Casing method and apparatus

Abstract

A caser is disclosed for packing filled containers in empty cases. The caser includes a conveyor belt that carries filled containers to the caser for loading and a pusher assembly for pushing the containers onto the loading tables wherein the containers are gravity fed into cases positioned below the loading tables. The loading tables preferably retract linearly to allow the containers to drop into the cases. A pair of bottle guides pivot to grip the containers while the loading tables retract.

Description

FIELD OF THE INVENTION

[0001] The present invention relates generally to casing machines for assembling and loading objects or containers into carrying cases, and more particularly, to production casers employed in bottling plants and dairies utilizing infeed conveyor lines of filled containers arriving at a casing station, grouping the filled containers by a predetermined number and loading the filled containers into cases without damaging the filled containers.

BACKGROUND OF THE INVENTION

[0002] It is an object of the invention to provide a high capacity apparatus which is of simple, modular and compact, yet sturdy construction and has a capacity which may be varied to accommodate the output of the container filler.

[0003] It is a further object of the invention to provide a high capacity apparatus wherein various components thereof may be readily replaced with a minimum amount of downtime, and the apparatus is capable of being readily cleaned so as to meet rigid sanitary requirements.

SUMMARY OF THE PREFERRED EMBODIMENTS

[0004] A caser is disclosed for packing filled containers in empty cases. The caser includes a conveyor belt that carries filled containers to the caser for loading and a pusher assembly for pushing the containers onto the loading tables wherein the containers are gravity fed into cases positioned below the loading tables. The loading tables preferably retract linearly to allow the containers to drop into the cases. A pair of bottle guides pivot to grip the containers while the loading tables retract.

[0005] The bottle guides and loading tables are preferably pneumatically powered. The bottle guides are operatively connected to air springs. When activated, the air springs move the lower portions of the bottle guides closer to each other, causing the guides to grip the lower parts of the containers.

[0006] The loading tables are preferably divided into two sections, i.e., a first table and a second table, each section movable by a piston and cylinder assembly. The piston and cylinder assembly operate to move the loading tables linearly toward each other to close the tables and away from each other to open the tables. The piston and cylinder assemblies and the air springs are in communication with a main air supply line available at the manufacturing plant. The main air supply line is attachable to an air intake manifold positioned on the caser.

[0007] In a preferred embodiment of the invention, the air intake manifold is in communication with a centralized air manifold on the caser. The centralized air manifold is preferably located equidistant from the piston and cylinder assemblies and from the respective air springs to ensure equal distribution of air to the various pneumatically powered components.

[0008] When the loading tables are fully retracted, the containers are gravity fed into cases positioned below. To ensure that the containers do not move out of alignment during the loading process, the caser provides various guides that direct the containers into the cases. For example, the sections of the loading tables each have an inclined ledge extending therefrom. The inclined ledges are configured to define a tapered passageway through which the containers can pass. The tapered passageway guides the containers into the cases and prevents the containers from hitting the sides of the cases or otherwise moving out of place.

[0009] Other objects, features and advantages of the present invention will become apparent to those skilled in the art from the following detailed description. It is to be understood, however, that the detailed description and specific examples, while indicating preferred embodiments of the present invention, are given by way of illustration and not limitation. Many changes and modifications within the scope of the present invention may be made without departing from the spirit thereof, and the invention includes all such modifications.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The invention may be more readily understood by referring to the accompanying drawings in which:

[0011] FIG. 1 depicts a first side of a preferred embodiment of the casing apparatus of the present invention;

[0012] FIG. 2 depicts a second side of a preferred embodiment of the casing apparatus of the present invention;

[0013] FIG. 3 depicts an upstream view of a preferred embodiment of the casing apparatus of the present invention;

[0014] FIG. 4 depicts a downstream view of a preferred embodiment of the casing apparatus of the present invention;

[0015] FIG. 5 depicts a partial view of the conveyor belt and the loading area of a preferred embodiment of the casing apparatus of the present invention;

[0016] FIG. 6 depicts a preferred embodiment of the casing apparatus of the present invention having jugs in the loading area;

[0017] FIG. 7 depicts a preferred embodiment of the casing apparatus of the present invention showing the jugs traveling onto the loading tables;

[0018] FIG. 8 depicts a preferred embodiment of the bottle guides of the present invention gripping the lower portions of the containers on the loading tables;

[0019] FIG. 9 depicts a preferred embodiment of the bottle guides of the present invention releasing the containers into the cases below;

[0020] FIG. 10 depicts a preferred embodiment of the casing apparatus of the present invention showing the containers loaded in the cases below;

