WO2018098557A1

WO2018098557A1 - Apparatus and method for folding a chain of containers

Info

Publication number: WO2018098557A1
Application number: PCT/CA2017/000251
Authority: WO
Inventors: Peter Guttinger; Gregory Arthur LAWRENCE; Peter BACLIJA
Original assignee: Langen Packaging Inc.
Priority date: 2016-11-28
Filing date: 2017-11-23
Publication date: 2018-06-07

Abstract

An apparatus is disclosed for folding a chain of containers such as a chain of bags. A chain may include a plurality of bags arranged in series and being foldable relative to each other. The apparatus may comprise a feeding apparatus such as a feeding conveyor for feeding a container chain in an unfolded configuration to a loading station. The apparatus may also comprise a bucket conveyor comprising a plurality of longitudinally spaced members defining at least one bucket cavity. The bucket conveyor may be operable to move the at least one bucket cavity to and from the loading station. The feeding apparatus feeds the container chain to the bucket conveyor such that a first container is fed into a bucket cavity and a second container connected to said first container is fed to a bucket cavity in such a manner as to form a folded configuration of said first container relative to said second container on said bucket conveyor.

Description

APPARATUS AND METHOD FOR FOLDING A CHAIN OF CONTAINERS

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of and priority from Indian Patent Application Serial Number 20161 1040606 filed on November 28, 2016. The contents of the aforementioned application are incorporated by reference herein.

TECHNICAL FIELD

[0002] The present disclosure relates to an apparatus and method for folding one or more chains of containers, such as one or more chains of bags. The bags may be pouches or sachets, holding one or more products.

BACKGROUND

[0003] Chains of containers such as chains of bags can be used in a variety of industries including in the food industry for the packing of foodstuff items. The containers may be bags made from a flexible or semi-flexible material and may be referred to as pouches or sachets. One or more chains of bags may be formed using known apparatuses and methods. Each chain can comprise a plurality of bags, for example, 2 to 25 bags, or from 5 to 30 bags. The bags may be generally square or rectangular in shape and may be respectively connected to adjacent bags in the chain at a top or bottom side by means of a weakening line in the bag material and/or providing some additional material to connect adjacent bags to one another and to allow relative rotation about transverse connection axes of the bags in the chain.

[0004] In some known apparatuses a filling machine fills the successive bags of the chain with a measured quantity of foodstuffs, after which a worker may manually fold the chain into a stack, in which the bags are folded about the weakening line / additional material in a zig-zag pattern and the stack may end up standing on the respective top and bottom side of the bags. In such a folded orientation of the chain, the chain of bags can be packed, for example, in a case. Such a manual folding operation is time-consuming and can limit the speed of the filling machine. Moreover, the manual folding of the successive chains into stacks is not uniform, so that the packing of the stacks into cases can present problems.

[0005] There are some known automated systems and methods for folding chains of bags. However, folding bags in a chain which contain bulky and / or rigid materials can pose enhanced challenges particularly when utilizing automated systems. Therefore, additional apparatuses and methods for folding one or more chains of containers such as bags are desirable.

SUMMARY

[0006] In one embodiment, there is described an apparatus for folding a chain of containers, the chain including a plurality of containers arranged in series and being foldable relative to each other. The apparatus includes a feeding apparatus operable for feeding a container chain in an unfolded configuration to a loading station, and a bucket conveyor including a plurality of longitudinally spaced members, the longitudinally space members defining at least one bucket cavity, the bucket conveyor being operable to move the at least one bucket cavity to and from the loading station. The apparatus is operable such that the feeding apparatus feeds the container chain to the bucket conveyor at the loading station such that a first container of the plurality of containers is fed into a bucket cavity of the at least one bucket cavity and a second container connected to the first container is fed to a bucket cavity of the at least one bucket cavity in such a manner as to form a folded configuration of the first container relative to the second container on the bucket conveyor.

[0007] The chain of containers may include a bag chain, the first container may include a first bag and the second container may include a second bag.

[0008] The feeding apparatus may be a feeding conveyor. [0009] The feeding apparatus may be a feeding conveyor that is oriented generally longitudinally. The bucket conveyor may be oriented generally longitudinally and in transverse alignment with the feeding conveyor, the feeding conveyor and the bucket conveyor being operable to generally move in a longitudinal direction. The apparatus may be operable such that the feeding conveyor feeds the bag chain to the bucket conveyor at the loading station such that the first bag of the plurality of bags is fed into a bucket cavity of the at least one bucket cavity and a second bag connected to the first bag is fed into a bucket cavity of the at (east one bucket cavity to pivot the first bag relative to the second bag to form a folded configuration of the first bag relative to the second bag on the bucket conveyor.

[0010] In operation the feeding conveyor may feed the bag chain to the bucket conveyor such that a first bag of the plurality of bags is first fed into a bucket cavity of the at least one bucket cavity, and a second bag connected to the first bag is fed to a bucket cavity of the at least one bucket cavity while the bucket conveyor and the bucket cavity are moving longitudinally, to form a folded configuration of the first bag relative to the second bag on the bucket conveyor.

[0011] The bucket conveyor may include a curved portion at the loading station. The apparatus may be operable such that in operation the feeding conveyor feeds the bag chain to the curved portion of the bucket conveyor such that the first bag of the plurality of bags is fed into a bucket cavity located at the curved portion of the bucket conveyor and a second bag connected to the first bag is fed to a bucket cavity located at the curved portion of the bucket conveyor, to form a folded configuration of the first bag relative to the second bag on the bucket conveyor.

[0012] The first bag may be a leading bag in the bag chain.

[0013] The bucket conveyor may include (i) a first run extending to the loading station, (ii) the curved portion located at the loading station, and (iii) a second run extending away from the loading station. [0014] In operation, the first bag of the bag chain may be fed into a first cavity of the bucket conveyor and the second bag in the bag chain may be fed into a second cavity of the bucket cavity, such that the first bag and the second bag are folded over a member of the bucket conveyor that defines the first cavity.

[0015] In operation, the first bag of the bag chain may be fed into a first cavity of the bucket conveyor and the second bag of the bag chain may be fed into the first cavity of the bucket conveyor, such that the first bag and the second bag are folded within the first cavity of the bucket conveyor.

[0016] It may be that neither the first bag nor the second bag is a leading bag of the bag chain.

[0017] In operation the first and second bag may be fed into respective first and second cavities as the first and second cavities of the bucket conveyor are moving through the curved portion.

[0018] In operation the first and second bag may be fed into respective first and second cavities as the first and second cavities are positioned within the curved portion.

[0019] In operation, the first and second bag may be fed into respective cavities as the respective cavities of the bucket conveyor are moving through the curved portion.

[0020] The infeed conveyor may have a first velocity in a longitudinal direction and the bucket conveyor may have a velocity in a longitudinal direction, and while the first bag of the bag chain is being fed into the cavity of the at least one cavity, the velocity of the bucket conveyor may be zero.

[0021] After the first bag of the bucket chain has been loaded into the cavity, the bucket conveyor may accelerate to a speed that is greater than or equal to the speed of the infeed conveyor. [0022] After the first bag of the bucket chain has been loaded into the cavity, the bucket conveyor may accelerate to a speed that is less than the speed of the infeed conveyor.

[0023] In operation, the first bag of the bag chain may be fed into a first cavity of the bucket conveyor and the second bag in the bag chain may be fed into a second cavity of the bucket cavity, such that the first bag and the second bag are folded over a member of the bucket conveyor, and a third bag in the bag chain that is connected to the second bag, may be fed into the second cavity of the bucket conveyor, such that the second and third bags are folded in a bottom region of the second cavity.

[0024] A fourth bag in the bag chain that is connected to the third bag, may be fed into a third cavity of the bucket conveyor that is adjacent to the second cavity, such that the third and fourth bags are over a flight of the bucket conveyor.

[0025] In operation the third and fourth bags may be fed into respective second and third cavities as the second and third cavities moving through the curved portion.

[0026] In operation, the first second and third bag may be fed into respective bucket cavities as the bucket cavities of the bucket conveyor is moving through the curved portion.

