Patent Grant
10766641
Technical Field
The present invention relates to an apparatus and method for settling products in a package.
Background
Many foodstuffs, such as potato chips, are packaged in pillow pouch packages that are made using a form, fill and seal (“FFS”) machine. Typically, a form, fill and seal machine forms the film into a tube, seals the bottom of the tube, fills the partially sealed tube with product, and then seals the top of the tube to form a packaged product. Often, a form, fill and seal machine is oriented so that film travels in a direction that is generally vertical as the film is formed into a tube, filled with product and sealed. Such a machine is an example of a vertical form, fill and seal (“VFFS”) machine.
When the product being packaged is an irregularly shaped product such as potato chips, there can be large void spaces between each piece. The void space takes up volume in the package and requires the package to be larger than required for the product alone. This requires more resources, which is less environmentally friendly. It is also more expensive for producers and ultimately consumers.
To avoid these and other problems posed by void space, some form, fill and seal machines are fitted with product settlers. These settlers typically shake the product to make it settle into a more compact configuration and thereby reduce void space.
In addition to reducing void space in a product, it is desirable to package product more quickly. One way to increase the speed with which product is packaged is to increase the speed with which film is fed to the form, fill and seal machines. Other things being equal, continuously feeding film to a machine is faster than intermittently feeding film.
To take advantage of this principle, some machines, called continuous motion machines, are capable of running in a continuous mode in which film is continuously being advanced, as opposed to being paused intermittently. However, running a machine in continuous mode is incompatible with conventional settlers that grab or pinch the film. This is because grabbing or pinching will damage the film unless the film is paused.
Examples of conventional settlers that require a film to be paused include settlers with beater bars that grab and shake the film. Another conventional settler that requires film to be paused uses two swinging panels. The two panels are positioned below the product conduit and can rotate together like doors. When the panels come together, they pinch and seal off the film below the product conduit. After product falls on the closed panels, seal jaws come together to form an end seal on the film. This forms the bottom of a partially formed package. Then, the panels rotate open, which releases the film and allows the product to fall to the bottom of the partially formed package. This process of repeatedly dropping and catching the product causes the product to be settled. However, it can also damage the product by causing breakage, for example, of chips.
As these examples illustrate, when using conventional settlers, form, fill and seal machines must run in an intermittent mode in which the film is stopped when the settlers grab the film, and the film advances when the settlers release the film. As a result, many continuous motion machines do not even come with a settler. Other machines come with a settler that can be installed by a user, but the machine must then be run in an intermittent mode. Running machines in intermittent mode is inefficient and results in additional wear and tear on the machines and film. Thus, using a conventional settler with a continuous motion form, fill and seal machine can be undesirable.
Accordingly, it would be advantageous to have a settler that is compatible with a form, fill and seal machine running in continuous mode. For example, it is desirable to have a settler that does not grab film and can be used with a machine that continuously conveys the film. Such a settler would not require the film to be paused during production of packages. This could, in turn, avoid wear and tear on the machine and film caused by large transient forces that occur when starting and stopping the machine.
It would also be advantageous if an inventive settler could be used to produce product-filled packages more quickly than conventional settlers that require packaging film to be paused intermittently.
In addition, it would be desirable if the inventive settler reduced the volume that product occupies in a package. For example, it would be desirable if the settler reduced the volume occupied by a product at least as much as a conventional settler.
Furthermore, it would be desirable if an inventive settler could increase the head space in a package of a given size. For example, increased head space can help prevent product inside the package from being too close to, or caught in, the end seal of the package. This helps to ensure that the package is properly sealed. Increased head space can also help prevent other manufacturing defects, for example, unintended pleats and unintended tucks. It would be even more desirable if the inventive settler could increase head space and/or reduce manufacturing defects when compared to conventional settlers.
Likewise, it would be beneficial if the inventive settler did not break a substantial amount of product by impacting the product. For example, it would be beneficial if the settler were positioned so that it did not impact a substantial amount of the product through the packaging film. It would also be advantageous if the inventive settler could optionally be mounted somewhere besides the seal jaw carriage of a form, fill and seal machine. As another example, it would be beneficial if the inventive settler could operate intermittently or continuously. For example, it would be beneficial if the inventive settler could stop settling while the product is in a position to be damaged by the settler. However, after the product is no longer in such a position, the inventive settler would begin settling again.