[0021] FIG. 11 depicts a preferred embodiment of the casing apparatus the present invention having case guides aligned with the cases;

[0022] FIG. 12 depicts a preferred embodiment of the case guides of the present invention;

[0023] FIG. 13 depicts a preferred embodiment of the centralized air manifold of the present invention in communication with the intake air manifold;

[0024] FIG. 14 depicts a preferred embodiment of the piston and cylinder assembly of the present invention;

[0025] FIG. 15 depicts a preferred embodiment of the removable cover of the present invention as installed on the piston and cylinder assembly;

[0026] FIG. 16 depicts the control panel of the central processor of the present invention; and

[0027] FIG. 17 depicts a preferred embodiment of the set collars and support rods of the present invention.

[0028] Like numerals refer to like parts throughout the several views of the drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0029] Referring to FIGS. 1-4, a high-capacity caser 10 is shown which is adapted to be used in a dairy plant or the like in conjunction with a high-speed filler, not shown, capable of filling plastic containers such as jugs J at a rate of approximately 160 to 200 jugs per minute. The caser will be described hereinafter with relation to jugs; however, the caser is not intended to be limited for use with such type containers.

[0030] In a preferred embodiment, the jugs are of conventional design and are blow molded from polypropylene or similar plastic material and each is provided at the top thereof with a centrally disposed upwardly projecting spout having a removable closure cap mounted thereon. The thickness of the plastic material and the inherent characteristics of the plastic itself are such that the jug J, even when filled with a liquid product, will distort a slight amount when an external pushing force is exerted on the side of the jug. Moreover, upon substantial impact, the plastic material could dent, tear or otherwise be damaged. It is for this reason, therefore, that many prior high-speed case filling apparatus could not effectively handle such jugs without damaging the jugs or causing serious jamming problems, particularly when the speed of operation is in the range of 160 to 200 jugs per minute.

[0031] As shown generally in FIGS. 1 through 4, a preferred embodiment of the caser 10 of the present invention includes an ingress end section 12 and an egress end section 14. The jugs to be packed approach the ingress end section 12 on the upper level 16 of the caser 10. Concurrently, empty cases C approach the ingress end section 12 on the lower level 18 of the caser. As will be described more fully below, the jugs are received on the upper lever 16 of the caser 10, arranged in a predetermined pattern, and simultaneously deposited into one or more empty cases on the lower level 18 of the caser. The packed cases then exit the caser 10 from the egress end section 14 on the lower level 18.

[0032] The direction of movement from the ingress end section 12 toward the egress end section 14 is the loading direction 20. In the embodiment shown in FIG. 1, the ingress end section 12 is shown on the left side and the egress end section 14 is shown on the right side, thereby defining the loading direction 20 as going from left to right. The orientation shown is for exemplary purposes only. The ingress end section 12, egress end section 14 and loading direction 20 may be reversed depending on the orientation of the manufacturing plant in which the caser is located and the placement of the caser in relation to the filler machine or the incoming conveyor.

[0033] As shown in FIG. 5, the jugs preferably approach the caser 10 on a conveyor belt 22 moving in a travel direction T. The conveyor belt carries the jugs from a filler machine or other origination point to a loading area 30 of the caser 10. The loading area 30 includes an end plate 32 and a pusher 34. When the conveyor belt 22 reaches the loading area 30, the travel direction T is preferably substantially perpendicular to the loading direction L. In a preferred embodiment of the invention, the end plate 32 carries a sensor 36, and more preferably a pair of sensors 36a, 36b for detecting the arrival of jugs at the loading area 30. The sensor 36 may be an electronic eye capable of detecting the presence of a jug at the loading area 30. Alternatively, the sensor can be triggered mechanically by the contact of the plastic jugs against the end plate 32. The present invention is not intended to be limited to the use of the sensors described herein. Rather, any known sensor that can detect the presence of jugs in the loading area may be used.

[0034] In one embodiment of the invention, the conveyor belt 22 extends to the threshold 38 of the loading area 30. In this embodiment, jugs traveling on the conveyor belt 22 are carried by the conveyor belt 22 to the threshold 38 and thereafter, are pushed onto the loading area 30 by other jugs arriving at threshold 38. In a more preferred embodiment of the invention, as shown in FIG. 5, the conveyor belt 22 preferably extends to the end plate 32 of the loading area 30. In this embodiment, jugs traveling on the conveyor belt 22 are carried directly to the loading area 30 by the conveyor belt 22. The latter embodiment moves the jugs to the loading area 30 at a faster speed.

