodegradable packaging (F) above the conveyor means (31) (see for example FIGS. 16A and 16B). In particular, the suction gripping member (320) is provided with a circular cutting member (321) (see the detail in larger scale of FIG. 16C) dimensioned and configured so as to perform a circular cut on the annular peripheral portions (27, 29) of the two valve-shaped elements (25, 26) heat-welded and sealed to one another in such a way as to define a final shape for the biodegradable packaging (F) that is exactly circular.
The conveyor means (31), on which the packaging (F) is positioned by the suction gripping member (320) can be realised in such a way as to comprise a load cell (35) configured and predisposed to detect the weight of the biodegradable packaging (F) (see for example FIG. 16D), and a trapdoor (36) raisable to cause the packaging (F) to fall towards a reject station in a case in which there is a non-conforming weight with respect to an ideal weight (FIG. 16E). In the possible preferred embodiment of the apparatus (100) of the invention and illustrated in the tables of drawings, the first feeder group (A1) of the first sheet (F1) made of polylactic acid, and the second feeder group (A2) of the second sheet (F2) made of Ecoralene can be structured and realised in the following way. The first feeder group (A1) (see figures from 2A to 2H) comprises first unwinding means (70), for unwinding a first film (M1) of biodegradable material (polylactic acid) from the first reel (B1), first positioning means (71), for positioning an advanced portion of the first film (M1) into a vertical position, and a first knife (72) to cut the advanced portion of the first film (M1) and obtain the first sheet (F1). The first feeder group (A1) is also structured in such a way as to comprise at least io a first suction plate (73) borne by a first frame (74) which is activatable in rotation about a vertical axis and configured to position the first suction plate (73) in four angular positions that are consecutive to one another.
In particular: in a first angular position, the first suction plate (73) is positioned at the first sheet (F1) cut from the first film (M1) so that the first suction plate (73) can retain the first sheet (F1) by suction, wherein, in a second angular position, the first suction plate (73) is positioned at the first cutting means (T1), activatable to cut the first circular piece (S1) and the second circular piece (S2) from the first sheet (F1), wherein, in a third angular position, the first suction plate (73) is positioned, with the first sheet (F1) in which the first circular piece (S1) and the second circular piece (S2) have been cut and retained by suction, in the first collecting position (C1) of the first circular piece (S1) and the second circular piece (S2), and wherein, in a fourth angular position, the first suction plate (73) is positioned at first waste recovery means (75) having the function of removing the waste residues of the first sheet (F1) from the first plate (73) after the first circular piece (S1) and the second circular piece (S2) have been collected from the first collecting position (C1) and positioned on the first support (11) and on the second support (13) of the plate (1) of the first carousel (G1).
The first cutting means (T1) of the first feeder group (A1) comprise first cylindrical cutting elements (T10, T11) and wherein the first suction plate (73) comprises circular grooves (730, 731) having a shape corresponding to the first cylindrical cutting elements (T10, T11) so as to be able to accommodate internally thereof an end part of the first cylindrical cutting elements (T10, T11) and enable the first cylindrical cutting elements (T10, T11) to cut the first circular piece (S1) and the second circular piece (S2) in the first sheet (F1) retained by suction by the first suction plate (73).
In turn, the second feeder group (A2) (see figures from 3A to 3H) comprises second unwinding means (90), for unwinding the second film (M2) of biodegradable material from the second reel (B2), second positioning means (91), for positioning an advanced portion of the second film (M2) in a vertical position, and a second knife (92) to cut the advanced portion of the second film (M2) and obtain the second sheet (F2).
The second feeder group (A2) is also structured in such a way as to comprise a second suction plate (93) borne by a second frame (94) which is activatable in rotation about a vertical axis and configured to position the second suction plate (93) in four angular positions, consecutive to one another.
In particular: in a first angular position, the second suction plate (93) is positioned at the second sheet (F2) cut from the second film (M2) so that the second suction plate (93) can retain the second sheet (F2) by suction, wherein, in a second angular position, the second suction plate (93) is positioned at the second cutting means (T2), activatable to cut the third circular piece (S3) and the fourth circular piece (S4) from the second sheet (F2), wherein, in a third angular position, the second suction plate (93) is positioned, with the second sheet (F2) in which the third circular piece (S3) and the fourth circular piece (S4) have been cut and retained by suction, in the second collecting position (C2) of the third circular piece (S3) and the fourth circular piece (S4), and wherein, in a fourth angular position, the second suction plate (93) is at second waste recovery means (95) having the function of removing the waste residues of the second sheet (F2) from the second suction plate (93) after the third circular piece (S3) and the fourth circular piece (S4) have been collected from the second collecting position (C2) and positioned on the first half-shell (21) and on the second half-shell (23) of the plate (2) of the second carousel (G2).