[0027] In operation the fourth bag may be fed into a third cavity as the third cavity is moving through the curved portion.

[0028] The apparatus may further include a fifth bag in the bag chain that is connected to the fourth bag, and which is fed into the third cavity of the bucket conveyor that is adjacent to the second cavity, such that the fourth and fifth bags are folded within and at a bottom of the third cavity. [0029] In operation the fifth bag may be fed into the third cavity as the third cavity is moving through the curved portion.

[0030] The apparatus may further include a sixth bag in the bag chain that is connected to the fifth bag, and which is fed into a fourth cavity of the bucket conveyor that is adjacent to the third cavity, such that the fifth and sixth bags are folded over a flight of the bucket conveyor.

[0031 ] In operation the sixth bag may be fed into the fourth cavity as the fourth cavity of the bucket conveyor is moving through the curved portion.

[0032] The apparatus may further include a seventh bag in the bag chain that is connected to the sixth bag, and which is fed into the fourth cavity of the bucket conveyor that is adjacent to the third cavity, such that the sixth and seventh bags are folded within and at a bottom of the fourth cavity.

[0033] In operation the seventh bag may be fed into the fourth cavity as the fourth cavity of the bucket conveyor is moving through the curved portion.

[0034] The apparatus may further include an eighth bag in the bag chain that is connected to the seventh bag, and which is fed into a fifth cavity of the bucket conveyor that is adjacent to the forth cavity, such that the seventh and eighth bags are folded are over a flight of the bucket conveyor.

[0035] In operation the eighth bag may be fed into the fifth cavity as the fifth cavity of the bucket conveyor is moving through the curved portion.

[0036] The infeed conveyor may have a first velocity in a longitudinal direction and the bucket conveyor may have a second velocity in a longitudinal direction, and while the first bag of the bag chain is being fed into the cavity of the at least one cavity, the velocity of the bucket conveyor may be zero. [0037] After the first bag of the bucket chain has been loaded into the cavity, the bucket conveyor may accelerate to a speed that is greater than or equal to the speed of the infeed conveyor.

[0038] In another embodiment, there is described an apparatus for folding a chain of containers, the chain including a plurality of containers arranged in series and being foldable relative to each other. The apparatus includes a feeding apparatus operable for feeding a container chain in an unfolded configuration to a loading station, and a first bucket conveyor including a plurality of longitudinally spaced members, the longitudinally space members defining at least one bucket cavity, the first bucket conveyor being operable to move the at least one bucket cavity of the first bucket conveyor to and from the loading station. The apparatus also includes a second bucket conveyor including a plurality of longitudinally spaced members, the longitudinally space members defining at least one bucket cavity, the second bucket conveyor being operable to move the at least one bucket cavity of the second bucket conveyor to and from the loading station. The apparatus is operable such that the feed apparatus feeds a first container chain to the first bucket conveyor at the loading station such that a first container of the first container chain is fed into a bucket cavity of the at least one bucket cavity of the first bucket conveyor and a second container of the first container chain connected to the first container of the first container chain is fed to a bucket cavity of the at least one bucket cavity in such a manner as to form a folded configuration of the first container of the first container chain relative to the second container of the first container chain on the first bucket conveyor. The apparatus is operable such that the feed conveyor feeds a second container chain to the second bucket conveyor at the loading station such that a first container of the second container chain is fed into a bucket cavity of the at least one bucket cavity of the second bucket conveyor and a second container of the second container chain connected to the first container of the second container chain is fed to a bucket cavity of the at least one bucket cavity in such a manner as to form a folded configuration of the first container of the second container chain relative to the second container of the second container chain on the second bucket conveyor. [0039] The first container chain may include a first bag chain including a first bag and a second bag of the first container chain and the second container chain may include a second bag chain including a first bag and a second bag of the second container chain.

[0040] The first bucket conveyor may operate in loading bag chains out of phase with respect to the second bucket conveyor.

[0041] In another embodiment, a system for processing a plurality of container chains includes an apparatus as described above, and a discharge apparatus operable to discharge a container chain from the bucket conveyor at a transfer station.

[0042] The system may further include a compression apparatus operable to compress a container chain discharged from the bucket conveyor.

[0043] The system may further include a collation apparatus operable to collate a plurality of rows of container chains at a collation station.

[0044] The system may further include a removal apparatus operable to remove the plurality of rows of container chains from the collation station.

[0045] In another embodiment, there is described a method for folding a chain of containers, the chain including a plurality of containers arranged in series and being foldable relative to each other. The method involves moving a bucket conveyor, the bucket conveyor including a plurality of longitudinally spaced members, the longitudinally space members defining at least one bucket cavity, to move the at least one bucket cavity to and from a loading station, and feeding a container chain in an unfolded configuration to a loading station such that a first container of the plurality of containers is fed into a bucket cavity of the at least one bucket cavity and a second container connected to the first container is fed to a bucket cavity of the at least one bucket cavity in such a manner as to pivot the second container relative to the first container to form a folded configuration of the first container relative to the second container on the bucket conveyor.

[0046] The chain of containers may include a bag chain, the first container may include a first bag and the second container may include a second bag.

[0047] The bag chain may be fed in a first longitudinal direction. The bucket conveyor may be oriented and moves in second longitudinal direction parallel with the first longitudinal direction and in transverse alignment with the bag chain. The bag chain may be fed to the bucket conveyor at the loading station such that the first bag of the plurality of bags is fed into a bucket cavity of the at least one bucket cavity and a second bag connected to the first bag is fed into a bucket cavity of the at least one bucket cavity to form a folded configuration of the first bag relative to the second bag on the bucket conveyor.

[0048] The bag chain may be fed to the bucket conveyor such that a first bag of the plurality of bags is first fed into a bucket cavity of the at least one bucket cavity, and a second bag connected to the first bag may be fed to a bucket cavity of the at least one bucket cavity while the bucket conveyor and the bucket cavity are moving longitudinally, to form a folded configuration of the first bag relative to the second bag on the bucket conveyor.

[0049] The bucket conveyor may include a curved portion at the loading station; and the bag chain may be fed to the curved portion of the bucket conveyor such that the first bag of the plurality of bags is fed into a bucket cavity located at the curved portion of the bucket conveyor and a second bag connected to the first bag is fed to a bucket cavity located at the curved portion of the bucket conveyor, to pivot the first bag relative to the second bag to form a folded configuration of the first bag relative to the second bag on the bucket conveyor.

[0050] The first bag may be a leading bag in the bag chain. [0051] The first bag of the bag chain may be fed into a first cavity of the bucket conveyor and the second bag in the bag chain may be fed into a second cavity of the bucket cavity, such that the first bag and the second bag are folded over a member of the bucket conveyor that defines the first cavity.

[0052] In operation, the first bag of the bag chain may be fed into a first cavity of the bucket conveyor and the second bag of the bag chain may be fed into the first cavity of the bucket conveyor, such that the first bag and the second bag are folded within the first cavity of the bucket conveyor.

[0053] It may be that neither the first bag nor the second bag is a leading bag of the bag chain.

[0054] The first and second bag may be fed into respective first and second cavities as the first and second cavities of the bucket conveyor are moving through the curved portion.

[0055] The first and second bag may be fed into respective first and second cavities as the first and second cavities are positioned within the curved portion.

[0056] The first and second bag may be fed into respective cavities as the bucket conveyor is moving through the curved portion.

[0057] The bag chain may be fed to the loading station at a first velocity in a longitudinal direction and the bucket conveyor may have a velocity in a longitudinal direction, and while the first bag of the bag chain is being fed into the cavity of the at least one cavity, the velocity of the bucket conveyor may be zero.

[0058] After the first bag of the bucket chain has been loaded into the cavity, the bucket conveyor may accelerate to a speed that is greater than or equal to the speed of speed of the chain bag being fed to the loading station.

