WO2005002747A1

WO2005002747A1 - System for packaging of sorted products

Info

Publication number: WO2005002747A1
Application number: PCT/AU2004/000889
Authority: WO
Inventors: Ivan John Davison
Original assignee: Hortilink Holdings Pty Ltd
Priority date: 2003-07-02
Filing date: 2004-07-02
Publication date: 2005-01-13
Also published as: NZ544909A; AU2003903378A0

Abstract

The present invention relates to systems and methods of tracking sorted products from source to final destination with the production of labels having information that may be read electronically or listed on the label. The preferred embodiment of the invention concerns the packaging of fruit, nuts and vegetables. An advantage of the preferred embodiment is that produce can be monitored and tracked from grower to retail display and provides an element of accountability allowing problems to be identified and performance remunerated.

Description

SYSTEM FOR PACKAGING OF SORTED PRODUCTS

FIELD OF INVENTION The present invention relates to systems and methods for packaging products. The present invention has particular but not exclusive application for the packaging of produce. Reference is made to the packaging of produce in the body of the specification by way of example only and the invention is not limited to this example.

BACKGROUND OF THE INVENTION When a product is packaged it is often labeled with an indication of the name and type of product. With respect to produce, it is often graded and passed through the relevant grading gate to a holding area. Grading can be based on, for example, colour, size and shape. The produce is then manually packed into containers or trays. The containers and trays are then labeled to indicate the type of produce, for example the type and variety of fruit and grade quality. Packed containers and trays are usually marked manually with a crayon or permanent marker. Before distribution, inventory is taken manually by a worker reading the manual markings and noting the numbers of containers of each type or grade of product. Where packed pallets include containers of products with different characteristics, each container on a pallet is inspected and details recorded. Data collected is typically entered manually into a computer for processing and inventory control. Batch and/or date stamping of the containers may then be performed as a separate operation. Recently containers have been labeled with barcodes to allow inventory assessment by use of barcode scanners. Preprinted barcode labels have been used at each grading gate and were placed on packed containers and trays. However the amount of information associated with a preprinted label is limited. For example time dependent information including packaging time, place, packer name and batch number can not be added. Furthermore the accuracy of information associated with the barcode and labeled container is questionable because of the preprinted nature of the barcode. For example information indicating the origin of the produce may be inaccurate as old or alternate barcode labels may be mistakenly used.

OBJECT OF THE INVENTION It is an object of the present invention to provide an embodiment of an alternative system that overcomes at least in part one or more of the abovementioned disadvantages.