The second cutting means (T2) of the second feeder group (A2) comprise second cylindrical cutting elements (T20, T21) and wherein the second suction plate (93) comprises corresponding circular grooves (930, 931) having a shape corresponding to the second cylindrical cutting elements (T20, T21) so as to be able to accommodate internally thereof an end part of the second cylindrical cutting elements (T20, T21) and enable the second cylindrical cutting elements (T20, T21) to cut the third circular piece (S3) and the fourth circular piece (S4) in the second sheet (F2) retained by suction by the second suction plate (93).
In fact, an especially advantageous aspect is constituted by the fact that the plates (1) of the first series of plates (1) are removably mounted on the first carousel (G1), and the plates (2) of the second series of plates (2) are removably mounted on the second carousel (G2).
In this way, the apparatus (100) of the invention can be predisposed according to various configurations and installations, also according to the type of use that is to be made thereof, such as for example the just-in-time preparation of single packages requested directly by the final customer, or the realising of industrial productions on a broader scale.
For example, in a first and basic version of installation, utilisable directly in commercial concerns, such as for example pharmacies, each plate of the first series of plates can be realised in such a way as to comprise a single first support and a single second support.
In this way, the first carousel will be predisposed to realise one pod at a time; in this regard the various work stations associated to the first carousel will be configured and predisposed so as to have the relative operating components destined to carry out the operations of realising one pod at a time (as described in the foregoing).
Correspondingly, each plate of the second series of plates can be realised in such a way as to comprise a single first half-shell and a single second half-shell, and the second carousel will be predisposed to realise a cladding for the pod obtained from the first carousel to obtain one final biodegradable packaging at a time. For this purpose, the work stations associated to the second carousel will also be configured and predisposed so as to have the relative operating components destined to carry out the operations of cladding a pod to obtain one relative final package at a time (as described in the foregoing).
An apparatus as described above will be overall modest in size and this will mean it can be use directly within a commercial concern, to which customers can go directly and directly request a personalised realising of biodegradable packagings containing a product for preparation of a beverage, in particular herbal teas or infusions that can be realised starting from the combination and mixing of particular herbs which can be packaged in the pod made of polylactic acid and clad with Ecoralene.
In the case of installations including use in industrial settings, first plates can be mounted on the first carousel which comprise 4 first supports and 4 second supports (as illustrated in the figures), which enables four pods to be made at a time, while correspondingly, second plates can be mounted on the second carousel, which comprise 4 first half-shells and 4 second half-shells, so as to be able to clad four pods at a time and obtain four biodegradable packagings at a time.
Clearly, the various work stations associated to the two carousels will be configured in such a way as to have a corresponding number of operating components in order to carry out the above-described operations at each pause of the plates, and the reels of polylactic acid and Ecoralene will have the corresponding dimensions which enable cutting relative sheets of suitable dimensions for cutting therefrom 4 first and second circular pieces of polylactic acid, as well as 4 third and fourth circular pieces of Ecoralene.
To increase the number of final packages obtainable in the time unit (for example per minute) it is possible also to mount, on the two carousels, first plates with 8 or 16 first supports and second supports, and 8 or 16 first half-shells and second half-shells, and consequently to set up the various work stations associated to the two carousels with the corresponding number of operating components and the two feeder groups with reels of adequate dimensions to obtain 8 or 16 first and second circular pieces made of PLA, and also 8 or 16 third and fourth circular pieces made of Ecoralene.
In this regard, the two carousels can be predisposed in such a way as to be able to adjust and vary the reciprocal position, enabling plates of different dimensions to be fitted.