[0059] The first bag of the bag chain may be fed into a first cavity of the bucket conveyor and the second bag in the bag chain may be fed into a second cavity of the bucket cavity, such that the first bag and the second bag are folded over a member of the bucket conveyor, and a third bag in the bag chain that is connected to the second bag, may be fed into the second cavity of the bucket conveyor, such that the third bag pivots relative to the second bag such that the second and third bags are folded in a bottom region of the second cavity.

[0060] A fourth bag in the bag chain that is connected to the third bag, may be fed into a third cavity of the bucket conveyor that is adjacent to the second cavity, such that the third and fourth bags are folded over a flight of the bucket conveyor.

[0061] The third and fourth bags may be fed into respective second and third cavities as the second and third cavities of the bucket conveyor are moving through the curved portion.

[0062] The first second and third bag may be fed into respective cavities as the bucket conveyor is moving through the curved portion.

[0063] In operation the fourth bag may be fed into a third cavity as the bucket conveyor is moving through the curved portion.

[0064] The method may further involve feeding a fifth bag in the bag chain that is connected to the fourth bag, into the third cavity of the bucket conveyor that is adjacent to the second cavity, such that the fifth bag pivots relative to the fourth bag such that the fourth and fifth bags are folded within and at a bottom of the third cavity.

[0065] The fifth bag may be fed into the third cavity as the third cavity of the bucket conveyor is moving through the curved portion.

[0066] The method may further involve feeding a sixth bag in the bag chain that is connected to the fifth bag, into a fourth cavity of the bucket conveyor that is adjacent to the third cavity, such that the fifth and sixth bags are folded over a flight of the bucket conveyor. [0067] The sixth bag may be fed into the fourth cavity as the fourth cavity of the bucket conveyor is moving through the curved portion.

[0068] The method may further involve feeding a seventh bag in the bag chain that is connected to the sixth bag into the fourth cavity of the bucket conveyor that is adjacent to the third cavity, such that the sixth and seventh bags are folded within and at a bottom of the fourth cavity.

[0069] In operation the seventh bag may be fed into the fourth cavity as the fourth cavity of the bucket conveyor is moving through the curved portion.

[0070] The method may further involve feeding an eighth bag in the bag chain that is connected to the seventh bag, into a fifth cavity of the bucket conveyor that is adjacent to the fourth cavity, such that the seventh and eighth bags are folded over a flight of the bucket conveyor.

[0071] In operation the eighth bag may be fed into the fifth cavity as the fifth cavity of the bucket conveyor is moving through the curved portion.

[0072] The bag chain may be fed to the loading station at a first velocity in a longitudinal direction and the bucket conveyor may have a second velocity in a longitudinal direction, and while the first bag of the bag chain is fed into the cavity of the at least one cavity, the velocity of the bucket conveyor may be zero.

[0073] After the first bag of the bucket chain has been loaded into the cavity, the bucket conveyor may accelerate to a speed that is greater than or equal to the first velocity.

[0074] In another embodiment, a method for processing a plurality of container chains involves (i) a method as described above, and (ii) discharging a container chain from the bucket conveyor at a transfer station.

[0075] The method may further involve compressing a container chain discharged from the bucket conveyor. [0076] The method may further involve collating a plurality of rows of container chains at a collation station.

[0077] The method may further involve removing the plurality of rows of container chains from the collation station.

BRIEF DESCRIPTION OF THE DRAWINGS

[0078] In the figures, which illustrate example embodiments:

[0079] FIGS. 1 A and 1 B are top plan and side views respectively of an example chain of bags;

[0080] FIG. 2 is a top plan view of a system for processing a chain of bags;

[0081] FIG. 3 is a side view of a folding subsystem comprising part of the system of FIG. 2;

[0082] FIG. 4 is a side schematic view of the sequential operation of the folding subsystem of FIG. 3 folding a chain of bags.

DETAILED DESCRIPTION

[0083] With reference to Figure 1 , a bag chain 100 may comprise a plurality of containers, such as for example bags 1 10, arranged in end to end longitudinal serial relation to each other. The bags 1 10 may hold one or more items or material, such as for example a food or beverage related product.

[0084] In the illustrated example - the bag chain 100 comprises eight (8) individual bags connected and arranged in series and numbered bags (1 ) to (8). The bag chain may comprise two or more bags. Containers such as bags 1 10 can be made from one or more of a wide variety of materials such as by way of example only paper, cardboard or a soft or hard plastic material, such as for example polypropylene, or aluminum foil. Depending upon the material from which they are made and what they contain, some bags may be referred to as pouches or sachets. Each bag 1 10 may in some embodiments have a length YB and width XB that are substantially greater than the depth ZB. However, bag chain processing system 120 may be configured to process bag chains 100 that have bags 1 10 of different and widely varying relative dimensions.

[0085] The bags 1 10 of bag chain 100 may be foldable relative to each other. For example, bag chain 100 can be provided with a transversely oriented weakening line or a perforation in the material of the bags on a respective top and bottom transverse edge portion of the bags, in which case bags 1 10 in bag chain 100 are connected to one another along the transverse weakening line or perforation to form the bag chain. Alternatively or additionally, adjacent bags 1 10 in the bag chain 100 may be joined by a common, transversely oriented material connection portion 1 12. In each case this can provide a hinge to allow for one bag to pivot relative to the other adjacent bag or bags in a bag chain. The bags 1 10 in bag chain 100 can pivot relative to each other about a transversely oriented axis (such as axis X between bags 1 and 2 in Figure 1 ) which allows them to be folded into a zig-zag arrangement.

[0086] Prior to forming and folding a bag chain 00, containers such as bags 1 10 may each be filled with one or more items or material, such as for example one or more food items, washing powder, liquid pouches of various kinds, and other types of items. By way of example only, each bag may contain a food like potato chips or noodles, both of which are commonly packaged and distributed in flexible pouches. This may be done in ways and with equipment known in the industry. Once the containers such as bags 1 10 in a bag chain 100 are filled they may be completely sealed. For example, some materials are suitable for hot or cold sealing at an edge/seam as is known.

[0087] With reference now to Figure 2, a bag chain processing system 120 may comprise a plurality of subsystems / components including a bag chain infeed apparatus such as an infeed conveyor 128, a bag chain folding subsystem 122 and a bag chain compression apparatus 124. Bag chain processing system 120 may also include a first overhead bag chain discharge system 1 16 (shown only schematically) for discharging one or more folded bag chains from bag chain folding subsystem 122 to bag chain compression apparatus 124. Bag chain processing system 120 may also include a second overhead bag chain discharge system 1 18 (shown only schematically) for discharging one or more folded bag chains 100 from bag chain compression apparatus 124 to a collating platform 1 14 and also for discharging a plurality of transversely positioned rows of collated bag chains 100 from the collating platform 1 14 to a pick up platform 170 at a pickup station 146.

[0088] Bag chain processing system 120 may also include a discharge system which may for example be a robotic pick up apparatus 126 (or another suitable pick up system) which may be operable to pick up a plurality of rows of one or more folded bag chains 100 from pick up platform 170 at pick-up station 146 and remove them for further processing / handling (eg. to be loaded into a case at a case packing station - not shown).

[0089] Bag chain processing system 120 may also include a controller 150 which may control the operation of the various systems / sub-systems / components of bag chain processing system 20.

[0090] The bag chain infeed apparatus may be configured in many different ways to deliver bag chains 100, with the bags 1 10 arranged in series, to a loading station. With reference to both Figures 2 and 3, infeed conveyor 128 that may be longitudinally oriented and aligned about longitudinal axis Y1 and may be operable to deliver a plurality of bag chains 100 in longitudinal alignment, and in a generally planar / flat configuration in series to bag chain folding subsystem 122. Infeed conveyor 128 may be a belt conveyor having a generally flat continuous conveyor belt 156 stretching between a drive wheel (not shown) and an idler wheel 157. Bags 1 10 of each bag chain 100 may lie in a generally flat orientation on the upward facing surface of upper run of conveyor belt 156 as shown in Figures 2-4. Each bag chain 100 being fed by infeed conveyor 128 to bag chain folding subsystem 122 may have a leading bag (eg. bag (1 ) in Figure 4), one or more intermediate bags (eg. bag (2) to bag (7) in Figure 4) and a trailing bag (bag (8) in Figure 4). [0091] Infeed conveyor 128 may also have a drive motor (not shown) that may be a servo drive motor controlled by controller 150 which may drive the drive wheel to move the conveyor belt. Controller 150 may control the servo drive motor to drive the drive wheel of infeed conveyor 128 at a velocity V1 . The servo drive motor may include an encoder which is in communication with controller 150. The velocity V1 and position of conveyor belt 156 may be monitored, varied and controlled in operation by controller 150.