[0035] In a preferred embodiment of the invention, as shown in FIGS. 6 and 7, the loading area 30 is dimensioned to receive four gallon jugs (in 2×2 configuration) or six half-gallon jugs (3×2 configuration). Hyphen the sensors detect that the appropriate number of jugs have been positioned in the loading area 30, as shown in FIG. 7, the pusher assembly 34 moves the jugs in the loading direction 20 onto loading tables 40. The pusher assembly 34 then retracts to its initial position, allowing conveyor 22 to continue to deliver filled jugs to the loading area 30 of the caser. Again, when the sensors detect that the appropriate number of jugs have been positioned in the loading area 30, the pusher assembly 34 moves the jugs in the loading direction 20 onto the loading tables 40. This process is repeated until the loading tables 40 is filled with a predetermined number of jugs.

[0036] The number of jugs positioned on the loading tables 40, and the pattern in which the jugs are positioned, depend on a number of variables, including the size of the jugs, the size of the cases in which the jugs are to be packed, and the size of the loading tables. In a preferred embodiment, the caser of the present invention assembles and loads the jugs in the patterns identified below:

				No. of	No. of
		Dimensions	Patterns	cases	bottles
		of Case	in Each	filled	cased per
	Bottle	Used	Case	per drop	drop
	Gallon	13″ × 13″	2 × 2	3	12
		13″ × 19″	2 × 3	2	12
	Half	13″ × 19″	3 × 4	2	24
	Gallon	13″ × 19″	3 × 3	3	27

[0037] For each of the different sizes of standard dairy containers, by adjusting the size and position of the pusher assembly and guide plates (which will be discussed below), and changing the stroke of the pusher assembly, different numbers of columns of filled containers may be assembled on the loading tables 40 and then loaded into cases.

[0038] In a preferred embodiment of the invention, when the loading tables 40 are filled, the pusher assembly 34 executes an additional stroke to stage the next group of jugs in a staging area 42. When the jugs or the loading tables 40 are deposited in cases, the staged 7 jugs will be in position to be pushed onto the loading tables 40 for another loading cycle. The caser 10 preferably includes a stage sensor (not shown) to detect the presence of jugs at the staging area 42. The stage sensor will transmit a signal to a central processor indicating that there are staged jugs present at the staging area 42. The central processor will adjust the number of strokes necessary by the pusher assembly to account for the jugs that are staged.

[0039] In a preferred embodiment of the invention, to load gallon jugs onto the loading tables, the pusher assembly executes three long strokes and one short stroke to fill the loading tables. The length of the long stroke is preferably about twelve inches and the length of the short stroke is preferably one-half the length of the long stroke. If there are staged jugs present at the staging area 42, the pusher assembly executes only three strokes to fill the loading tables. Similarly, when loading half-gallons onto the loading tables, the pusher assembly executes five strokes to fill the loading tables. If there are staged jugs present at the staging area 42, the pusher assembly executes four strokes.

[0040] When plastic jugs are pushed from behind, inertia can cause the jugs to tip over, especially if the pusher assembly is operating with a substantial force in an effort to increase the rate of speed of the caser. This problem is particularly evident when using half-gallon square jugs, which are typically tall, narrow and more prone to tipping over. To protect against the jugs falling over, being damaged and bringing the casing process to a halt, a series of stabilizer plates 50, as shown in FIG. 7, are pivotally attached to the upper frame 100 of the caser. The stabilizer plates 50 are dimensioned such that the front surface 52 of the stabilizer place 50 contacts the jugs as they are pushed into the loading area 40. The stabilizer plates 50 are weighted to counteract the forward inertia of the jugs, thus preventing the jugs from tipping over. Although the stabilizer plates 50 initially stop or decelerate the forward motion of the jugs, the stabilizer plates are pivotally attached such that as the jugs move further into the loading area (by subsequent pushes from the pusher assembly 34), the jugs push the stabilizer plates 50 out of the loading path. The stabilizer plates are preferably moved out of the loading path by pivoting upward, as best shown in FIG. 7. When the jugs are removed from the loading tables 40 and are loaded into the cases, the stabilizer plates 50 pivot downward and return to their initial vertical position. To prevent the back surface 54 of the stabilizer plates 50 from hitting the upper frame 100, the back surface 54 carries a bumper or shock absorber 56. When the stabilizer plate 50 pivots down to its initial vertical position, the shock absorber 56 contacts the upper frame 100 protecting the stabilizer plate 50 from traveling past center, keeping the plates from locking, reducing noise and absorbing vibrations.