Claims

1. An apparatus for realising a biodegradable packaging of a product for preparation of beverages, comprising:

a first feeder group, for unwinding a first film of biodegradable material, in particular a first film made of polylactic acid, from a first reel of biodegradable material and for cutting the first film so as to obtain a first sheet and comprising first cutting means configured and activatable to cut the first sheet so as to obtain at least a first circular piece and at least a second circular piece, wherein the at least a first circular piece has a greater diameter than the at least a second circular piece and has dimensions that are such as to enable folding thereof in order to form a hollow body having a circular base and a lateral wall, the first feeder group being configured in such a way as to position the first circular piece and the second circular piece at a first collecting position;

a first rotary carousel, configured in such a way as to be activatable in rotation about a first vertical axis of rotation, comprising a first series of plates angularly arranged with respect to one another about the first vertical axis of rotation, wherein each plate comprises a first support, comprising suction holes, configured to receive and retain, by suction, the first circular piece, and a second support, comprising suction holes, configured to receive and retain, by suction, the second circular piece, the first support being conformed in such a way as to centrally comprise a cylindrical housing having a diameter smaller than the diameter of the first circular piece, and so as to comprise a plate provided with suction holes, predisposed internally of the cylindrical housing so as to be translatable vertically with respect to the cylindrical housing, between a raised position and a lowered position, wherein the first carousel is arranged with respect to the first feeder group and is activatable in angular rotation about the first vertical axis of rotation according to successive angular rotations so that, at each angular rotation, a plate at a time of the first series of plates is positioned in a first angular position situated at the first collecting position wherein the first feeder group positions the first circular piece and the second circular piece, so that the first circular piece can be collected from the first feeder group and positioned on the first support, with the plate in a raised position at the upper end of the cylindrical housing, which retain the first circular piece by suction, and the second circular piece can be collected from the first feeder group and positioned on the second support which retains it by suction, the first carousel being activatable in angular rotation about the first vertical axis of rotation in successive angular rotations so as to position, at each angular rotation, the plate of the first carousel with the first circular piece and the second circular piece paused in successive angular positions at relative work stations which are configured in such a way that at which, in succession:

an internal circular portion of the first circular piece is pushed into the cylindrical housing, together with the lowering of the plate, so as to fold an external circular portion with respect to the internal circular portion and form a hollow body having a circular base, defined by the internal circular portion, and a lateral wall defined by the external circular portion folded with respect to the internal circular portion;

a product for preparing a beverage is inserted and dosed in the hollow body so as to fill a part of the volume of the hollow body in such a way that an upper portion of the lateral wall of the hollow body is free and not occupied by the product;

the upper portion of the lateral wall of the hollow body is bent by means of pleating with respect to the lateral wall of the hollow body to form a pleated crown above the product contained in the hollow body and the second circular piece is collected from the second support and positioned above the pleated crown, carrying out a welding, to form a closing cover and close the hollow body in such a way as to obtain a pod containing the product for preparation of a beverage;

the apparatus further comprising:

a second feeder group, for unwinding a second film of biodegradable material, in particular a second film made of Ecoralene, from a second reel of biodegradable material and for cutting the second film so as to obtain a second sheet and comprising second cutting means configured and activatable to cut the second sheet so as to obtain at least a third circular piece and at least a fourth circular piece, wherein the at least third circular piece and the at least fourth circular piece have a diameter that is substantially identical to one another and that is of greater dimensions than the diameter of the pod obtained on the plate of the first series of plates of the first carousel, the second feeder group being configured in such a way as to position the third circular piece and the fourth circular piece at a second collecting position;

a second rotary carousel, arranged flanked to the first carousel and configured in such a way as to be activatable in rotation about a second vertical axis of rotation, comprising a second series of plates angularly arranged with respect to one another about the second vertical axis of rotation, wherein each plate of the second series of plates of the second carousel comprises a first half-shell, provided with suction holes, and a second half-shell, provided with suction holes, hinged to one another and configured in such a way as to be activatable between a splayed position, in which they are splayed with respect to one another, and a superposed position, wherein they are superposed on one another and closed to one another, the first half-shell and the second half-shell having dimensions such as to be able to receive internally thereof respectively the third circular piece and the fourth circular piece, wherein the second carousel is arranged with respect to the second feeder group and is activatable in angular rotation about the second vertical axis of rotation according to successive angular rotations so that, at each angular rotation, one plate at a time of the second series of plates, with the first half-shell and the second half-shell in the splayed position, is positioned in a first angular position situated at the second collecting position wherein the second feeder group positions the third circular piece and the fourth circular piece, so that the third circular piece can be collected from the second feeder group and then pushed and positioned in the first half-shell to form a first valve-shaped element, which is retained by suction in the first half-shell, and the fourth circular piece can be collected from the second feeder group and then pushed and positioned in the second half-shell to form a second valve-shaped element, which is retained by suction in the second half-shell, the second carousel being thus activatable in rotation about the second vertical axis of rotation with an angular rotation such as to position the plate, with the first valve-shaped element retained by suction in the first half-shell and the second valve-shaped element retained by suction in the second half-shell, in a successive angular position at a work station in which the first valve-shaped element is heat-formed internally of the first half-shell, into an annular peripheral portion and a first seat such as to be able to accommodate a lower part of the pod formed on the plate of the first carousel, and the second valve-shaped element is heat-formed internally of the second half-shell, into an annular peripheral portion and a second seat such as to be able to accommodate the upper part of the pod formed on the plate of the first carousel;