[0092] Bag chain folding subsystem 122 may include one or more folding bucket conveyors 129 which may also extend longitudinally parallel to infeed conveyor 128 and may also be generally transversely aligned with infeed conveyor 128 about axis Y1 . Folding bucket conveyor 129 may thus also be aligned about longitudinal axis Y1 (Figure 2). Infeed conveyor 128 may be vertically, transversely and longitudinally positioned to facilitate the loading and folding of bag chains 100 on folding bucket conveyor 129 as described below. Folding bucket conveyor 129 may comprise two separate but overlapping bucket conveyors having a first continuous conveyor belt 152a stretching between a first drive wheel 142a and a first longitudinally spaced idler wheel 144a. Thus conveyor belt 152a may have a first lower run portion that stretches below the upper run and from first drive wheel 142a to first idler wheel 144a. Conveyor belt 152a may have a first curved portion at first idler wheel 144a that is positioned at the location of loading station 141 and linking the lower run with the upper run. Conveyor belt 152a may also have a second curved portion at first drive wheel 142a. Bag chain folding subsystem 122 may also have a first drive motor 143a that may be a servo drive motor controlled by controller 150. First drive motor 143a may drive first drive wheel 142a to move first conveyor belt 152a longitudinally at a velocity/speed V2. The servo drive motor 143a may include an encoder which is in communication with controller 150. Thus the velocity V2 and position of conveyor belt 152a may be monitored, varied and controlled in operation by controller 150 controlling first drive motor 143a. [0093] Attached to conveyor belt 152a may be a first bucket train 132a. Bucket train 132a may comprise a plurality of spaced flights / wall members 138a that extend vertically orthogonal to conveyor belt 152a and may extend transversely across the entire width of the operational zone of folding conveyor 129. Bucket flights 138a may be spaced to create a bucket carriage 133a that has bucket cavities 134a, 136a formed for holding folded bags 1 10 of a bag chain 100. Each bucket train 132a may have a plurality of bucket carriages 133a arranged in series, such that each bucket train 132a may handle more than one folded bag chain 100.

[0094] With reference to Figure 3, a bucket carriage 133a of bucket train 132a may have transversely oriented bucket flights 138a to provide single bucket cavities 136a, that may in some embodiments provide transverse side openings. Single bucket cavities 136a may be located at both the front and back of bucket carriage 133a. Bucket train 132a may also have transversely oriented bucket flights 138a that provide one or more double bucket cavities 134a between the leading and trailing single bucket cavities 136a. Double bucket cavities 134a may in some embodiments provide transverse side openings. The height that each of the bucket flights 138a extends from the bucket conveyor upper surface of the conveyor belt 152a and the spacing of bucket flights 138a and the respective longitudinal lengths L2 and L1 of the cavities 134a, 136a is selected such that it allows the bags 1 10 numbered 1 to 8 to be loaded into cavities 134a, 136a in the folded arrangement shown in Figure 4.

[0095] Folding bucket conveyor 129 may also having a second continuous conveyor belt 152b that may operate out of phase with and independently of the movement of first continuous conveyor belt 152a. Conveyor belt 152b may be oriented parallel and positioned close to conveyor belt 152a. Conveyor belt 152b may stretch between a second drive wheel 142b (that is positioned parallel and adjacent drive wheel 142a) and an idler wheel 144b (that is adjacent and parallel to idler wheel 144a). Conveyor belt 152b may have a first lower run portion that stretches below the upper run and between second drive wheel 142b and second idler wheel 144b. Conveyor belt 152b may have a first curved portion at idler wheel 144b that is positioned at the location of loading station 141 and links the lower run and the upper run. Conveyor belt 152b may also have a second curved portion at drive wheel 142b that links the upper run with the lower run.

[0096] Bag chain folding subsystem 122 may also have a first drive motor 143a that may be a servo drive motor controlled by controller 150 and may drive the drive wheel 142a to move the conveyor belt 152a at a velocity V2. Bag chain folding subsystem 122 may also have a second drive motor 143b that may also be a servo drive motor controlled by controller 150 which may drive the drive wheel 142b to move the conveyor belt 152b at a velocity V3 that is independent of the velocity V2 of conveyor belt 152a. The servo drive motor 142b may include an encoder which is in communication with controller 150. Thus, the velocity V3 and position of conveyor belt 152b may be monitored, varied and controlled in operation as described hereinafter by controller 150 controlling first drive motor 143b.

[0097] As will become evident from the following discussion, controller 150 can control the movement of conveyor belts 152a, 152b which includes varying the velocities/speeds V2 and V3, and during part of the cyclical movement of belts 152a, 152b, V2 and V3 may become zero.

[0098] Like conveyor belt 152a, attached to conveyor belt 152b may be a second bucket train 132b. Bucket train 132b may comprise a plurality of spaced flights or wall members 138b that extend vertically orthogonal to conveyor belt 152b and also extend transversely across the entire width of folding bucket conveyor 129. Bucket flights 138b may be spaced to create a bucket carriage 133b that has cavities 134b, 136b formed for holding folded bags 1 10 of a bag chain 100. Each bucket train 132b may have a plurality of bucket carriages 133b arranged in series, such that each bucket train 132b may handle more than one folded bag chain 100.

[0099] The height that each of the bucket flights 138b extends upwards from the upper surface of the conveyor belt 152b and the spacing of bucket flights 138b and the respective longitudinal lengths L2 and L1 of the cavities 134b, 136b is also selected such that it allows bags 1 10 numbered (1 ) to (8) in a bag chain 100 to be loaded into cavities 134b, 136b and into the folded arrangement shown in Figure 4.

[00100] By providing first continuous conveyor belt 152a that can move independently of the movement of second continuous conveyor belt 152b, folding bucket conveyor 129 can have one of the bucket trains 132a, 132b of respective continuous conveyor belts 152a, 152b at the loading station 141 and engaged in folding one more bag chains 100 that are being fed in series by infeed conveyor 128, while the other of the of the bucket trains 132a, 132b of respective continuous conveyor belts 152a, 52b can move to and stay at a discharge station where one or more folded bag chains 100 are unloaded from folding bucket conveyor 129 on to bag chain compression apparatus 124. This permits a relatively high throughput of bag chains 100 that are processed by bag chain folding subsystem 122, and bag chain processing system 120 as a whole.

[00101] Bag chain folding subsystem 122 may also include a sensor 154 such as an electronic eye that is in communication with controller 150. Sensor 154 may be operable to detect the presence of a leading edge of leading bag (1 ) in a bag chain 100 on conveyor 128 reaching a position at or proximate the end of conveyor 28 such that it may be fed to bag chain folding subsystem 122 by infeed conveyor 128. Upon detecting the presence of a leading edge of a leading bag (1 ) of a bag chain 100 on conveyor 128 at a position at or proximate the end of conveyor 128, sensor 154 may send a signal to controller 150 to cause controller 150 to activate a drive motor 143a or 143b associated with the one of the conveyor belts 152a or 152b that is waiting at a loading position (such conveyor belt 152b as shown in Figures 2 and 3) to start to effect the loading and folding of a bag chain 100 into bucket train 132b.

[00102] With reference to Figures 2, 3 and 4, in operation, infeed conveyor 128 feeds one or more chains of bags 100 in series to a transfer location where each chain of bags 100 is transferred from infeed conveyor 128 to a bucket carriage 133a or 133b of a respective bucket train 132a, 132b driven by a respective conveyor belt 152a, 152b under control of controller 150.