Similarly, it would be desirable if the inventive settler decreased the amount of film required to package a given amount of product. This could help reduce waste, increase the environmental friendliness of a process, reduce manufacturing costs, and further increase the speed of a manufacturing process. For example, using a settler that can be used with a continuous motion form, fill and seal machine can increase the speed of a manufacturing process. Also, if the inventive settler could decrease the amount of film necessary to package a product, less film would need to be conveyed for a unit of product. This could further reduce the amount of time required to produce each unit.
In addition, it would be advantageous if the inventive settler did not interfere with the continuous motion of a package film when the inventive settler stopped. For example, it would be advantageous if the inventive settler had a low torque motor so that if the settler stopped running or even failed while the settler was in contact with a package film, the film could push the settler out of the path of the film, and the film could continue to be advanced. It would also be advantageous if the inventive settler could be stopped in a position where it does not impede the continuous conveyance of packaging film.
It would be another benefit if the inventive settler were simple compared to conventional settlers. For example, it would be beneficial if the inventive settler had fewer moving parts than conventional settlers, had a less complicated operating mechanism, and were easier to maintain, repair and/or replace. It would also be beneficial if the inventive settler required minimal training of or input from maintenance personnel.
Furthermore, it would be useful if the inventive settler were small compared to conventional settlers. For example, conventional settlers can have components that take up a large amount of space and it would be advantageous to avoid these components.
Additionally, it would be desirable if the inventive settler could be easily installed on existing form, fill and seal machines. For example, it would be desirable if the inventive settler were modular and could be easily added to existing continuous motion vertical form, fill and seal machines. It would also be useful if a modular form of the inventive settler were easier to maintain, repair, and/or replace than conventional settlers. For example, it would be desirable if an inventive settler needing maintenance could be easily removed from a continuous motion form, fill and seal machine and replaced with a recently serviced settler. It would also be desirable if the inventive settler were designed so that the form, fill and seal machine could run without needing to be substantially reconfigured if the inventive settler were removed and were not replaced. For example, the machine could be instructed to create bigger packages due to a lack of settling, but the machine would not require other reconfiguration. This could increase the versatility of a product manufacturing line and increase its resilience in the face of maintenance issues.
Similarly, it would be advantageous if a form, fill and seal machine were easier to maintain and repair when the inventive settler is used with the machine instead of a conventional settler. It would also be advantageous if the small size and location of the inventive settler made it easier to access and service the machine compared to conventional settlers. For example, the size and location of conventional settlers can block or substantially impede access to the seal jaw carriage of a form, fill and seal machine. In contrast, it would be advantageous if the inventive settler could be installed on one side of a machine making it easy to access the seal jaw carriage even when the inventive settler is installed. It would also be advantageous if the inventive settler could easily be removed in comparison to a conventional settler, for example, if the inventive settler were modular, as this would also increase the ease of servicing of form, fill and seal machine.
The present invention is a method and apparatus for settling products. For example, the inventors have developed a new type of settler that can be used in conjunction with a form, fill and seal machine even when the machine is running in continuous mode.
In a first aspect, the invention provides a method for settling a product in a package made on a form, fill and seal machine. The method comprises the steps: providing a package material on a product conduit of a form, fill and seal machine; forming a first end seal on the package material to form a partially formed package; filling the partially formed package with product; and settling the product in the partially formed package while continuously conveying the package material along the product conduit.
In a second aspect, the invention provides an apparatus comprising an improved continuous motion form, fill and seal machine. The machine comprises a product conduit, a conveyor, and seal jaws. The conveyor is positioned to convey a package material that is wrapped around the product conduit, and the conveyor moves the package material along the product conduit. The seal jaws are positioned adjacent to opposite portions of the package material to form a first end seal on the package material, thereby forming a partially formed package. The product conduit is positioned so that a product passing through the product conduit will enter the partially formed package after exiting the product conduit, and the product conduit is positioned above the seal jaws. The improvement comprises a product settler comprising a first object positioned to cause an impact against the package material. The impact agitates the package material and settles the product from an unsettled height to a settled height while the machine continuously conveys the package material along the product conduit.