the first carousel, with the relative plate of the first series of plates which bears the pod, and the second carousel, with the relative plate of the second series of plates bearing the two heat-formed valve-shaped elements retained by suction by the two half-shells, being activatable in rotation according to relative angular rotations so as to position the plate, with the pod, and the plate, with the valve-shaped elements, in respective successive angular positions opposite one another, so that the pod can be collected and positioned in the first seat of the first valve-shaped element retained by aspiration by the first half-shell, with a lower part of the pod in the first seat, and the second half-shell can thus be activated into the superposed position, so as to superpose on the first half-shell, and position the second valve-shaped element, retained thereby by suction, above the first valve-shaped element and with an upper part of the pod being accommodated in the second seat of the second valve-shaped element, and so that the annular peripheral portion of the second valve-shaped element superposes on the annular peripheral portion of the first valve-shaped element,

wherein the second carousel is thus consequently activatable in angular rotation about the second vertical axis of rotation according to successive angular rotations so as to position, at each angular rotation, the plate of the second series of plates with the two half-shells in the superposed position, and the two valve-shaped elements, superposed on one another and internally containing the pod, in successive angular positions at relative work stations which are configured in such a way that at which, in succession:

the second half-shell, once the suction action has been deactivated so as to release the second valve-shaped element, is returned into the splayed position from the first half-shell, and the first valve-shaped element and the second valve-shaped element are heat-welded at the relative peripheral annular portions superposed on one another in such a way as to seal the pod internally thereof and obtain a sealed biodegradable packaging of a product for preparation of a beverage;

the sealed biodegradable packaging containing a product for preparation of a beverage is collected from the plate of the second series of plates of the second carousel and transferred onto a conveyor means.

2. The apparatus of claim 1, comprising:

a first collecting work station, at the first collecting position wherein the first feeder group positions the first circular piece and the second circular piece and at the first angular position wherein the plate of the first series of plates is positioned by the first carousel, comprising collecting means configured and activatable to collect the first circular piece and the second circular piece from the first feeder group and to position the first circular piece on the first support of the plate, so that the first circular piece is centred with respect to the cylindrical housing so that an internal circular portion of the first circular piece is at the cylindrical housing and resting on the plate, the plate being positioned in a raised position with respect to the cylindrical housing at the upper end of the cylindrical housing, and an external circular portion of the first circular piece is external of the cylindrical housing, and in such a way that the first support and the plate can retain the first circular piece by suction, and in order to position the second circular piece on the second support of the plate, so that the second support can retain the second circular piece by suction;

a second folding and heat-forming work station, at a second angular position wherein the plate of the first carousel, with the first circular piece and the second circular piece being retained by suction by the first support and the second support, is positioned following an angular rotation of the first carousel, comprising first folding and heat-welding means that are configured and activatable in synchrony with the lowering of the plate with respect to the cylindrical housing of the first support towards a relative lowered position, in order to push the internal circular portion of the first circular piece in the cylindrical housing in such a way as to fold the external circular portion with respect to the internal circular portion and to heat-form a hollow body having a circular base, defined by the internal circular portion, and a lateral wall defined by the external circular portion folded with respect to the internal circular portion,

a third dosing work station, at a third angular position wherein the plate of the first carousel, with the hollow body formed in the cylindrical housing of the first support and the second circular piece retained by suction by the second support, is positioned following an angular rotation of the first carousel, comprising dosing means which are configured for dosing a product for preparing a beverage in the hollow body so as to fill a part of the volume of the hollow body in such a way that an upper portion of the lateral wall of the hollow body is free and not occupied by the product;