[00103] As shown in position 1 in Figure 4, the leading single bucket cavity (such as single bucket cavity 136b in Figure 4) may be at the end curved portion of conveyor belt 152b at a loading position that is positioned at a slight upward angle from the horizontal and close to the end of conveyor belt 156 such that the mouth of the single bucket cavity 36b is suitably positioned to receive the leading portion of the first bag (1 ) of the bag chain 00. The single bucket cavity 136b is relatively narrow which assists in holding the first bag (1 ) of the chain in the single bucket cavity once the first bag (1 ) has been loaded.

[00104] A sensor 154 detects the presence of a leading edge of the first bag (1 ) of a bag chain 100 on conveyor 28 as it reaches the loading position which means that it may be fed to folding bucket conveyor 129 of bag chain folding subsystem 122 by infeed conveyor 128. A signal is sent by sensor 154 to controller 150. A bucket carriage such as carriage 133b of bucket train 132b may be stationary at the initial loading position shown as position (1 ) in Figure 4. Upon detecting the presence of a leading edge of a bag chain 100 on conveyor 128 at a position at or proximate the end of conveyor 128, sensor 154 having sent a signal to controller 150, controller 150 will then activate drive motor 143b associated with conveyor belt 152b that is waiting at a loading position at loading (and folding) station 141 to start to effect the loading and folding of a bag chain 100 into bucket train 132b. The velocity V1 of conveyor 128 may be selected such that the first bag (1 ) in the bag chain 1 10 can be loaded at least partially into the leading single bucket cavity 136b before the conveyor belt 152b starts moving.

[00105] Once conveyor belt 152b starts moving the first bag (1 ) will be almost entirely or entirely within leading single bucket cavity 136b. After bag (1 ) has entered the leading single bucket cavity, conveyor 152a will accelerate and then may run at a steady, continuous speed until the last bag 1 10, bag (8) in the bag chain 100 is received into the trailing single bucket cavity 136b in the bucket train 133b, and that speed may be equal or faster than the speed of infeed conveyor 128.

[00106] The clockwise rotation / pivoting of the leading single bucket cavity 136b including the upper edge of the second bucket flight 138b of the leading bucket cavity 136b, above the level of the conveyor belt 156 will cause the second bag (2) to pivot counter-clockwise / downwards relative to bag (1 ) as shown at positions (2) to (3) in Figure 4 as infeed conveyor 128 continues to feed bag chain 1 10 forward. The connection portion 1 12 between bag (1 ) and bag (2) at the corresponding fold line will be positioned above or at the top edge of the second flight 138b, such that continued forward motion of conveyor belt 156 of infeed conveyor 128, and the rotational movement of the flights 138b of conveyor 152b around idler wheel 144b, will cause bag number 2 to move forward and be rotated / pivoted into the first double cavity 134b of carriage 133b as shown at position (3) in Figure 4.

[00107] Next once bag (2) is within cavity 134b, it starts to become oriented generally upright but possibly also oriented at a small angle with respect to the vertical (relative to the conveyor belt surface) flight 38b against which it is situated. Also, the next bag (3) in the bag chain 100 starts to be also moved forward into the same first, double cavity 134b, as shown in the movement from position (3) to position (4) in Figure 4. By position (4), bag (3) of the bag chain 100 is substantially entirely within the first double cavity 134b along with bag (2). Due the fact that the flights 138b that form the cavity 134b are moving around the circular / curved end portion at the end of the conveyor 152b formed by idler wheel 144b, the angles of the leading and trailing flights 138b of the first double bucket cavity are such that they are angled away from each other creating an open funnel effect which assists in the reception of bag (3) into the cavity.

[00108] Also, as can be seen at the position (4) in Figure 4, the next (the third) flight 138b on conveyor 152b is positioned to engage with a side surface of the bag (3) and/or connection portion 12 between bag (3) and bag (4) of the bag chain 100. As conveyor 128 and conveyor 152b continue to move from positions (4) to (5) to (6), the next third flight 138b on conveyor 152b engages the side surface of bag (3) and/or the connection portion 12 between bag (3) and bag (4) which causes bag (3) of the bag chain 1 10 to pivot / rotate clockwise causing it to fold relative to bag (2) with both bags (2) and (3) being positioned and folded with a lower fold line within the second double cavity 134b.

[00109] In moving from positions (4) to (5) of Figure 4 the clockwise rotation of conveyor 52b, also causes the upper edge of the flight 138b demarcating the first and second double bucket cavities 134b to be above the level of the conveyor belt 56 which will cause bag (4) to rotate counter clockwise relative to bag (3) as shown at position (5) in Figure 4. The connection portion 1 12 between bag (3) and bag (4) and corresponding fold line will be positioned above or at the top edge of the third flight 138b, such that continued forward motion of conveyor 152b and rotational movement of the flights 138b of conveyor 152b will cause bag (4) to move and be rotated into the second double cavity 134b as shown at position (5) in Figure 4. Again it will be appreciated that the relative velocities V1 of conveyor 128 and V3 of conveyor 152b will need to be selected and the radius of idler wheel 144b, and the height and spacing of the flights 138b, will also need to be selected, in order to achieve the desired result.

[00110] Next once bag (4) is within second double bucket cavity 134b, it starts to become oriented generally angled upright with respect to the third flight 138b. Also, the next bag (5) in the bag chain 100 starts to be also moved into the same second double bucket cavity 134b as bag (4), as shown in the movement from position (5) to position (6) in Figure 4. By position (7), the connection portion between bag (4) and bag (5) has been folded over the top edge of the third flight 138b and bag (5) of the bag chain 100 is substantially also entirely within cavity 134b and the connection portion 1 12 between bag (5) and bag (6) is positioned above or on the upper edge of the fourth flight 138b that demarcates the third and fourth, double bucket cavity 134b. Bags (4) and (5) are now also folded with a bottom fold line and are held within second double bucket cavity 134b. Also, due to the fact that the flights 138b that form the third double bucket cavity 134b are moving around the circular end portion and idler wheel 144b at the end of the conveyor 152b, the angles of the leading and trailing flights 138b are such that they are angled away from each other creating a funnel effect which assists in the reception of bag (5) into the cavity.

[00111] Also, as can be seen at the position (7) in Figure 4, the fourth flight 138b on conveyor 152b is positioned to engage with a side surface of bag (5) and / or a connection portion 138 between bag (5) and bag (6) of the bag chain 100. As conveyor 128 and conveyor 152b continue to move from positions (6) to (7) to (8), the fourth flight 138b on conveyor 152b engages a side surface of bag (5) and / or the connection portion 1 12 between bag (5) and bag (6) which causes bag (6) to rotate / pivot counter clockwise and causing it to fold relative to bag (7) at a lower fold line.

[00112] Once bag (6) is within the third, double bucket cavity 134b, it starts to become oriented generally angled upright with respect to the fourth flight 138b. Also, the next bag (7) in the bag chain 100 starts to be also moved into the same double bucket cavity 134b as bag (6), as shown in the movement from position (7) to position (8) in Figure 4. By position (9) of Figure 4, bag (7) of the bag chain 100 is substantially entirely within cavity 134b and the connection portion 1 12 between bag (7) and bag (8) is positioned above or on the upper edge of the final flight 138b in bucket carriage 133b that demarcates the third double bucket cavity 134b and one side of the trailing single bucket cavity 136b.

[00113] As can be seen at the position (8) to (9) in Figure 4, the fifth flight 38b on conveyor 152b is positioned to engage with a side surface of bag (7) and / or a connection portion 1 12 between bag (7) and bag (8) of the bag chain 100. As conveyor 128 and conveyor 152b continue to move from positions (8) to (9) to (10) and then to (1 1 ), the fifth flight 138b on conveyor 152b engages the a side surface of bag (5) and / or connection portion 1 12 between bag (7) and bag (8) which causes bag (8) to rotate counter clockwise causing it to fold relative to bag (7). [00114] In moving from positions (8) to (9) of Figure 4 the clockwise rotation of conveyor 152b, causes the upper edge of fifth flight 138b demarcating the last double bucket cavity 134b and the trailing bucket cavity 136b above the level of the conveyor belt 156 will cause bag (8) to rotate counter clockwise and downwards relative to bag (7) as shown at position (10) in Figure 4. The connection portion 1 12 between bag (7) and bag (8) will be positioned above or at the top edge of that the final flight 138b, such that continued forward motion of conveyor 156b and rotational movement of the flights 138b of conveyor 152b will cause bag (8) to move and be rotated into the trailing cavity 134b as shown at position (1 1 ) in Figure 4 and create a top fold line with bag (7).