SUMMARY OF THE INVENTION In one aspect the present invention broadly resides in a system for sorting and packaging of products including sorting means including a plurality of sorting stations; recordal means including one or more processing units, each of said processing units includes a processor operatively associated with one or more of said sorting stations and a labeling means operatively associated with said processor, said processor records information in one or more predetermined fields relevant to the products being sorted; and packaging means for packaging one or more of the products to produce a packaging unit, wherein the recordal means produces a label containing at least part of said information when a packaging unit is produced. Sorting means may suitably be means for grading a product according to a particular characteristic. With respect to produce, fruits, nuts and vegetables may be graded by a variety of methods based on characteristics such as colour, weight, size and shape. The grading of the product is preferably non-invasive. When the produce satisfies the grading characteristic it passes through a grading gate of the relevant sorting station and preferably collects in a collection area. The collection area is preferably a container or bin. When there is enough product to form a packaging unit, the product(s) are packaged with a label from the recordal means. The operatively associated processor records the relevant information for the label. The relevant information may be entered prior to or during the processing of the product. The relevant information may be entered by means of recording by sensors, electronic readers, keyboard entries, voice activated entries, control panel entries and touch-screen entries. In one preferred embodiment there is a radio frequency identification (RFID) means operatively associated with the processor that records the name of the packer packing the package unit. This allows the subsequent identification of the packer. It also provides a means whereby efficiency of packing can be recorded and packers remunerated on the number of package units packed. The labeling means preferably includes a printer. Labels are preferably printed labels. The printed labels preferably have a barcode or some other form of electronic readable sign. An operator actuates the processor to print a label with the relevant information with the pushing of a button on the control panel associated with the processor or entry on a keypad or keyboard associated with the processor or via an RFID means. Labels are preferably printed on demand and applied to the packaging unit at the point of packing. A central computer has relevant recorded historical information and the processor provides it with time sensitive information from its proximal input devices including sensor inputs, RFID reader and keyboard or keypad devices. The records formed by the processor are sent to the computer so that a packaged product can be monitored during its shipment by reference to electronically stored records. Furthermore where the package is shipped to a warehouse or retail store, an electronic readable label such as a barcode can be used by the handlers/retailers to monitor and record the package on their systems so that there is a continuous accumulation of information from the start to final destination or use. This provides the system with the advantage of being a traceable record and introducing accountability to the system. The recorded information also provides identification and history of the packaged products in a printed and electronic format. Said recorded information is relevant to the particular product. In one embodiment where the product is produce, the recorded information preferably includes produce type, variety, quantity, grade, batch number, shed, farm, grower name and address, date and time of packing, packer name, consignee name, destination, certification of post harvest treatments and other relevant indications. The processor is preferably operatively linked to between 1 and 15 sorting stations and more preferably to less than 9 sorting stations. In a preferred embodiment the processor is operatively linked to 4 to 8 sorting stations. The processor is preferably linked via a computer to a dedicated printer for printing labels. Each processor in the system is preferably operationally linked to a single computer. A system may have one or more processing units depending on the product type and quantity of products being processed. The products are preferably commercial products. Products may suitably include produce including fruit, nuts and vegetables; processed food including processed fruits; seafood such as oysters and shellfish; meats; compost types; and industrial products such as screws, bolts and nuts. In another aspect the invention broadly resides in a method of sorting and packaging of products using the abovementioned system including sorting of products using sorting means; recording of relevant information with the recordal means so that the relevant information is entered into the processor, processed and provided to the labeling means for the production of a label for the packaging unit; packaging of one or more of the products to form the packaging unit using the packaging means and applying the label to the packaging means enabling the packaged products to be monitored. The variations discussed with the abovementioned system also apply to the method of sorting and packaging of the products.