[0041] In a preferred embodiment of the invention, a plurality of stabilizer plates 50 are positioned in a spaced apart relationship over the length of the loading tables 40, each pivotally connected to the upper frame 100 of the caser. The stabilizer plates are preferably made of a self-lubricating food-grade plastic material, and more preferably, the stabilizer plates are made of Nylatron which is a material that is commercially available from Vandeveer Plastics in Placentia, Calif. The self-lubricating plastic minimizes wear on the stabilizer plates 50 resulting from repeated contact with the surface of the jugs. The stabilizer plates 50 preferably do not have any type of moving bearings, further reducing the maintenance of the stabilizer plates by eliminating the need to maintain or replace moving bearings.

[0042] Referring to FIGS. 8 through 10, the process of loading the jugs from the loading tables 40 into the cases is now described. The loading tables 40 preferably include two tables 40a, 40b which are collectively referenced herein as loading tables 40. In a preferred embodiment of the invention, caser 10 includes bottle guides 60 that are pivotally attached to the side frames 102 of the caser. The bottle guides 60 are positioned in parallel facing relationship on either side of the loading tables 40. When the loading tables 40 are filled with the predetermined number of jugs, the bottle guides 60 pivot on hinges 64 such that the lower portions 66 of the bottle guides 60 move closer to each other and grip the lower portions of the jugs, as shown in FIG. 6. By gripping the jugs from both sides, the bottle guides 60 prevent the jugs, particularly the middle jug, from moving out of position during the packing process. After the jugs are securely gripped, the loading tables 40 retract to provide the jugs with an access path to the empty cases positioned below.

[0043] As shown in FIG. 9, the loading tables 40 are preferably divided into two equal sections 40a, 40b, whereby the sections move away from each other toward the direction of the bottle glides 60 during the tables' retraction. When the loading tables have fully retracted, the bottle guides 60 pivot on hinges 64 to their initial position, namely, the lower portions 66 of the bottle guides 60 move away from each other and release the grip on the jugs. The jugs are then gravity fed to the cases positioned below. The pivoting motion of the bottle guides 60 ensures that the jugs are gravity fed into the cases simultaneously. If the jugs were not gripped during the retraction of the loading tables 40, the center jug could fall faster than the jugs positioned at the ends, particularly if the tables are opening at a slower speed that provides the center jug with opportunity to drop into the case first and possibly tip over, preventing other jugs to be properly packed in the case. By allowing the jugs to drop into the case simultaneously as a packaged unit, the process minimizes damage to the jugs and product waste, and ensures that the jugs fit properly in the case.

[0044] In a preferred embodiment of the invention, as shown in FIG. 9, each section 40a, 40b of the loading tables 40 includes an inclined ledge 46 for guiding the jugs into the cases. When the loading tables 40 retract, the inclined ledges 46 on each of the table sections 40a, 40b form a funnel-type access path for the jugs. The inclined ledges 46 facilitate the packing of the jugs into the case and prevent the jugs from moving out of position, hitting the sides of the cases and separating from the other jugs in the group. The inclined ledges 46 also decelerate the drop of the jugs to lessen the impact on the jugs upon hitting the bottom of the cases and to prevent jugs from bouncing and knocking the caps off. The angle of inclination of the table ledges 45 is preferably about 85 degrees.

[0045] The loading tables 40 and their ledges 46 are preferably made of a solid, durable, and low-maintenance material, and more preferably made of stainless steel. When the jugs drop past the inclined ledge 46, parts of the jugs come in contact with the tip 48 of the inclined ledge 46. Over time, the material on the tip 48 of the inclined ledge may feather and wear like a sharp knife that damages the jugs as they drop past the tip 48 of the ledge 46. To prevent the wear described herein, the lower portion of the inclined ledge 46 preferably has a plastic insert, and more preferably has a Nylatron insert that keeps the metal on tip 48 from feathering and wearing like a sharp knife. By providing a hard plastic insert, the wear issue on the tables 40 as the jugs pass by the ledges 46 is eliminated.

[0046] As shown in FIGS. 11 and 12, to further facilitate the loading of the jugs into cases, caser 10 preferably includes case guides 70. Case guides 70, shown in phantom in FIG. 11, extend transversely on the caser and indicate the boundaries of the cases positioned on the lower level 18 of the caser. When the jugs are gravity fed into the cases, the case guides 70 facilitate the packing of the jugs into the cases by guiding the jugs into the case and preventing the jugs from hitting the sides of the cases. As shown in FIG. 12, the case guides 70 preferably have a triangular cross-section having an inclined surface 72 on either side of each guide 70. The inclined surfaces 72 of the case guides 70, like the inclined ledges 46 of the loading tables 40, facilitate the packing of the jugs into the cases by preventing the jugs from moving out of position, hitting the sides of the cases and separating from the other jugs in the group. The inclined surfaces 72 also decelerate the drop of the jugs to lessen the impact on the jugs upon hitting the bottom of the cases and prevent the jugs from bouncing and knocking the caps off.