[00115] At the position shown at position 1 1 in Figure 4, a bucket carriage 133b of a bucket train 132b has been loaded with a bag chain 100 in which the bags 1 10 have been placed into an initial folded zig-zag configuration. In position 12 in Figure 4, bucket train 132b with its single bucket carriage 133b is shown moving away from the loading (and folding) station 141 .

[00116] It will be appreciated, as stated above, that the relative velocities V1 of conveyor 128 and V3 of conveyor 152b will need to be selected, and the radius of idler wheel 144b, and the height of the flights 138b, will also need to be selected, in order to achieve the desired result as described above.

[00117] By way of an example only:

- the radius of idler wheels 144a. 144b may be about 190mm;

- the height of each of the flights 138a, 138b may be about 80mm; and

- the length of a bag 10 may be about 140mm (seal to seal).

[00118] The speed V1 of infeed conveyor 128 during operation may be selected at a suitable speed that may be a substantially constant speed. The speed V2 of belt 152a and the speed V3 of belt 152b may vary throughout each cycle. For example, when at the unloading station 145, the speeds V2 and V3 may be zero. At the loading/folding station 4 , the speeds V2 and V3 may be zero for a short period of time, during which a first leading bag (1 ) in a chain 100 is loaded into a bucket carriage 133a, 133b. V2 and V3 may then accelerate from zero to a speed which is held during the remainder of the loading sequence as shown for example in Figure 4. For example in some embodiments, once the conveyor belts are moving, V2 and V3 may accelerate to a speed that is equal to or faster than the speed of infeed conveyor 128. In other embodiments, once the conveyor belts are moving, V2 and V3 may accelerate to a speed that is less than the speed of infeed conveyor 128. Once all bucket carriages 133a, 133b of the respective bucket trains 132a, 132b are loaded, the speeds V2 and V3 may be increased to move the bucket trains to the unloading station 145. Thus, speeds V2 and V3 can be adjusted by controller 150 to provide for the operational loading sequence shown in Figure 4.

[00119] Bucket train 132a and its one or more carriages 133a, may also be loaded in the same manner as describe above, but may operate and be loaded (and unloaded) out of phase with bucket train 132b.

[00120] One or both of bucket trains 132a, 132b may each comprise more than one bucket carriage 133a, 133b. Thus a single bucket train such as bucket train 132a and/or bucket train 132b, may each have a plurality of respective bucket carriages 133a, 133b, each bucket carriage 133a, 133b carrying a single folded bag chain 100. Each bucket carriage 133a, 133b of a plurality of bucket carriages in the respective bucket train 132a, 132b, may be grouped together and may be loaded sequentially and continuously, with each bucket carriage 133a, 133b moving through the loading sequence as described above in relation to bucket carriage 133b.

[00121] Once a bucket train 132a, 132b has been loaded with one or more folded bag chains 1 10, the loaded bucket train 132a, 132b is moved by its respective conveyor 152a, 152b under control of controller 150 to the unloading station 145.

[00122] Bag chain processing system 120 may also include a first overhead bag chain discharge system 1 16 (shown only schematically) for discharging a folding bag chain 100 positioned at unloading station 145 from bag chain folding subsystem 122 to bag chain compression apparatus 124. First overhead bag chain discharge system 1 16 may include an overhead gantry mechanism that may be movable with reciprocating transverse movement. The gantry mechanism of first overhead bag chain discharge system 1 16 may support a longitudinally oriented lower pushing plate device 160 that may include a plurality of individual longitudinally oriented wall members 161 separated by openings that are wide enough to permit the width of bucket flights 138a, 138b of each bucket train 132a, 132b of conveyor belts 152a, 152b to pass there through. The gantry mechanism of first overhead bag chain discharge system 1 16 may be controlled by controller 150 which may respond to signals sent from the encoders associated with the servo motors driving conveyor belts 152a, 152b.

[00123] When the controller 150 receives a signal (from a sensor or encoder) indicative of a bucket train 132a or 132b being at the unloading position, the controller will cause the respective conveyor belt 152a or 152b of folding bucket conveyor 129 to stop at an appropriate position at the unloading station 145. The gantry mechanism of first overhead discharge apparatus 1 16 will be activated by controller 150 to move pushing plate 160 transversely to cause longitudinally oriented wall members 161 to move transversely through the cavities 134a, 136a or 134b, 136b, that hold the bags 1 10 of the one or more bag chains 100, and move the row of one or more bag chains 100 away from folding bucket conveyor 129 and onto a horizontally oriented compression platform 165.

[00124] The positioning of the row of one or more bag chains 100 on compression platform 165 may be facilitated in part by either a sensor (eg. an electronic eye) located near compression platform 165 and/or by an encoder associated with a servo drive motor that drives the gantry mechanism of first overhead discharge apparatus 1 16. Such sensor / encoder will be in communication with controller 150 and send a signal to controller 150 once the row of one or more bag chains is suitably positioned on compression platform 165, to simultaneously activate compression cylinders 166 and 167 to cause the pistons thereof with plates 168, 169 attached thereto to move inwardly towards each other a small distance. Compression cylinders 166, 167 may be conventional pneumatic cylinders supplied with pressurized air from a source and have opening/closing valves associated therewith that are controlled by controller 150. When the pistons of compression cylinders 166, 167 extend their piston with plates 168, 169 attached inwardly towards each other a small distance, this causes the row of one or more folded bag chains 100 on compression platform 165 to be compressed a small amount.

[00125] Once the row of one of more folded bag chains 100 is compressed, it is ready to again be moved in a transverse direction further away from folding bucket conveyor 129 from compression platform 165 to collating platform 1 14. This may be accomplished by second overhead bag chain discharge system 1 18 (shown only schematically) for discharging one or more folded bag chains 100 from bag chain compression apparatus 124 to the collating platform 1 14.

[00126] Second overhead bag chain discharge system 1 18 may include an overhead gantry mechanism that may be movable with reciprocating transverse movement. It may also be configured to provide a walking beam type cyclical motion. The gantry mechanism of second overhead bag chain discharge system 1 18 may support a longitudinally oriented lower plate device 1 19. The gantry mechanism may be controlled by controller 150 which may act on signals one or more sensors / encoders associated with servo drive motors in communication with controller 150.

[00127] When the controller 150 has received a signal indicating that a row of one or more bag chains 100 on compression platform 165 has been compressed and is ready to be transferred, gantry mechanism of second overhead bag chain discharge system 1 18 will be activated by controller 150 to move the associated plate device 1 19 transversely to cause the row of one or more bag chains 1 10 on compression platform to move transversely onto collating platform 1 14. The positioning of the row of one or more bag chains 100 on collating platform 1 14 may be facilitated in part by either a sensor (eg. an electronic eye) located near collating platform 1 14 and/or by an encoder associated with a servo drive motor that drives the gantry mechanism. Such sensor / encoder will be in communication with controller 150 and send a signal to controller 150 once the row of one or more bag chains is suitably positioned on collating platform 1 14.

[00128] Collating platform 1 14 may collect one or more rows (eg. two rows, three rows) of one or bag chains 100 in transversely positioned rows (see Figure 2). Each row of one or more bag chains 100 will be serially moved in turn onto collating platform 1 14 and so that under control by controller 150, gantry mechanism of second overhead bag chain discharge system 1 18 will sequentially move transversely far enough each time to properly place each particular row on collating platform 1 14 so as to collect the correct number of rows (eg. three rows in Figure 2).