a fourth folding and closing work station, at a fourth angular position wherein the plate of the first carousel, with the hollow body in the cylindrical housing of the first support filled with the product for preparing a beverage and the second circular piece retained by suction by the second support, is positioned following an angular rotation of the first carousel, comprising second folding means which are configured and activatable so as to be able to fold the upper portion of the lateral wall of the hollow body with respect to the lateral wall by means of pleating, to form a pleated crown above the product contained in the hollow body, and comprising gripping and welding means configured to grip the second circular piece from the second support and to position the second circular piece above the pleated crown, carrying out a welding to form a closing cover and close the hollow body in such a way as to obtain a pod containing the product for preparation of a beverage;

a fifth collecting work station, at the second collecting position wherein the second feeder group positions the third circular piece and the fourth circular piece and at the first angular position wherein the plate of the second series of plates is positioned by the second carousel, with the first half-shell and the second half-shell in the splayed position, comprising second collecting means configured and activatable to collect the third circular piece and the fourth circular piece from the second feeder group and to position the third circular piece in the first half-shell, pushing the third circular piece into the first half-shell so that the third circular piece adheres to the walls of the first half-shell and is retained by suction by the first half-shell, forming a first valve-shaped element, and to position the fourth circular piece in the second half-shell, pushing the fourth circular piece into the second half-shell so that the fourth circular piece adheres to the walls of the second half-shell and is retained by suction by the second half-shell, forming a second valve-shaped element;

a sixth heat-forming work station, at a second angular position wherein the plate of the second carousel, with the first valve-shaped element retained by suction in the first half-shell and with the second valve-shaped element, retained by suction in the second half-shell, is positioned following an angular rotation of the second carousel, comprising heat-forming means which are configured and activatable to insert in the first half-shell and the second half-shell and go into contact with the first valve-shaped element and the second valve-shaped element, the heat-forming means being conformed so as to heat-form the first valve-shaped element so that the first valve-shaped element comprises an annular peripheral portion and a first seat such as to be able to accommodate a lower part of the pod formed in the fourth folding and closing work station on the plate of the first carousel, and so as to heat-form the second valve-shaped element so that the second valve-shaped element comprises an annular peripheral portion and a second seat such as to be able to accommodate the upper part of the pod formed in the fourth folding and closing work station on the plate of the first carousel;

a seventh collecting and transferring work station of the pod, at a fifth angular position in which the plate of the first carousel, with the pod containing the product for the preparation of a beverage formed in the fourth folding and closing work station, is positioned following an angular rotation of the first carousel and at a third angular position in which the plate of the second carousel, with the first valve-shaped element heat-formed and retained by suction in the first half-shell and the second valve-shaped element, heat-formed and retained by suction in the second half-shell, is positioned following an angular rotation of the second carousel so that it is opposite the plate of the first carousel, comprising collecting and transfer means that are configured and activatable to collect the pod and transfer and position the pod in the first seat of the first valve-shaped element so that a lower part of the pod is accommodated in the first seat, and wherein the second half-shell is subsequently activated in the superposed position, so as to superpose on the first half-shell so as to position the second valve-shaped element, retained thereby by suction, above the first valve-shaped element, in such a way that an upper part of the pod is accommodated in the second seat of the second valve-shaped element and so that the annular peripheral portion of the second valve-shaped element superposes on the annular peripheral portion of the first valve-shaped element;

an eighth heat-welding and sealing station, at a fourth angular position in which the plate of the second carousel, with the two valve-shaped elements, superposed on one another and internally containing the pod is positioned following a further angular rotation of the second carousel, comprising heat-forming and sealing means which are configured and activatable, once the second half-shell is returned into the splayed position with respect to the first half-shell, to heat-weld the first valve-shaped element and the second valve-shaped element at the relative peripheral annular portions superposed on one another in such a way as to seal the pod internally thereof and obtain a sealed biodegradable packaging of a product for preparation of a beverage;

a ninth outfeed work station, at a fifth angular position wherein the plate of the second carousel, with the biodegradable packaging sealed, obtained in the eighth heat-welding and sealing work station, is positioned following a further angular rotation of the second carousel, comprising second collecting and transfer means, which are configured and activatable to collect the biodegradable packaging and transfer the biodegradable packaging onto the conveyor means.

3. The apparatus of claim 2, comprising a compression work station, associated to the first carousel between the third dosing work station and the fourth folding and closing work station, at a first intermediate angular position, between the third angular position and the fourth angular position, wherein the plate of the first carousel, with the hollow body filled with the product for preparation of a beverage, supported by the plate in the cylindrical housing of the first support and the second circular piece retained by suction by the second support, is positioned following an angular rotation of the first carousel, the compression work station comprising compression means which are configured and activatable to insert in the hollow body and push downwards, rotating about a vertical axis of rotation, the product for preparing a beverage contained in the hollow body so as to compress it, reducing the volume thereof.