BRIEF DESCRIPTION OF THE DRAWINGS .. In order that the present invention can be more readily understood and put into practical effect, reference will now be made to the accompanying drawings wherein: Figure 1 is a flow diagram showing the method of sorting and packaging of produce; Figure 2 is a diagrammatic view of the sorting and packaging of produce; and Figure 3 is an example of a printed label for a packaged product.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention relates to systems and methods of tracking sorted products from source to final destination with the production of labels having information that may be read electronically or listed on the label. The preferred embodiment of the invention concerns the packaging of fruit, nuts and vegetables. An advantage of the preferred embodiment is that produce can be monitored and tracked from grower to retail display and provides an element of accountability allowing problems to be identified and performance remunerated. By way of example the preferred embodiment will be described with reference to the sorting and packaging of produce. The first preferred embodiment refers to the sorting and packaging of mangos. With reference to Figures 1 and 2, there is shown a method and system of grading and packaging a product being mangoes. The described method and system enables any given operator packing produce at a given time of a large number of drops (or grading gates) of a fruit grading and/or sorting machine (henceforth called a grader) to quickly obtain a label, printed on demand and individualized to reflect the product associated with the given drop. In particular, the described method enables a single printer to be shared between a number of operators at a number of physically adjacent drops, but still to provide individualized labels, on demand, for each drop. A grader may have twenty- four or even ninety-six drops, and a single printer is shared between four or six drops. Historical information regarding the produce including shed, grower, farm, block, planting, crop and variety, is provided to the computer of system. The information may be provided from database records of compatible systems or by direct entry. The computer is preferably able to communicate with other computers in order to maintain up-to-date records. In the first embodiment the computer communicates (wired or wireless) with the processors associated with the drops. Information flows one way from the processor to the computer. The computer is also programmed with information corresponding to each input device and thus each drop with the identifying number for each drop and information relating to the products being packed at each drop such as the grade, size etc. This may be regarded as a grader "recipe", being entered into the computer. Recipe information relating to the various drops may, of course, be entered or changed when the different grades or types of product are allocated to the different drops. Information entered into the computer may therefore include batch and drop variables and also the label format required for a given batch of products. The computer will also have information about the system and the relationship between the components such as allocation of sensor inputs, RFID readers and printers to processors, and printing format information. The printers are preferably centrally controlled by the computer while being dedicated to particular drops. Each printer is allocated to four, five or six drops so that a single printer can be shared between four, five or six drops. The processor includes providing information about the printing environment such as the required printer drives and software for producing barcodes and/or selection of barcode type (dedicated or EAN) and label formats. The processor initiates the production of the labels via the computer. The computer is directly linked to the printer. Information recorded by the processor is sent to the computer for production of the label and to enable the packaged product to be monitored and traced during shipment. The information sent to the computer is preferably added to the database together with the historical and other relevant data. The information is sent to the computer directly by cable or wireless communication. The product, which in this example is mangoes, are transported to the sorting area and placed on a cup conveyor or belt. The mangoes travel along the conveyor or belt and are optically imaged to determine size, shape or colour or weighed by inline scales to determine a grade for each particular mango. The grading, whether by optical imaging or by weight determination, determines which grading gate or drop the fruit passes. In Figure 2 there is shown a conveyor 20 on which mangoes 21 travel. Adjacent the conveyor 20 there is shown twenty-four grading gates 22. The grading gates 22 are numbered one to twenty-four in Figure 2 whereby grading gate number one allows the entry of large mangoes while grading gate number twenty-four allows the entry of comparatively small mangoes. In the present example the mangoes are graded by size and the larger mangoes are allowed to pass through the earlier grading gates 22. By way of example, Kensington Pride mangoes are relatively small mangoes and the majority would pass through grading gates fourteen to eighteen. In comparison, R2E2 mangoes are comparatively larger and the majority would pass through grading gates eight to fourteen. After passing through the grading gate 22, the mangoes are collected in a bin or soft conveyor. A packer then manually takes the mangoes and packs them into a tray. Where the mangoes are large there will be fewer in a tray compared with the number of smaller sized mangoes in a tray. When the tray is full, the packer brings their RFID tag within range of the RFID reader 23 or pushes one or more buttons on the control panel 24 associated with the processor 25 depending on the system installed. Most systems will either have an RFID reader or buttons on a control panel. With activation time sensitive data such as packer identification, batch number, grading gate (or drop), packing time and date, pallet number is produced. The processor 25 then initiates printing of a label via the computer to the dedicated printer 26. The label is then fixed to the tray and the tray is placed on a pallet. The label is preferably a self- adhesive label. The label preferably contains historical information as well as time- sensitive information regarding the packing process in an encoded format that may - be read electronically such as a barcode and/or listed information. The label contains up-to-date information and is printed on demand. The time-sensitive information is then communicated to the computer 29 using standard communication systems such as RS485 or RS232. In a preferred embodiment, the computer software includes a database of relevant information. The database is preferably stored on the computer 29. The computer 29 may be remotely located, and the processors 25 communicate via an internet interface. The database preferably includes information relating to the batches to be graded and packed. This can considerably facilitate the programming step. A database of growers and the various farms blocks and planting provided by each grower can enable the computer to provide a small number of choices for some of the variables. For example, if the database specifies that a given grower produces on only one farm and on two blocks, then if that grower is selected the database need not seek information regarding farm identity and can ask a user to select which of the two blocks the batch originated from. This information may be used to determine other information, such as the variety of the products being graded, so that this information need not be entered by a user. Of course, the menus may include an option for correcting or updating the database information. It is also a desirable variation to have the computer able to communicate directly with the grader regarding grader recipes and selection of variables. In this case, once the input devices at each drop are identified, the information in the grader recipe (which is part of the mode of operation of the grader) may be read by the computer direct from the grader. This would increase efficiency and accuracy of the labeling system by reducing or eliminating the need to re-key grader settings and recipes into the computer. In some applications, the grader recipe may change while a batch is being graded and automatic reading of the current grader recipe by the computer would enable the output from the printers to be kept accurate even with frequent recipe changes. With reference to Figure 3 there is shown a typical label that is produced by the printer in the abovementioned system. Label 40 is in respect of a tray of