In a third aspect, the invention provides a method for settling a product in a partially formed package. The method comprises the steps: providing a partially formed package; filling the partially formed package with a product; and settling the product in the partially formed package. The settling step comprises rotating a paddle wheel comprising at least one paddle against the partially formed package.
In a fourth aspect, the invention provides an apparatus comprising an improved product settler for settling product in a partially formed package. The improved product settler comprises a paddle wheel. The paddle wheel comprises at least one paddle that is positioned to cause an impact against the partially formed package. The impact agitates the partially formed package and thereby settles the product.
The invention described herein provides many advantages in its various embodiments. In one aspect, the invention provides a settler that is compatible with a form, fill and seal machine running in continuous mode. For example, it provides a settler that does not grab film and can be used with a machine that continuously conveys the film. Such a settler does not require the film to be paused during the production of packages. This, in turn, avoids large transient forces that occur when starting and stopping the machine and avoids associated wear and tear on the machine. In one embodiment, the inventive settler comprises a rotating paddle wheel with a paddle that impacts the film in substantially the same direction that the film is conveyed. Accordingly, in one embodiment, the inventive settler comprises paddles that intermittently contact the film and scrub the film in the film's direction of conveyance.
The inventive settler also can be used to produce product-filled packages more quickly than conventional settlers, which require packaging film to be paused intermittently.
In addition, the inventive settler can reduce the volume that product occupies in a package. For example, the settler reduces the volume occupied by a product at least as much as a conventional settler.
Furthermore, the inventive settler increases the head space in a package of a given size. For example, increased head space can help prevent product inside the package from being too close to, or caught in, the end seal of the package. This helps to ensure that the package is properly sealed. Increased head space can also help prevent other manufacturing defects, for example, unintended pleats and unintended tucks. Additionally, the inventive settler can increase head space and/or reduce manufacturing defects when compared to conventional settlers.
As another advantage, the inventive settler does not break a substantial amount of product by impacting the product. In one embodiment, the inventive settler causes little or no breakage of product. For example, the settler can be positioned so that the settler does not impact a substantial amount of the product through the packaging film when the settler is in operation. In one embodiment, the inventive settler can be mounted somewhere besides the seal jaw carriage of a form, fill and seal machine. For example, the settler can be positioned just below the product conduit of a form, fill and seal machine so that the settler does not impact a substantial amount of product as the product falls from the product conduit and into the packaging film. The inventive settler can also operate intermittently or continuously. For example, the inventive settler can stop settling while the product is in a position to be damaged by the settler. However, after the product is no longer in such a position, the inventive settler can begin settling again.
The inventive settler can also decrease the amount of film required to package a given amount of product. This helps reduce waste, increase the environmental friendliness of the process, reduce manufacturing costs, and further increase the speed of a manufacturing process. For example, the inventive settler can be used with a continuous motion form, fill and seal machine which increases the speed of a manufacturing process relative to using an intermittent machine. Also, although conventional settlers cannot be used with continuous motion machines, the inventive settler can. Accordingly, the inventive settler can decrease the amount of film necessary to package a product on a continuous motion machine. Since less film needs to be conveyed for a unit of product, this further reduces the amount of time required to produce each unit.
In addition, the inventive settler does not interfere with the continuous motion of a package film when the inventive settler stops. For example, the inventive settler has a low torque motor so that if the settler stops running or even fails while the settler is in contact with a package film, the film can push the settler out of the path of the film, and the film can continue to be advanced. As another example, the inventive settler can be stopped in a position where it does not impede the continuous conveyance of packaging film.
The inventive settler is also simple compared to conventional settlers. For example, compared to conventional settlers, the inventive settler has fewer moving parts, has a less complicated operating mechanism, is easier to maintain, is easier to repair and/or is easier to replace. The inventive settler also requires minimal training of and input from maintenance personnel.
Furthermore, the inventive settler is small compared to conventional settlers. For example, conventional settlers can have components that take up a large amount of space and the inventive settler advantageously avoids this.