[00129] Once all the desired number of rows (eg. three in Figure 2) have been collected on collating platform 1 14, gantry mechanism of second overhead bag chain discharge system 1 18 will be activated by controller 150 to move the associated plate device 1 19 transversely to cause all three rows of one or more bag chains 1 10 on collating platform 1 14 to move transversely from collation platform 1 14 onto a pick up platform 170 at pick up station 146.

[00130] Another sensor located near pick up platform 170 will be in communication with controller 150 and send a signal to controller 150 once the three rows of one or more bag chains is on pick up platform 170. This may cause controller 150 to simultaneously activate compression cylinders 171 and 172 to cause the pistons thereof with plates 173, 174 attached thereto to move inwardly towards each other a small distance. Compression cylinders 171 , 172 may be conventional pneumatic cylinders supplied with pressurized air from a source and have opening/closing valves associated therewith that are controlled by controller 150. When the pistons of compression cylinders 171 , 172 extend their piston with plates 173, 174 attached inwardly towards each other a small distance, this causes each of the three rows of one or more folded bag chains 100 on pick up platform 170 to be compressed a small amount. [00131] Once all three rows of one of more folded bag chains 100 are, compressed, they are ready to be removed from pick up platform 170 by robotic pick up apparatus 126 (or some other suitable apparatus). Robotic pick up apparatus 126 may include a robot 184 with an articulated arm 181 having an end effector 180 at the end thereof. End effector 180 may include a plurality of pick up members 182 that may include vacuum cups. Thus robotic apparatus 126 may be operable to pick up the plurality of rows of one or more folded bag chains 1 10 from the pick-up platform 170 and transfer them to another station for further processing/handling (eg. to be loaded into a case at a case packing station - not shown).

[00132] In bag chain processing system 120, controller 150 can control the operation of bucket conveyor 129 to provide for the continuous operation of both conveyor belts 152a, 52b and their respective bucket trains 132a and 132b, to process multiple bag chains 100 delivered in series to loading (and folding) station 141. As indicated above, bucket trains 132a, 132b may be operated out of phase with each other.

[00133] Many variations to the foregoing are possible. By way of example only, the configuration of the bucket carriages and bucket cavities thereon may be varied. Also, bucket chains of more or less than eight bags may be folded with such a system.

[00134] Some systems may be configured to process container chains, where the containers themselves are rigid or semi-rigid but are foldable relative to each other.

[00135] In some embodiments, the container chain processing system may include a chain feed apparatus that is not an infeed conveyor and may not feed the container chains horizontally. For example, bag chains may be fed from a chain forming apparatus directly to the loading station and at an angle such as about 60 or 70 degrees or more to the horizontal, while still feeding the chain to bucket cavities located at a curved portion of the bucket conveyor path. [00136] Of course, the above described embodiments are intended to be illustrative only and in no way limiting. The described embodiments of carrying out the invention are susceptible to many modifications of form, arrangement of parts, details, and order of operation. The invention, therefore, is intended to encompass all such modifications within its scope.

[00137] When introducing elements of the present invention or the

embodiments thereof, the articles "a," "an," "the," and "said" are intended to mean that there are one or more of the elements. The terms "comprising," "including," and "having" are intended to be inclusive and mean that there may be additional elements other than the listed elements.

Claims

CLAIMS:

1 . An apparatus for folding a chain of containers, said chain comprising a plurality of containers arranged in series and being foldable relative to each other, said apparatus comprising:

- a feeding apparatus operable for feeding a container chain in an unfolded configuration to a loading station;

- a bucket conveyor comprising a plurality of longitudinally spaced members, said longitudinally spaced members defining at least one bucket cavity, said bucket conveyor being operable to move said at least one bucket cavity to and from said loading station;

- wherein said apparatus is operable such that said feeding apparatus feeds said container chain to said bucket conveyor at said loading station such that a first container of said plurality of containers is fed into a bucket cavity of said at least one bucket cavity and a second container connected to said first container is fed to a bucket cavity of said at least one bucket cavity in such a manner as to form a folded configuration of said first container relative to said second container on said bucket conveyor.

2. An apparatus as claimed in claim 1 wherein said chain of containers comprises a bag chain, said first container comprises a first bag and said second container comprises a second bag.

3. An apparatus as claimed in claim 2 wherein said feeding apparatus is a feeding conveyor.

4. An apparatus as claimed in claim 2 wherein:

- said feeding apparatus is a feeding conveyor that is oriented generally longitudinally; - said bucket conveyor is oriented generally longitudinally and in transverse alignment with said feeding conveyor, said feeding conveyor and said bucket conveyor being operable to generally move in a longitudinal direction;

- wherein said apparatus is operable such that said feeding conveyor feeds said bag chain to said bucket conveyor at said loading station such that said first bag of said plurality of bags is fed into a bucket cavity of said at least one bucket cavity and a second bag connected to said first bag is fed into a bucket cavity of said at least one bucket cavity to pivot said first bag relative to said second bag to form a folded configuration of said first bag relative to said second bag on said bucket conveyor.

5. An apparatus as claimed in claim 3 or 4 wherein in operation said feeding conveyor feeds said bag chain to said bucket conveyor such that a first bag of said plurality of bags is first fed into a bucket cavity of said at least one bucket cavity, and a second bag connected to said first bag is fed to a bucket cavity of said at least one bucket cavity while said bucket conveyor and said bucket cavity are moving longitudinally, to form a folded configuration of said first bag relative to said second bag on said bucket conveyor.

6. An apparatus as claimed in any one of claims 3, 4 or 5 wherein:

- said bucket conveyor comprises a curved portion at said loading station; and

- said apparatus is operable such that in operation said feeding conveyor feeds said bag chain to said curved portion of said bucket conveyor such that said first bag of said plurality of bags is fed into a bucket cavity located at said curved portion of said bucket conveyor and a second bag connected to said first bag is fed to a bucket cavity located at said curved portion of said bucket conveyor, to form a folded configuration of said first bag relative to said second bag on said bucket conveyor.

7. An apparatus as claimed in any one of claims 2 to 6 wherein said first bag is a leading bag in said bag chain.

8. An apparatus as claimed in any one of claims 2 to 7 wherein said bucket conveyor comprises: (i) a first run extending to said loading station; (ii) said curved portion located at said loading station; and (iii) a second run extending away from said loading station.

9. An apparatus as claimed in any one of claims 2 to 8 wherein in operation, said first bag of said bag chain is fed into a first cavity of said bucket conveyor and said second bag in said bag chain is fed into a second cavity of said bucket cavity, such that said first bag and said second bag are folded over a member of said bucket conveyor that defines said first cavity.

10. An apparatus as claimed in any one of claims 2 to 6 wherein in operation, said first bag of said bag chain is fed into a first cavity of said bucket conveyor and said second bag of said bag chain is fed into said first cavity of said bucket conveyor, such that said first bag and said second bag are folded within said first cavity of said bucket conveyor.

1 1 . An apparatus as claimed in claim 10 wherein neither said first bag nor said second bag is a leading bag of said bag chain.

12. An apparatus as claimed in claim 8 wherein in operation said first and second bag are fed into respective first and second cavities as said first and second cavities of said bucket conveyor are moving through said curved portion.

13. An apparatus as claimed in claim 8 wherein in operation said first and second bag are fed into respective first and second cavities as said first and second cavities are positioned within said curved portion.

14. An apparatus as claimed in claim 8 wherein in operation, said first and second bag are fed into respective cavities as said respective cavities of said bucket conveyor are moving through said curved portion. 5. An apparatus as claimed in any one of claims 2 to 9 or claims 12 to 14, wherein said infeed conveyor has a first velocity in a longitudinal direction and said bucket conveyor has a velocity in a longitudinal direction, and wherein while said first bag of said bag chain is being fed into said cavity of said at least one cavity, said velocity of said bucket conveyor is zero.

16. An apparatus as claimed in claim 15 wherein after said first bag of said bucket chain has been loaded into said cavity, said bucket conveyor will accelerate to a speed that is greater than or equal to the speed of the infeed conveyor.

17. An apparatus as claimed in claim 15 wherein after said first bag of said bucket chain has been loaded into said cavity, said bucket conveyor will accelerate to a speed that is less than the speed of the infeed conveyor.