Celebration mangoes. The variety of mangoes, Celebration, is indicated in the upper left hand corner of the label 40 at 41. The name of the farm, Orison Mango Farm, and its address, Lot 713/224 Brougham Rod, Darwin River, Northern Territory, is shown on the label 40 at 42. There are twelve mangoes packed in a tray and this number is prominently displayed near the centre of the label 40 at 43. The packaging details are provided on the left hand side of the label 40 at 44. The consignee name is recorded along the right hand edge of the label 40 at 45. The category or class of mangoes is provided on the lower left hand corner of the label 40 at 46. Certification that the mangoes have met certain standard quarantine requirements is shown on the label 40 at 47. The label 40 also encodes this information in a barcode that is electronically readable with reference to database information. In this way the progress of the mangoes from farm to retail display can be tracked and separate stages be held accountable. Problems at any one stage such as prolonged storage or delayed arrival of produce can be identified. Furthermore, with accountability, productivity of systems and workers can be monitored and remuneration can be based on performance. With printing on demand errors in labeling the product are substantially eliminated and packers will not need to handwrite labels or apply multiple labels or stamps over the trays. As a consequence there is a labour saving through direct label application at the point of packing. Also as a consequence of the abovementioned system shed capacity is consequently increased by reducing down time between batches and by removing bottlenecks in the palletizing area. Pallets are accurately scanned in a few minutes regardless of how many different sizes/grades/brands/blocks are mixed up on the pallet. Batch changeovers can happen continuously or with a minimal pause in.processing. Information that can be printed on product labels includes Shed, Grower, Farm, Block, Planting, Crop, Variety, Class, Count/Size, Brand, Pack, Batch No. and Date/time Packed. The system supports EAN bar coding or any other suitable bar coding system. The system also is adaptable for integration into other complimentary systems including grower-based systems or systems used in retail outlets.

VARIATIONS It will of course be realised that while the foregoing has been given by way of illustrative example of this invention, all such and other modifications and variations thereto as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of this invention as is herein set forth. Throughout the description and claims this specification the word "comprise" and variations of that word such as "comprises" and "comprising", are not intended to exclude other additives, components, integers or steps.

Claims

1. A system for sorting and packaging of products including sorting means including a plurality of sorting stations; recordal means including one or more processing units, each of said processing units includes a processor operatively associated with one or more of said sorting stations and a labeling means operatively associated with said processor, said processor records information in one or more predetermined fields relevant to the products being sorted; and packaging means for packaging one or more of the products to produce a packaging unit, wherein the recordal means produces a label containing at least part of said information when a packaging unit is produced.

2. A system as claimed in claim 1 wherein the sorting means is a means for grading a product according to a particular characteristic and the grading is noninvasive, said products pass through an allocated grading gate based on satisfying the particular grading characteristic and are collected for packaging.

3. A system as claimed in claim 1 or 2 wherein the product is fruit, nuts or vegetables and is graded by optical imagery to determine size, shape or colour or weighed, by in-line scales to determine weight of the produce.

4. A system as claimed in any one of the preceding claims wherein said processor records time sensitive information from proximal input devices including sensor inputs, RFID reader and keyboard or keypad devices and transmits it to a central computer which has access to relevant historical information

5. A system as claimed in any one of the preceding claims wherein the labeling means includes a printer and a label is printed on demand initiated by the processor and via a central computer.

6. A system as claimed in claim 5 wherein the label contains electronically readable information and or listed information for human recognition.

7. A system as claimed in claim 6 wherein the electronically readable information is in the form of a bar code.

8. A system as claimed in claim 6 wherein the electronically readable information is read with reference to details recorded on an accessible database.

9. A system as claimed in any one of the preceding claims wherein an RFID reader serves as an input device where a person can record their identity, time and date and other time-sensitive data and actuates the printing of a label.

10. A system as claimed in claim 9 wherein an operator actuates the processor to print a label with the relevant information with the pushing of a button on the control panel associated with the processor.

11. A system as claimed In any one of the preceding claims wherein the product Is produce and the recorded information Includes produce type, variety, quantity, grade, batch number, shed, farm, grower name and address, date and time of packing, packer name, consignee name, destination, certification of post harvest treatments and other relevant data.

12. A system as claimed In any one of the preceding claims wherein the processor Is operatively linked to between 1 and 15 sorting stations.

13. A system as claimed in any one of the preceding claims wherein the processor is operatively linked to between 4 and 8 sorting stations.

14. A system as claimed in any one of the preceding claims wherein each processor In the system is operationally linked to a single computer.

15. A method of sorting and packaging of products using the system as claimed in any one of the preceding claims Including sorting of products using sorting means; recording of relevant Information with the recordal means so that the relevant information Is entered Into the processor, processed and provided to the labeling means for the production of a label for the packaging unit; packaging of one or more of the products to form the packaging unit using the packaging means and applying the label to the packaging means enabling the packaged products to be monitored.