Additionally, the inventive settler can be easily installed on existing form, fill and seal machines. For example, in one embodiment, the inventive settler is modular and can be easily added to existing continuous motion vertical form, fill and seal machines. Also, the inventive settler is easier to maintain, repair, and/or replace than conventional settlers. For example, a modular form of the inventive settler can be installed, uninstalled, and serviced with ease. As another example, the inventive settler can be easily removed from a continuous motion form, fill and seal machine and replaced with another inventive settler. Also, the inventive settler is designed so that the form, fill and seal machine can run without needing to be substantially reconfigured if the inventive settler is removed and is not replaced. For example, the machine can be instructed to create bigger packages due to a lack of settling, but the machine does not require other reconfiguration to continue producing product. Accordingly, the inventive settler increases the versatility of a product manufacturing line and increases its resilience in the face of maintenance issues.
Similarly, a form, fill and seal machine is easier to maintain and repair when the inventive settler is used with the machine instead of a conventional settler. In one embodiment, the small size and location of the inventive settler during operation make the machine easier to access and service when compared to machines using conventional settlers. For example, the size and location of conventional settlers can block or substantially impede access to the seal jaw carriage of a form, fill and seal machine. In contrast, the inventive settler can be installed on one side of a machine, rather than, for example, having components that are adjacent to opposite sides of the machine. For example, the inventive settler can comprise a paddle wheel that is positioned adjacent to one side of a product conduit of a form, fill and seal machine. Accordingly, when the inventive settler, as opposed to a conventional settler, is installed on a machine, it is easier to access the components (e.g., seal jaw carriage) of the machine. Furthermore, the inventive settler can easily be removed in comparison to a conventional settler. When the inventive settler is modular, this further increases the ease of servicing a form, fill and seal machine when compared to servicing a machine using a conventional settler.
Another benefit of the inventive settler is that it can be used to settle many different kinds of products. For example, the inventive settler is especially useful for settling larger or irregularly shaped products such as tortilla chips or potato chips. The settler is also useful for settling smaller or regularly shaped products such as Cheetos® cheese puffs. Although, when compared to larger or irregularly shaped products, smaller or regularly shaped products may experience less settling.
Other aspects, embodiments and features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings. The accompanying figures are schematic and are not intended to be drawn to scale. In the figures, each identical or substantially similar component that is illustrated in various figures is represented by a single numeral or notation. For purposes of clarity, not every component is labeled in every figure. Nor is every component of each embodiment of the invention shown where illustration is not necessary to allow those of ordinary skill in the art to understand the invention.
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will be best understood by reference to the following detailed description of illustrative embodiments when read in conjunction with the accompanying drawings, wherein:
Several embodiments of Applicant's invention will now be described with reference to the drawings. Unless otherwise noted, like elements will be identified by identical numbers throughout all figures.
One embodiment of the invention will now be described with respect to
Second, in a longitudinal sealing step 104, the film 202 is sealed to form a longitudinal seal 402 (e.g. back seal) on a package 404.
Third, in a first end-sealing step 106, a first end seal 212a is formed on the film 202 to form a partially formed package (e.g., partially formed second package 404b in
Fourth, in a filling step 108, the partially formed package (e.g., partially formed package 404b) is filled with a product 302. An example of how a package 404b can be filled with product is illustrated in
Fifth, in a settling step 110, the product 302 in the package (see, e.g., partially formed second package 404b in
In some embodiments, the settled package film length 318 required for settled product is about 0.5 to about 1.0 inches shorter than the unsettled package film length 316 required for unsettled product. Accordingly, in some embodiment, the settler can reduce overall package lengths for a product by about 0.5 to about 1.0 inches.
In some embodiments, the settler 308 settles product 302 while the product is falling. In other embodiments, the settler 308 settles product 302 after the product has fallen. In some embodiments, the settler 308 settles product 302 while the product is falling and after the product has fallen. In some embodiments, the settler 308 comprises a paddle (e.g., one of a plurality of paddles 320a,b) that rotates in a rotational direction 322 so that when the paddle contacts the film 202, the paddle pushes the film generally in the direction of conveyance 306 of the film.