[0047] In the embodiment shown in FIG. 11, the caser 10 includes three case guides 70 that define the boundaries of two cases positioned below . Additional case guides 70 may be added when the caser is configured to load more than two cases at a time. For instance, if smaller cases are used, the caser can be adapted to load three smaller cases at one time, instead of the two larger cases shown. In this instance, one additional case guide can be added, and the case guides 70 can be repositioned to define the boundaries of the cases in the new configuration.

[0048] As best shown in FIG. 12, the case guides 70 are preferably carried on case guide support rods 74 that extend laterally along the caser. The case guides 70 are slidably engaged on the support rods 74 and secured thereon using set screws 76 or other known fasteners. To adjust the position of the case guides 70, the set screw 76 is loosened and the case guide 70 simply slides on the support rod 74 to the desired position. The set screw 76 is tightened to secure the support rod 74 at the new location.

[0049] The bottle guides 60 and loading tables 40 are preferably pneumatically energized. As best shown in FIGS. 3 and 4, sections 40a, 40b of the loading tables are each operatively connected to a piston and cylinder assembly 80. A piston 82 moves the tables linearly in a transverse direction. Similarly, bottle guides 60 are operatively connected to air springs 90 that pivot the bottle guides 60 about hinges 64. To operate the piston and cylinder assembly 80 and the air springs 90, the caser 10 is preferably supplied with air pressure from a centralized air supply line provided in the manufacturing plant. In a preferred embodiment of the invention, the air supply line provides 30 cubic feet per minute of air at 90 psi.

[0050] The plant's air supply line is preferably connected to the caser's air intake surge tank, shown in FIG. 13. In a preferred embodiment of the invention, the pressurized air is distributed evenly to the piston and cylinder assemblies 80 on either side of the caser. However, the air manifold 92 can be positioned closer to the piston and cylinder assembly 80 of one side. Because the air must travel through fittings and air lines, the piston and cylinder assembly located farther from the air intake manifold 92 may receive air later than the piston and cylinder assembly located closer to the air manifold. To ensure that the piston and cylinder assemblies receive an equal distribution of air at the exact same time, the caser 10 preferably includes a centralized air manifold 94. As shown in FIG. 13, air entering into air intake manifold 92 is directed to the solenoid valve manifold and then to the centralized air manifold 94, which in turn distributes the air evenly to the air springs 90 and the piston and cylinder assemblies 80. The centralized air manifold 94 is preferably positioned equidistant from the air springs 90 and from the piston and cylinder assemblies 80. Accordingly, the pressurized air will be distributed evenly and simultaneously between the two piston and cylinder assemblies 80 and between the air springs 90.

[0051] In a more preferred embodiment of the invention, as shown in FIG. 13, caser 10 includes a surge tank 96 to ensure that the caser receives the volume of pressurized air that it needs to operate smoothly. In manufacturing plants, typically there are several pieces of equipment that utilize the air supply line of the plant. From time to time, there may be a shortage of air volume in the plant's air supply line. To ensure that the caser of the present invention continues to function smoothly, regardless of fluctuations in the volume of air in the plant's air supply line, the surge tank 96 carries a reserve air supply. Preferably, the surge tank 96 contains sufficient air to operate two complete cycles of the caser, each cycle including the operation of the pusher assembly to push sufficient jugs onto the table to fill the loading tables with jugs, operating the air springs to pivot the bottle guides to grip the jugs on the loading tables, retracting the loading tables to provide an access path to the cases, releasing the jugs into the cases below, and closing the loading tables.

[0052] To further ensure efficient operation of pneumatic parts of the caser, each piston and cylinder assembly 80 preferably includes a local exhaust 86, shown in FIGS. 14 and 15. If the air in the piston and cylinder assembly 80 was required to exit at a centralized exhaust, the air would have to be pushed out of the cylinder through valves and air lines, back to the manifold to a centralized exhaust. The time required for the air to exit the cylinder delays the response time of moving the loading tables 40. To provide a faster response time, the local exhaust 86 provides a less restrictive path of travel for the air exiting the cylinder. By allowing the air to exit the cylinder quickly, the speed of operation of the caser is increased.