4. The apparatus of claim 2, comprising a compacting and sealing work station, associated to the first carousel between the fourth folding and closing work station and the seventh collecting and transferring work station, at a second intermediate angular position, between the fourth angular position and the fifth angular position, wherein the plate of the first carousel, with the pod containing the product for preparation of a beverage supported by the plate of the first support, is positioned following an angular rotation of the first carousel, the compacting and sealing work station comprising compacting and sealing means which are configured and activatable to be lowered towards the plate, in synchrony with the raising of the plate into the raised position to raise the pod beyond the cylindrical housing of the first support, so as to be able to abut the pod and compact the pod, reducing the overall volume there, and seal it completely.

5. The apparatus of claim 4, wherein the compacting and sealing means comprise a sonotrode which is configured in such a way as to be vertically activatable and be lowered towards the plate and abut the pod raised by the plate beyond the cylindrical housing of the first support, in order to compact the pod, completely sealing it.

6. The apparatus of claim 4, wherein the compacting and sealing means comprise a pusher element, vertically movable, provided with a welding cartridge.

7. The apparatus of claim 2, comprising a first cleaning station, associated to the first carousel, between the seventh collecting and transferring work station of the pod and the first collecting work station, at a third intermediate angular position, between the fifth angular position and the first angular position, wherein the plate of the first carousel is positioned after the pod has been transferred onto the plate of the second carousel, and so that any eventual working waste can be removed and the first support, with the relative suction holes, the plate, with the relative suction holes and the second support, with the relative suction holes, can be subjected to cleaning operations.

8. The apparatus of claim 2, comprising a first pre-welding station, associated to the second carousel, between the seventh collecting and transferring work station and the eighth heat-welding and sealing work station, at a first intermediate angular position, between the third angular position and the fourth angular position, wherein the plate of the second carousel, with the two half-shells in the superposed position thereof with the two valve-shaped elements, superposed on one another and internally containing the pod, is positioned following an angular rotation of the second carousel, the first pre-welding station comprising spot welding means comprising a vertically movable element, which is provided with heated contact rods, the movable element being configured and activatable to be vertically lowered towards the second half-shell, closed above the first half-shell, so that the heated contact rods pass through through-holes realised in the second half-shell so that the heated contact rods reach into contact with the superposed annular portions of the valve-shaped elements, in order to carry out the reciprocal welding in the contact points with the heated contact rods.

9. The apparatus of claim 8, comprising a second pre-welding station, associated to the second carousel, between the first pre-welding station work station and the eighth heat-welding and sealing work station, at a second intermediate angular position, between the first intermediate angular position and the fourth angular position, wherein the plate of the second carousel, with the two half-shells in the superposed position thereof and the two valve-shaped elements, superposed on one another and internally containing the pod and pre-welded to one another with weld spots at the relative annular portions, is positioned following an angular rotation of the second carousel, the second pre-welding station comprising a ring heat welding element which is configured and activatable in order to be vertically translatable and lowerable towards the plate, once the second half-shell, with the suction action deactivated to release the second valve-shaped element, is moved into the splayed position with respect to the first half-shell, in order to abut the superposed annular portions of the two valve-shaped elements and carry out a ring welding thereof.

10. The apparatus of claim 9, wherein the ring welding using the ring heat welding element is carried out in a controlled-atmosphere environment following the partial raising of the second half-shell from the first half-shell so as to expose the mutually-superposed two valve-shaped elements, and pre-welded to one another with weld spots at the relative annular portions, and internally containing the pod, to the controlled-atmosphere environment, and subsequently to an aspiration of oxygen from the controlled-atmosphere environment, in order to remove the residual oxygen inside the two valve-shaped elements, and to an injection of inert gas into the controlled-atmosphere environment, so that the inert gas inserts between the two valve-shaped elements.

11. The apparatus of claim 10, wherein the second pre-welding station comprises a bell element configured and activatable in vertical translation so as to be lowered and positioned on the plate of the second carousel so as to create a controlled-atmosphere environment which contains the two half-shells closed in the superposed position thereof, and containing the two valve-shaped elements, superposed on one another, pre-welded to one another with weld spots in the relative annular portions, and internally containing the pod, with the bell element which is provided with a first conduit, connected to an oxygen aspiration source, and with a second conduit, connected to an inert gas injection source, the ring heat welding element being mounted on the bell element vertically movable with respect to the bell element so as to be lowered towards the plate, against the recall action of elastic means.