Sixth, in a second end-sealing step 112, a second end seal 212b is formed on the partially formed package 404b to form a package 404a. The second end seal 212b is located on a second face of the package (e.g., second end 416 of the first package 404a). This can be seen, for example, in
In the illustration shown in
In one embodiment, the settling step 110 comprises the step of intermittently contacting the package (e.g., the partially formed second package 404b in
In one embodiment, the settling step further comprises the step of intermittently applying a force to the film (e.g., by impacting or contacting the film) that does not pause the conveyance of the film. For example, the component of the force that is opposed to the conveyance of the film is not sufficient to pause the conveyance of the film.
In one embodiment, the settling step 110 further comprises the steps of continuously or intermittently rotating a paddle wheel 326 that comprises a paddle (e.g., paddle 320a or paddle 320b). The paddle is rotated into contact with the package (e.g., second package 404b in
In one embodiment, gas is directed into the partially formed package 404b. For example, some form, fill and seal machines 206 use pressurized gas to maintain positive pressure inside the package 404b. Such a machine can also be used in conjunction with the inventive settler. For example, when pressured gas is used, it can be directed in the fall direction 304 shown in
In one embodiment, gas is directed (e.g., in the fill direction 304) into the package (e.g., partially filled second package 404b in
In one embodiment, the paddle wheel 326 rotates continuously. In another embodiment, the paddle wheel 326 rotates intermittently. When the paddle wheel 326 rotates intermittently, the paddle (e.g. paddle 320a or paddle 320b) also rotates intermittently. In one embodiment, a paddle rotates intermittently in the sense that an actuator (e.g., motor 616 in
One embodiment of the invention will now be described with reference to
As seen in
As shown in the embodiment of
Generally speaking, because the inventive settler does not pause a package film, the number of packages per minute that a machine produces with the inventive settler is greater than the number of packages per minute that a machine produces when using a conventional settler. For example, the speed at which packages of product are produced can depend on the speed at which a film is conveyed for forming a package, the speed at which the package is filled with product, and any pause in conveying the film that is required to settle a product. If a package can be filled with product faster than the film can be conveyed into position to form a package, the limiting factor for producing a package of product is the speed at which the film is conveyed. Furthermore, if film speed is the limiting factor for the rate at which packages of a product can be manufactured, pausing the film during the activation of a conventional settler will further reduce the number packages per minute produced. Thus, when film speed is the limiting factor for a machine's rate of package production and settling is desired, settling with the inventive settler will result in an increased rate of package production when compared to settling with a conventional settler.
Accordingly, the product settler 308 is especially useful in conjunction with continuous, form, fill and seal machines because the product settler does not require the package film 202 to stop in order to settle product 302 in the package film. Although the product settler 308 has been described with reference to a continuous form, fill and seal machine, the product settler can also be used with machines that intermittently advance the package film 202. An example is any form, fill and seal machine that that stops or pauses the film 202 of a package 404a while the package 404a is being formed. Although a partially formed package has been described with reference to a package that has been made on a form, fill and seal machine, this is only an illustrative example.
As another example, the product settler can be used to settle product in a package that is open. For example, a partially formed package can be an open package and the formed package can be the closed package. Although using a product settler on a package that is open, but otherwise formed, may not result in savings related to package materials (e.g., film or paper), it can still provide other benefits. For example, it can decrease the size of the package and reduce costs associated with shipping, including secondary packaging costs for items such as shipping crates.
With reference to
An example of an object directly impacting the film is shown in
In some embodiments, a first object (e.g., paddle 320a) is positioned to intermittently and directly contact the package film 202 and the first object thereby agitates the product 302. In other embodiments, the first object (e.g., paddle 320a) is positioned to intermittently and directly contact a second object (e.g., the product conduit 204), and the second object contacts the product film 202 and thereby agitates the product 302.
As shown in
In one embodiment, the package film 202 comprises an impact face (e.g., back side 406 in
In one embodiment, the settler 308 is used with a form, fill and seal machine that further comprises a source of pressurized gas (e.g., compressor 224). In one embodiment, the source of pressurized gas 224 comprises a nozzle 226 to direct the pressurized gas into the package film 202. In one embodiment, the source of pressurized gas 224 is selected from the group consisting of a fan, a blower, or a centrifugal compressor.