[0053] In a preferred embodiment of the invention, the operation of the caser is regulated by a central processor that utilizes a number of sensors positioned on various parts of the caser to monitor the performance of the caser and report the status to a central processor 110 (shown in FIGS. 1 and 2). For example, as previously discussed, sensors 36 located on the end plate 32 detect the presence of jugs in the loading area 30. A signal is transmitted to the central processor 110, which then signals the pusher assembly 34 to push the jugs onto the loading tables 40. In a preferred embodiment, staging sensor (not shown) is provided to detect the presence of jugs at the staging area 42. If jugs are present, the central processor 110 signals the pusher assembly 34 to change the number of strokes, or the length of the stroke, depending on the application, to accommodate the staged jugs. Other sensors can be located at various points on the caser. For example, sensors placed near the ingress end section 12 can detect if jugs have fallen over on the upper level 16 or if cases are positioned at predetermined locations on the lower level 18.

[0054] When the loading tables 40 have been filled with the predetermined number of jugs, the sensors can signal the processor to activate the air springs 90 to grip the jugs. In a preferred embodiment of the invention, as shown in FIG. 14, a piston sensor 88 is attached to the cylinder 84 of the piston and cylinder assembly 80. The piston sensor 88 detects the position of a magnet (not shown) located on the piston inside the cylinder. When the piston 82 is in the position corresponding to the position of fully retracted tables, the piston sensor 88 signals the processor 110 to release the air springs 90 and drop the jugs into cases. The sensors used by the caser are not limited to those described herein but can be electronic eyes, read switches, or any other known indicator that detects a particular condition and transmits a signal to the processor.

[0055] By checking for certain conditions, such as the correct positioning of the jugs and the cases, the sensors ensure efficient operation of the caser. If a particular condition is not satisfied, for example, if a jug has fallen over or if a case has not been positioned on the lower level, the appropriate sensor transmits a signal to the processor and the processor ceases operation of the caser until the condition has been satisfied. In a preferred embodiment of the invention, as shown in FIG. 1, the caser includes an alarm 112 that is activated by the processor if any of the sensors detect an unsatisfactory condition. The alarm notifies personnel that the caser has ceased operation because of an unsatisfactory condition. Unsatisfactory conditions include, but are not limited to, absence of cases or jugs, incorrect positioning of cases or jugs, jams or malfunction, or any other condition that interferes with the operation of the caser.

[0056] As shown in FIG. 16, the caser preferably includes a control panel 120 that enables a user to provide manual input into the processor. In a preferred embodiment of the invention the control panel 120 includes a power switch 122 and a reset button 124. The user can utilize the control panel to indicate the type of jugs used 126, and to set manual or automatic operation for the caser 130 and the loading tables 128. The control panel preferably includes a counter 132 that indicates the number of jugs that have been cased, and an alarm 134 that alerts the user to the presence of an unsatisfactory condition. The panel preferably also includes a case stop 136 to control the opening of the loading tables 40.

[0057] In a preferred embodiment of the present invention, the caser operates at a rate of speed of 160 gallon jugs to 200 half gallon jugs per minute. The various components described above enable the caser to operate at high speeds without jamming the caser, damaging the jugs or wasting product. Prior art casers do not operate as efficiently and thus, are not capable of operating at such a rate.

[0058] The caser of the present invention is preferably made of materials and parts that minimize the need for maintenance and repair. Moreover, should the need for maintenance and repair arise, the caser is adapted to enable the user to perform any maintenance or repair quickly and efficiently. Prior art casers are manufactured with many parts that require lubrication and periodic replacement. To access the parts in the prior art casers, it could take several hours to dismantle the caser to replace the drive chain, bearings, cylinders or other parts. To minimize the inconvenience of maintenance and repair, the support rods, bearings and pivot points of the caser are preferably made of stainless steel. Stainless steel rod end bearings do not need to be lubricated and, unlike cad-coating, will not rust or corrode. In a more preferred embodiment, linear bearings are used with stainless steel support rods and ceramic bearings. To minimize maintenance requirements, in the preferred embodiment of the invention, ball bearings are not used.

[0059] In the event that the caser requires maintenance or repair, the caser of the present invention is designed to allow easy dismantling for access to the various parts. For example, if the linear bearings have to be replaced, the user simply disconnects the piston 82 (shown in FIG. 12) and loosens up the set collars 78 (shown in FIG. 17). The support rods 79 will then slide out allowing the tables 40 to be easily removed for bearing replacement.