12. The apparatus of claim 2, comprising detecting means predisposed so as to detect the height and integrity of the biodegradable packaging borne by the plate of the second series of plates of the second carousel during the passage of the plate between the eighth heat-welding and sealing work station and the ninth outfeed work station, so that any packages that are defective or have a different height to a predetermined height are not collected by the second collecting and transfer means and are left on the second plate, and comprising a second cleaning station, associated to the second carousel, between the ninth outfeed work station and the fifth collecting work station, at a third intermediate angular position, between the fifth angular position and the first angular position, wherein the plate of the second carousel is positioned following an angular rotation of the second carousel, so that any defective packages left on the second plate can be removed and the first half-shell, with the relative suction holes, and the second half-shell, with the relative suction holes, can be subjected to cleaning operations.

13. The apparatus of claim 2, wherein the collecting means of the first collecting work station comprise a suction plate mounted by means of relative rods on a support frame that is rotatable about a horizontal axis of rotation, wherein the rods are mounted translatably with respect to the frame in order to enable the suction plate to be translated distancingly or nearingly from or to the frame.

14. The apparatus of claim 2, wherein the first support is conformed so as to comprise radial seats arranged radially with respect to the cylindrical housing and is mounted on the plate in such a way as to be activatable in rotation about a vertical axis of rotation that is axial to the cylindrical housing, and wherein the first folding and heat-welding means of the second folding and heat-forming work station comprise: a first cylindrical pusher element, heatable by means of a resistance, and activatable in vertical translation to be lowered towards the plate in order to abut the internal circular portion of the first circular piece and push it into the cylindrical housing so that the external circular portion of the first circular on, external with respect to the cylindrical housing and to the internal circular portion, is folded with respect to the internal circular portion forming the hollow body with the base wall and the lateral wall; and comprise a second pusher element conformed and configured in such a way as to comprise a series of radial paddles, activatable in vertical translation, so as to be lowered in synchrony with the first pusher element towards the plate, so that the series of radial paddles abut radial portions of the external circular portion of the first circular piece and push the radial portions into the radial seats of the cylindrical housing, so as to form radial tabs projecting externally from the lateral wall of the hollow body, and wherein the second pusher element is activatable in vertical translation raising with respect to the radial seats of the cylindrical housing so as to disengage from the cylindrical housing so that the first support, with the first pusher element maintained in the cylindrical housing in contact with the hollow body and heated by the resistance, can be activated in rotation about the vertical axis of rotation that is axial with respect to the cylindrical housing so as to fold the radial tabs against the lateral wall of the hollow body, with the first pusher element being activatable in vertical translation in order to be distanced from the cylindrical housing and in order to disengage from the hollow body.

15. The apparatus of claim 2, wherein the second folding means in the fourth folding and closing work station comprise a series of blades hinged to one another and reciprocally arranged in such a way as to form between them a central opening and activatable in reciprocal rotation with respect to one another in order to be able to narrow the central opening, and wherein, when the plate is positioned by the first carousel in the fourth angular position at the fourth folding and closing work station with the hollow body formed in the cylindrical housing of the first support and containing the product for preparation of a beverage, the plate is activatable in vertical translation in order to be raised with respect to the cylindrical housing and to raise and position the hollow body so that the upper portion of the lateral wall of the hollow body not occupied and free of the product inserts in the central opening present between the blades, with the blades being then activatable in rotation with respect to one another, about the relative hinge points, so as to narrow the central opening in order to abut the upper portion and fold the upper portion with respect to the lateral wall of the hollow body, carrying out a folding with pleating and forming a pleated crown above the product contained in the hollow body.

16. The apparatus of claim 2, wherein the second collecting means in the fifth collecting work station comprise a second suction plate on which are mounted, translatably with respect to the second suction plate, a pair of pusher elements, wherein the second suction plate is movable from a first position, at the second collecting position wherein the second feeder group positions the third circular piece and the fourth circular piece, wherein the second suction plate collects, by suction, the third circular piece and the fourth circular piece, at a second position above the first half-shell and the second half-shell of the plate positioned by the second carousel in the first angular position, so as to position the third circular piece above the first half-shell and the fourth circular piece above the second half-shell, the pair of pusher elements, following the deactivation of the suction of the second suction plate, being translatable with respect to the second suction plate to push the third circular piece into the first half-shell, so that the third circular piece adheres to the walls of the first half-shell and is retained by suction by the first half-shell, forming the first valve-shaped element, and to push the fourth circular piece in the second half-shell, so that the fourth circular piece adheres to the walls of the second half-shell and is retained by suction by the second half-shell, forming the second valve-shaped element.