In one embodiment, pressurized gas is used to provide pressure on the inside of the package film 202. This can be useful when a package film is not resilient enough on its own to move out of a deformed position (e.g., the deformed position illustrated in
As another example, in one embodiment, the package film 202 comprises an impact face 406 that is adjacent to the product settler 308. When the package film 202 is filled with the pressurized gas and hangs under the force of gravity, the impact face 406 defines a second position of the impact face. This position can be substantially similar to the first position of the impact face 406 described with reference to
For example, in one embodiment, the distance from the first tip 328 of a paddle 320a to the axle 602 of a paddle wheel 326 is about 2.5 inches and the axle of the paddle wheel is positioned about 0.5 inches from the impact face 406 of a package 202. Accordingly, when the paddle 320a rotates, the first tip 328 reaches past the original position of the impact face 406 by about 2.0 inches and the third distance is about 2.0 inches.
In one embodiment of an apparatus according to the invention, a package film 202 is wrapped around the product conduit 204. The apparatus can comprise a plurality of conveyors 214a,b positioned to convey the package film 202 along the product conduit 204 at substantially a single speed along a perimeter 218 of the packaging film. The product conduit 204 is selected, for example, from the group consisting of a tube, a chute, a duct, and a pipe.
In one embodiment illustrated in
The positional sensor 614 can be, for example, a camera or electromagnetic device. The positional sensor 614 can also be a proximity switch. For example, in one embodiment, the positional sensor 614 senses the presence or absence of a sensor target 622 (e.g., a magnet) within a given range of the positional sensor. In another embodiment, the positional sensor 614 senses a distance from the positional sensor 614 to the sensor target 622. For example, the sensor target 622 can move (e.g. rotate) with the paddle wheel 326 so that the position of the sensor target indicates the position of the paddle wheel. In another example, the position of a portion 624 (e.g., a magnet or discontinuity) of the sensor target indicates the position of the paddle wheel 326.
In one embodiment, the positional sensor 614 is used to position the paddle wheel 326 or a paddle (e.g., paddle 320a). For example, when the paddle wheel 326 is stopped, the paddle wheel can be stopped outside the path of a package film 202. This can be desirable because if the paddle wheel 326 is stopped in the path of the package film 202, the paddle wheel 326 will increase the resistance that must be overcome to convey the package film.
One embodiment of the invention will now be described with reference to
As shown, for example, in
With reference to
Turning back to
As can be seen in
As shown in
As shown in
One embodiment of the invention will now be described with reference to
In one embodiment shown in
The product settler 308, shown in
In the embodiment shown in
As can be seen in
Additionally, the product settler can be easily installed or uninstalled. For example, with reference to the embodiment shown in
Although the inventive product settler has been described by reference to use of a package made from film. The package material can be made from a film or some other form of material. For example, the inventive settler can be used with packages made from package materials of varying thicknesses. Furthermore, the package material can be, for example, paper, metal, metal oxides, polymer, or some combination thereof.
Illustrative examples of the inventive settler and experiments involving the inventive settler will now be described.
An experiment was conducted to measure certain benefits of using the inventive product settler 308 described herein. A continuous motion vertical form, fill and seal machine 206 was fitted with the inventive settler 308. Then, the machine 206 was used to produce 13.0 oz packages 202 containing TOSTITOS® Restaurant Style Tortilla Chips. The machine 206 ran at a speed of about 26 packages per minute. The packages 202 were produced on a product conduit 204 (e.g., former) with a circular cross-section. The cross-section of the product conduit 204 had a diameter of about 10.5 inches, and accordingly the packages 202 had a diameter of about 10.5 inches while wrapped around the product conduit. The packages 202 had a length of about 15.75″ from the tip of a first end seal 212a to the opposite tip of a second end seal 212b. Each end seal 212a,b was approximately ⅜ inches long providing a total usable package length of about 15 inches. In other words, the length of the package 202 that could be filled with product was approximately 15 inches.