[0060] In a preferred embodiment of the invention, as best shown in FIGS. 8 through 10, the caser 10 includes a removable cover 140 that fits over the cylinder and piston assembly 80 and provides a working surface on each side of the caser. In the embodiment shown in FIGS. 8 through 10, one side of the caser is shown with the cover 140 installed thereon and the other side shows the cover removed from the caser. The cover 140 is preferably made of stainless steel and does not include any holes or fasteners. To install the cover 140 on the caser 10, the cover 140 is placed on a clip or bracket 142 installed on the side frame 102. A ledge of the cover 140 preferably fits into a channel 144 between the bracket 142 and the side frame 102. The cover 140 is installed on the caser 10 by simply dropping the ledge of the cover into the channel 144 defined between the bracket 142 and the frame 102. As best shown in FIG. 15, the flat surface 146 of the cover rests on shock absorbers 150 installed on the cylinder support 81. The shock absorbers 150 are preferably made of polyurethane or other plastic material that absorbs vibrations and noise. In this embodiment of the invention, there is no need for nuts and bolts or other fastening devices to install the cover on the caser. A user can quickly gain access to parts of the caser by simply removing the cover without using any tools.

[0061] The embodiments described above are exemplary embodiments. Those skilled in the art may now make numerous uses of, and departures from, the above-described embodiments without departing from the inventive concept natures disclosed herein. Accordingly, the present invention is to be defined solely by the scope of the following claims.

Claims

1. A caser for packing filled containers in empty cases, the caser comprising: a support frame having an upper level and a lower level; a conveyor belt having a traveling direction and delivering containers to a loading area of the caser; a pusher assembly movable in a loading direction, wherein at the loading area, the traveling direction is substantially perpendicular to the loading direction; a pair of bottle guides hingably connected to the upper level of the support frame; a pair of loading tables linearly retractable to provide access between the upper level and the lower level of the support frame; and wherein the bottle guides pivot to grip containers when the containers are loaded on the loading tables and pivot to release the containers when the loading tables have retracted.

2. The caser of claim 1 wherein the caser is made substantially of stainless steel.

3. The caser of claim 1 wherein the loading tables are pneumatically powered.

4. The caser of claim 3 wherein the loading tables comprise a first section operatively connected to a first piston and cylinder assembly, and a second section operatively connected to a second piston and cylinder assembly, wherein the first and second piston and cylinder assemblies linearly move the first and second sections of the loading tables away from each other.

5. The caser of claim 4 further comprising: an intake air manifold; and a centralized air manifold in communication with the intake air manifold and positioned substantially equidistant from the first and second piston and cylinder assemblies, wherein the centralized air manifold distributes air evenly to the first and second piston and cylinder assemblies.

6. The caser of claim 5 further comprising a surge tank in communication with the intake air manifold.

7. The caser of claim 1 further comprising a central processor and a plurality of sensors, wherein the sensors detect predetermined conditions and transmit signals to the central processor regarding the conditions.

8. The caser of claim 7 further comprising an alarm operatively connected to the central processor wherein the alarm is activated upon detection of a predetermined condition by one of the plurality of sensors.

9. The caser of claim 4 further comprising a piston sensor positioned on each of the first and second piston and cylinder assemblies, wherein the piston sensors detect the position of the piston when the loading tables are fully retracted and transmit a signal to the central processor, and wherein, in response, the central processor signals the bottle guides to release the containers.

10. The caser of claim 4 wherein the first and second sections of the loading tables each have an inclined ledge extending therefrom such that when the loading tables are retracted, the inclined ledges of the first and second sections define a tapered passageway.

11. The caser of claim 10 wherein the inclined ledges each have an angle of inclination of 85 degrees.

12. The caser of claim 10 wherein the inclined ledges each have a wear protective insert.

13. The caser of claim 12 wherein the wear protective insert is plastic.

14. The caser of claim 13 wherein the wear protective insert is Nylatron.

15. The caser of claim 1 further comprising a stabilizer plate pivotally attached to the support frame, wherein the stabilizer plate is weighted to counteract inertial force of the containers.

16. The caser of claim 15 wherein the stabilizer plate has an initial vertical position at rest, wherein the stabilizer is pivoted upward when the containers advance on the loading tables and wherein the stabilizer plate returns to its initial vertical position when the containers are loaded into cases.

17. The caser of claim 15 wherein the stabilizer plate is made of a self-lubricating material.

18. The caser of claim 15 wherein the stabilizer plate is made of Nylatron and U.H.M.W.

19. The caser of claim 1 further comprising, a cover having a flat working surface, wherein the cover is removably secured to the support frame of the caser.