18. An apparatus as claimed in claim 9 wherein in operation, said first bag of said bag chain is fed into a first cavity of said bucket conveyor and said second bag in said bag chain is fed into a second cavity of said bucket cavity, such that said first bag and said second bag are folded over a member of said bucket conveyor, and wherein a third bag in said bag chain that is connected to said second bag, is fed into said second cavity of said bucket conveyor, such that said second and third bags are folded in a bottom region of said second cavity.

19. An apparatus as claimed in claim 18 wherein a fourth bag in said bag chain that is connected to said third bag, is fed into a third cavity of said bucket conveyor that is adjacent to said second cavity, such that said third and fourth bags are over a flight of said bucket conveyor.

20. An apparatus as claimed in claims 18 or 19, wherein in operation said third and fourth bags are fed into respective second and third cavities as said second and third cavities moving through said curved portion.

21. An apparatus as claimed in claim 20 wherein in operation, said first second and third bag are fed into respective bucket cavities as said bucket cavities of said bucket conveyor is moving through said curved portion.

22. An apparatus as claimed in claim 19 wherein in operation said fourth bag is fed into a third cavity as said third cavity is moving through said curved portion.

23. An apparatus as claimed in claim 20 further comprising a fifth bag in said bag chain that is connected to said fourth bag, and which is fed into said third cavity of said bucket conveyor that is adjacent to said second cavity, such that said fourth and fifth bags are folded within and at a bottom region of said third cavity.

24. An apparatus as claimed in claim 23 wherein in operation said fifth bag is fed into said third cavity as said third cavity is moving through said curved portion.

25. An apparatus as claimed in any one of claims 2 to 24 wherein said infeed conveyor has a first velocity in a longitudinal direction and said bucket conveyor has a second velocity in a longitudinal direction, and wherein while said first bag of said bag chain is being fed into said cavity of said at least one cavity, said velocity of said bucket conveyor is zero.

26. An apparatus as claimed in claim 25 wherein after said first bag of said bucket chain has been loaded into said cavity, said bucket conveyor will accelerate to a speed that is greater than or equal to the speed of the infeed conveyor.

27. An apparatus for folding a chain of containers, said chain comprising a plurality of containers arranged in series and being foldable relative to each other, said apparatus comprising:

- a first bucket conveyor comprising a plurality of longitudinally spaced members, said longitudinally space members defining at least one bucket cavity, said first bucket conveyor being operable to move said at least one bucket cavity of said first bucket conveyor to and from said loading station;

- a second bucket conveyor comprising a plurality of longitudinally spaced members, said longitudinally space members defining at least one bucket cavity, said second bucket conveyor being operable to move said at least one bucket cavity of said second bucket conveyor to and from said loading station;

- wherein said apparatus is operable such that said feed apparatus feeds a first container chain to said first bucket conveyor at said loading station such that a first container of said first container chain is fed into a bucket cavity of said at least one bucket cavity of said first bucket conveyor and a second container of said first container chain connected to said first container of said first container chain is fed to a bucket cavity of said at least one bucket cavity in such a manner as to form a folded configuration of said first container of said first container chain relative to said second container of said first container chain on said first bucket conveyor; and

- wherein said apparatus is operable such that said feed conveyor feeds a second container chain to said second bucket conveyor at said loading station such that a first container of the second container chain is fed into a bucket cavity of said at least one bucket cavity of said second bucket conveyor and a second container of said second container chain connected to said first container of said second container chain is fed to a bucket cavity of said at least one bucket cavity in such a manner as to form a folded configuration of said first container of said second container chain relative to said second container of said second container chain on said second bucket conveyor.

28. An apparatus as claimed in claim 27 wherein said first container chain comprises a first bag chain comprising a first bag and a second bag of said first container chain and wherein said second container chain comprises a second bag chain comprising a first bag and a second bag of said second container chain.

29. An apparatus as claimed in claim 28 wherein said first bucket conveyor operates in loading bag chains out of phase with respect to said second bucket conveyor.

30. A system for processing a plurality of container chains comprising: a. An apparatus as claimed in any one of claims 1 to 29; b. A discharge apparatus operable to discharge a container chain from said bucket conveyor at a transfer station.

31 . A system as claimed in claim 30 further comprising a compression apparatus operable to compress a container chain discharged from said bucket conveyor.

32. A system as claimed in claim 31 further comprising a collation apparatus operable to collate a plurality of rows of container chains at a collation station.

33. A system as claimed in claim 32 further comprising a removal apparatus operable to remove said plurality of rows of container chains from said collation station.

34. A method for folding a chain of containers, said chain comprising a plurality of containers arranged in series and being foldable relative to each other, said method comprising:

- moving a bucket conveyor, said bucket conveyor comprising a plurality of longitudinally spaced members, said longitudinally space members defining at least one bucket cavity, to move said at least one bucket cavity to and from a loading station;

- feeding a container chain in an unfolded configuration to a loading station such that a first container of said plurality of containers is fed into a bucket cavity of said at least one bucket cavity and a second container connected to said first container is fed to a bucket cavity of said at least one bucket cavity in such a manner as to pivot the second container relative to the first container to form a folded configuration of said first container relative to said second container on said bucket conveyor.

35. A method as claimed in claim 34 wherein said chain of containers comprises a bag chain, said first container comprises a first bag and said second container comprises a second bag.

36. A method as claimed in claim 34 wherein:

- said bag chain is fed in a first longitudinal direction;

- said bucket conveyor is oriented and moves in second longitudinal direction parallel with said first longitudinal direction and in transverse alignment with said bag chain;

- wherein said bag chain is fed to said bucket conveyor at said loading station such that said first bag of said plurality of bags is fed into a bucket cavity of said at least one bucket cavity and a second bag connected to said first bag is fed into a bucket cavity of said at least one bucket cavity to form a folded configuration of said first bag relative to said second bag on said bucket conveyor.

37. A method for processing a plurality of container chains comprising:

(i) A method as claimed in any one of claims 34 to 36;

(ii) discharging a container chain from said bucket conveyor at a transfer station.

38. A method as claimed in claim 37 further comprising compressing a container chain discharged from said bucket conveyor.

39. A method as claimed in claim 38 further comprising collating a plurality of rows of container chains at a collation station.

40. A method as claimed in claim 39 further comprising removing said plurality of rows of container chains from said collation station.

41 .A method as claimed in any one of claims 34 to 40 wherein:

- said bucket conveyor comprises a curved portion at said loading station; and

- said bag chain is fed to said curved portion of said bucket conveyor such that said first bag of said plurality of bags is fed into a bucket cavity located at said curved portion of said bucket conveyor and a second bag connected to said first bag is fed to a bucket cavity located at said curved portion of said bucket conveyor, to form a folded configuration of said first bag relative to said second bag on said bucket conveyor.

42. A method as claimed in any one of claims 34 to 41 wherein said first bag is a leading bag in said bag chain.

43. A method as claimed in any one of claims 34 to 42 wherein said bucket conveyor comprises: (i) a first run extending to said loading station; (ii) said curved portion located at said loading station; and (iii) a second run extending away from said loading station.

44. A method as claimed in any one of claims 34 to 43 wherein first bag of said bag chain is fed into a first cavity of said bucket conveyor and said second bag in said bag chain are fed into a second cavity of said bucket cavity, such that said first bag and said second bag are folded over a member of said bucket conveyor that defines said first cavity.

45. A method as claimed in any one of claims 34 to 43 wherein said first bag of said bag chain is fed into a first cavity of said bucket conveyor and said second bag of said bag chain is fed into said first cavity of said bucket conveyor, such that said first bag and said second bag are folded within said first cavity of said bucket conveyor.

46. A method as claimed in claim 45 wherein neither said first bag nor said second bag is a leading bag of said bag chain.

47. A method as claimed in claim 41 wherein said first and second bag are fed into respective first and second cavities as said first and second cavities of said bucket conveyor are moving through said curved portion.

48. A method as claimed in claim 41 wherein said first and second bag are fed into respective first and second cavities as said first and second cavities are positioned within said curved portion.