A first set of five packages 202 were produced on a machine 206 without using the inventive settler 308. The average package head space was about 1.3 inches and the average unsettled height 314 of the product was about 13.7 inches. A second set of five packages 202 were produced on the machine 206 with the inventive settler 308 activated. Using this set up, the average package head space was about 2.9 inches and the average settled height 312 of the product was about 12.1 inches. As can be seen, the inventive settler resulted in an average settling of about 1.6 inches, which is a settling fraction of at least about 0.116 relative to the unsettled height 314 of the product.
Additionally, the inventive settler reduced the average length of film required to package each unit of product by about 1.6 inches. For example, rather than increasing the head space in a package, the product settler could also have been used to maintain a given head space while decreasing the length of film required for the package. In this example, the length of film required to package each unsettled unit of product was 15.75 inches. Since the product settler resulted in settling of about 1.6 inches, the product settler could have reduced the length of film required by 1.6 inches. This is a film reduction fraction of at least 0.101 relative to the length of film required if no settler is used.
Breakage of product occurring with and without the inventive settler activated was substantially the same. The use of the inventive settler did not result in any statistically significant increase in the ratio of broken product to non-broken product in a package. In other words, any increase in breakage was within the margin of error for the experiment.
Table 1
Table 1 provides speeds in packages per minute at which an illustrative form, fill and seal machine can produce packages with a clamp on. All information in the table corresponds to a seal time of 70 milliseconds. In other words, the seal jaws press against the film for approximately 70 milliseconds to form package end seals. The table shows how package production speeds vary with bag length. As can be seen, increased package lengths result in lower package production speeds. This is because, given a fixed speed for conveying packages, longer packages require more time to be convey.
Although the inventive settler is described herein as being installed on specific embodiments of vertical form, fill, and seal machines, the inventive settler is not limited to being used with these machines. Rather, the inventive settler can be used, for example, with essentially any process where a product can be settled in a package. Although, the inventive settler is especially useful with processes where a film is being continuously advanced to form a package that is filled with product and then sealed. When used with such a process, the inventive settler can settle product within the film while the film is being continuously advanced. This is a substantial improvement over conventional settlers that require a film to pause intermittently for settling.
Additionally, while the product settler has generally be described in the form of a paddle wheel, some embodiments of the product settler for use with a form, fill and seal machine are also possible. For example, the product settler can be in the form of an object such as a rod that is positioned and actuated to intermittently impact a partially formed package and thereby settle product in the package. In some embodiments, the object can provide settling by contacting the partially formed package on one and only one face. In some embodiments, the object impacts the partially formed package more than 300 times per minute. In some embodiments, the object impacts the partially formed package more than 600 times per minute.
Furthermore, while the steps for particular embodiments of the invention have been described herein, a person skilled in the art would understand from the disclosure that the steps can be modified. For example, as appropriate, steps can occur at different times, steps can occur simultaneously or sequentially, the order of steps can be swapped or varied, certain steps can overlap even if they start at different times, and steps can be added or removed.
While this invention is particularly shown and described herein with reference to preferred embodiments, it will be understood by those skilled in the art that various changes in form and detail can be made therein without departing from the spirit and scope of the invention. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the elements described herein, in all possible variations thereof, is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context. For example, various advantages of the invention can still be realized if additional elements are added to provide additional advantages or if certain elements are omitted because a particular feature is unnecessary or undesirable for a given application.
The following clauses are offered as further description of the disclosed invention.
1. A method for settling a product in a package made on a form, fill and seal machine, the method comprising the steps:
| Number | Name | Date | Kind |
|---|---|---|---|
| 2863475 | Lau | Dec 1958 | A |
| 2915866 | Bartlo | Dec 1959 | A |
| 2960808 | Pike | Nov 1960 | A |
| 3070931 | Zwight | Jan 1963 | A |
| 3525193 | Cutler | Aug 1970 | A |
| 3614850 | Brochot | Oct 1971 | A |
| 3668815 | Henry | Jun 1972 | A |
| 3789888 | James | Feb 1974 | A |
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| 20160176549 A1 | Jun 2016 | US |