20. The caser of claim 19 further comprising a clip attached to the support frame defining a channel between the clip and the support frame, wherein the cover comprises an edge configured to fit in the channel to secure the cover to the support frame.

21. A easer for packing containers in cases, the caser comprising: a pair of loading tables that are retractable, the loading tables having a longitudinal direction along the length of the table and a transverse direction along the width of the table; and a pusher assembly actuatable to push containers onto the loading tables in the longitudinal direction.

22. The caser of claim 21 further comprising a drive chain traveling substantially perpendicular to the longitudinal direction proximal the pusher assembly.

23. A caser for packing containers in cases, the caser comprising: a support frame having an upper level and a lower level; a pair of loading tables having a closed position and an open position, wherein in the closed position, the loading tables support containers thereon and in the open position, the loading tables provide access from the upper level to the lower level; and at least two bottle guides attached to the support frame, wherein the bottle guides are movable to hold the containers and release the containers when the loading tables are in the open position.

24. The caser of claim 23 wherein the loading tables retract linearly.

25. The caser of claim 23 wherein the loading tables include a first section and a second section, and wherein the first and second sections move apart from each other linearly.

26. The caser of claim 23 wherein the bottle guides pivot such that a lower portion of each bottle guide contacts containers.

27. The caser of claim 25 wherein each of the first and second sections comprise an inclined surface, wherein in the open position, the inclined surfaces define a tapered path.

28. The caser of claim 27 wherein the inclined surface comprises a plastic insert.

29. A caser for packing containers in cases, the caser comprising: a pair of loading tables; and a stabilizer plate swingably positioned over the loading tables, the stabilizer plate weighted to counteract the inertial force of containers pushed onto the loading tables and to prevent the containers from tipping over.

30. The caser of claim 29 wherein the stabilizer plate is plastic.

31. A caser for packing filled containers in empty cases, the caser comprising: a support frame having an upper level and a lower level; a conveyor belt having a traveling direction and delivering containers to a loading area of the caser; a pusher assembly movable in a loading direction, wherein at the loading area, the traveling direction is substantially perpendicular to the loading direction; a pair of bottle guides hingably connected to the upper level of the support frame; a pair of air springs, each air spring operatively connected to one of the bottle guides, the air springs operational to pivot the bottle guides; a pair of loading tables having a first section and a second section, wherein the first and second sections are linearly retractable in opposing directions to provide access between the upper level and the lower level of the support frame; a first and second piston and cylinder assembly, each piston and cylinder assembly connected to a respective one of the first and second sections of the loading tables, the piston and cylinder assembly operational to move the first and second sections linearly toward each other and away from each other; and wherein the bottle guides pivot to grip containers when the containers are loaded on the loading tables and pivot to release the containers when the loading tables have retracted.

32. A method of packing jugs into cases, the method comprising the steps of pushing jugs at a rate greater than 160 jugs per minute.

33. The packing method of claim 32 wherein the jugs are pushed at a rate greater than 180 jugs per minute.

34. The packing method of claim 33 wherein the jugs are pushed at a rate of about 200 jugs per minute.

35. A method of packing jugs into cases, the method comprising the steps of: carrying jugs on a conveyor belt; pushing the jugs together; and letting the jugs fall into cases.

36. A method of packing jugs into cases, the method comprising the steps of: carrying jugs on a conveyor belt; pushing the jugs together in a predetermined pattern; and letting the jugs fall into cases.

37. A method of packing jugs into cases, the method comprising the steps of: carrying jugs on a conveyor belt; pushing the jugs together in a predetermined pattern; and releasing the jugs after the jugs have been pushed together; and dropping the jugs into cases.

38. A method of packing jugs into cases, the method comprising the steps of: providing a caser having a support frame with an upper level and a lower level, a conveyor belt, a pusher assembly, a pair of bottle guides and a pair of loading tables; delivering jugs to the upper level of the caser via the conveyor belt; pushing the jugs onto the loading tables; gripping the jugs with the bottle guides; retracting the loading tables; and releasing the bottle guides to drop the jugs into cases.

39. A method of packing jugs into cases, the method comprising the steps of: providing a sensor in communication with a central processor; detecting the presence of jugs at a staging area using the sensor; transmitting a first signal to the central processor if jugs are present at the staging area; and transmitting a second signal to the central processor if jugs are not present at the staging area.

40. The packing method of claim 39 wherein the first signal corresponds to a first predetermined number of strokes, and wherein the second signal corresponds to a second predetermined number of strokes.