17. The apparatus of claim 2, wherein the second collecting and transfer means in the ninth outfeed work station comprise a suction gripping member movable from a first position, wherein the suction gripping member is positionable above the plate, positioned by the second carousel in the fifth angular position, at the first half-shell which bears the biodegradable packaging, so as to collect, by suction, the biodegradable packaging, at a second position, wherein it is above the conveyor means, in order to release the biodegradable packaging above the conveyor means, wherein the suction gripping member is provided with a circular cutting member dimensioned and configured so as to perform a circular cut on the peripheral annular portions of the two valve-shaped elements heat-welded and sealed to one another in such a way as to define a final shape for the biodegradable packaging that is exactly circular.

18. The apparatus of claim 17, wherein the conveyor means comprises a load cell configured and predisposed to detect the weight of the biodegradable packaging, and a trapdoor raisable to cause the packaging to fall towards a reject station in a case in which there is a non-conforming weight with respect to an ideal weight.

19. The apparatus of claim 1, wherein the first feeder group comprises:

first unwinding means, for unwinding a first film of biodegradable material from the first reel, first positioning means, for positioning an advanced portion of the first film into a vertical position, and a first knife to cut the advanced portion of the first film and obtain the first sheet;

at least a first suction plate borne by a first frame which is activatable in rotation about a vertical axis and configured to position the first suction plate in four angular positions that are consecutive to one another;

wherein, in a first angular position, the first suction plate is positioned at the first sheet cut from the first film so that the first suction plate can retain the first sheet by suction, wherein, in a second angular position, the first suction plate is positioned at the first cutting means, activatable to cut the first circular piece and the second circular piece from the first sheet, wherein, in a third angular position, the first suction plate is positioned, with the first sheet in which the first circular piece and the second circular piece have been cut and retained by suction, in the first collecting position of the first circular piece and the second circular piece, and wherein, in a fourth angular position, the first suction plate is positioned at first waste recovery means having the function of removing the waste residues of the first sheet from the first plate after the first circular piece and the second circular piece have been collected from the first collecting position and positioned on the first support and on the second support of the plate of the first carousel.

20. The apparatus of claim 19, wherein the first cutting means of the first feeder group comprise first cylindrical cutting elements and wherein the first suction plate comprises circular grooves having a shape corresponding to the first cylindrical cutting elements so as to be able to accommodate internally thereof an end part of the first cylindrical cutting elements and enable the first cylindrical cutting elements to cut the first circular piece and the second circular piece in the first sheet retained by suction by the first suction plate.

21. The apparatus of claim 1, wherein the second feeder group comprises:

second unwinding means, for unwinding the second film of biodegradable material from the second reel, second positioning means, for positioning an advanced portion of the second film in a vertical position, and a second knife to cut the advanced portion of the second film and obtain the second sheet;

at least a second suction plate borne by a second frame which is activatable in rotation about a vertical axis and configured to position the second suction plate in four angular positions, consecutive to one another;

wherein, in a first angular position, the second suction plate is positioned at the second sheet cut from the second film so that the second suction plate can retain the second sheet by suction, wherein, in a second angular position, the second suction plate is positioned at the second cutting means, activatable to cut the third circular piece and the fourth circular piece from the second sheet, wherein, in a third angular position, the second suction plate is positioned, with the second sheet in which the third circular piece and the fourth circular piece have been cut and retained by suction, in the second collecting position of the third circular piece and the fourth circular piece, and wherein, in a fourth angular position, the second suction plate is at second waste recovery means having the function of removing the waste residues of the second sheet from the second suction plate after the third circular piece and the fourth circular piece have been collected from the second collecting position and positioned on the first half-shell and on the second half-shell of the plate of the second carousel.

22. The apparatus of claim 21, wherein the second cutting means of the second feeder group comprise second cylindrical cutting elements and wherein the second suction plate comprises corresponding circular grooves having a shape corresponding to the second cylindrical cutting elements so as to be able to accommodate internally thereof an end part of the second cylindrical cutting elements and enable the second cylindrical cutting elements to cut the third circular piece and the fourth circular piece in the second sheet retained by suction by the second suction plate.