Patent Application
20130067864
Products during transit and delivery to store shelves are often packaged in corrugated boxes. However, during delivery, the added thickness of corrugated boxes takes up area in a cargo area that may be used to carry additional products, especially when the cargo area, such as a truck trailer, carries many rows of products per truck shipment.
Many aspects of the present disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
Embodiments of the present disclosure package a bundle of products using packaging films instead of corrugated boxes, where a bundle may consist of one or more product items. In one embodiment, when heat is applied to the packaging film (via a shrink tunnel, as an example), the film draws up or shrinks down to a tighter package around the bundle than from which it originated.
Consider, in an illustrative and non-limiting example, if a corrugated box that has a wall thickness of ⅛ inch is eliminated from packaging of a product bundle, the product bundle's packaging would reduce for each package or case by ¼ inch in one linear direction. For a 40 foot truck load, in an illustrative and non-limiting example, one may be able to obtain 1 to 2 more bundles of products by eliminating the corrugated boxes, thereby reducing shipping costs.
Further, consider, in an illustrative and non-limiting example, that a corrugated box may cost $1 as compared to 34 cents for packaging film used to package the same size product bundle. For 120 million cases per year that would be $70 million dollars of savings in packaging costs alone. Additionally, with increased amounts of units being carried per truck load, a significant amount of gas emissions may be reduced which is an environmental benefit, among others.
One of the benefits for having corrugated boxes as packaging is that barcode(s), graphics, or other indicia can be affixed to multiple sides of or all sides of the product packaging. Barcodes are often used to route the product boxes through a manufacturing plant or distribution facility so that the boxes are routed to the correct packaging station and placed on the correct pallets and/or on the correct delivery trucks. Some manufacturing facilities utilize one or more barcodes on side panels of the product's packaging to route the product through a facility, which can include automated routing via conveyor systems, where in some cases, 4 or more barcodes are printed on the packaging.
If a single wrap of wound packaging film was used to wrap a loose sleeve around the product bundle and moved through a shrink tunnel to shrink the film around the bundle, the loose ends of the film that extended away from the ends of the product shrink would form a “bullseye” at two of the four sides of the product. Accordingly, barcodes (or other indicia and/or graphics) that is pre-printed on the film to coincide with the center portion of the four sides will be properly displayed on the two sides without the bullseyes and will be distorted on the two sides with the bullseyes. In particular, a barcode printed on a loose end of the film may shrink and become distorted.
Therefore, in the conventional process described above, although a barcode may be desired on a side of the product packaging adjacent to the bullseye, the barcode may become distorted and not be properly scannable after undergoing shrinking. Accordingly, only two sides of the product packaging (not counting the top and bottom faces) may therefore be able to feature a barcode or other insignia or design, without distortion, when using a single wrap of packaging film and employing a bullseye.
Embodiments of one method of the present disclosure apply a first wrap of packaging film in one direction around a product and then apply a second wrap of packaging film around the product in a second direction, thereby allowing for pre-printed barcodes (or other graphics/indicia) to be properly displayed on at least four sides of a packaging of the product bundle.
In one embodiment, the first wrap of packaging film comes in full contact with each side of the product and therefore there is minimal shrinkage during shrinking (e.g., via shrink tunnel). The first wrap of packaging film may therefore be pre-printed with barcodes, graphics, or other indicia that can be displayed and accessible for scanning by a barcode reader, for example, in a conveyor packaging system.
Referring now to
Referring next in
Therefore, the packaging film 210 makes first contact with the side labeled as the left side of the product bundle. Then, two ends of the packaging film 210 are wrapped around two additional adjacent sides labeled as the front side and the back side, and wrapped around a fourth side which is labeled as the right side, where the two free ends of the packaging film are sealed in the conveyor packaging system. Alternatively, various embodiments of a packaging line or process may wrap the packaging film 210 as a single sheet of film with one seal flange connecting the web as opposed to two seal flanges connecting one single web or roll or two different webs.
The width (W) of the packaging film 210 in the first wrap is designed to correspond to the width (W) of the sides of the bundle 100 as the bundle 100 is positioned on its side. With the film width restricted, a bullseye is not formed on the top and bottom faces of the bundle 100 in the first wrap. In some embodiments, instead of positioning a product bundle on its side, the bundle may be positioned vertically and packaged with a vertical seal configuration. In this configuration, graphic presentation on four side panels rather than just two is possible. In addition, in some embodiments, the web of film can envelope the product beyond the boundaries of each panel so that it partially or fully envelopes the top and bottom panels as illustrated below in
Also, as depicted in
Next, in
In one embodiment, the packaging film 410 used in the second wrap is designed so that it is physically larger than a width of the top and bottom labeled faces of the product bundle 100 as the bundle is positioned on its side. The packaging film 410 in the second wrap may be of any width, but the width is selected in one embodiment such that it is greater than the width dimension of the product bundle, so as to ensure at least partial coverage of the lateral sides of the bundle when the wrap shrinks. This is a non-limiting example and in some embodiments the width dimension may be the same as or possibly less than the width of the lateral side of the product bundle.
In an exemplary embodiment, the packaging film 410 extends over the side edges of the product bundle 100 by approximately 4 inches forming a loose sleeve. Therefore, during shrinking in the packaging conveyor system, the loose edges that extend over the product bundle 100 will shrink up around the end of the bundle to form bullseyes 510 on two opposite sides, as depicted in
As long as the packaging film comes into contact with a semi-rigid structure, the film does not shrink and distort significantly. However, any part of the packaging film 410 that goes beyond the rigid structure of the product bundle will distort and shrink significantly, as evidenced by the bullseye formation. In
In one embodiment, the packaging films 210, 410 in the two wraps are designed to overwrap a product bundle 100 without adhering or sticking to the product or products that are contained within, whether the products are further packaged in another film or not. The outer structure of film 210, 410 might or might not be perforated for ease of opening and they can be printed on one or both film structures. In one embodiment, the outer two structures of film are designed to be wrapped in 90 rotated degrees machine direction of each other to achieve both package integrity as well as better graphic display of artwork if printed. This is a non-limiting example and in some embodiments the inner and outer wraps may be wrapped at an angular relativity that is less than or greater than 90 degrees.
In an exemplary embodiment, the outer layer of film 410 has a high COF (Coefficient of Friction) level so as to achieve better palletization so that if the pallets are managed by clamp trucks they will maintain better uniformity, in one embodiment. In order to achieve these objectives, the films 210, 410 are engineered so that the polymers of the inner film and outer film are adverse to sticking to each other when heated and or shrunk in a heat tunnel to constrict the product into a tight uniform unit. This is a non-limiting example and in some embodiments the inner and outer wraps may be engineered to adhere or stick to one another when heated.
As described above, product items may be bundled together using an externally-applied packaging film, such as a clear or substantially transparent single or coextruded ply film made of a polymeric material, including polyethylene, polypropylene polyolefin, cellophane, or polyvinyl chloride or netting material. The film may be provided in the form of an open-ended sleeve or band, but may also be provided on one or more continuous rolls. A variety of techniques and machines for applying such a sleeve, band, or film over the product items and shrinking it to form a packaged product bundle is known in the art.
One exemplary technique uses the conventional “C-fold” wrapping technique, which relies on a single roll of packaging film manipulated into a C-shape for receiving a group of product items or articles. More specifically, a plurality of articles positioned adjacent to one another are advanced into the C-shaped film, such as by a pusher or conveyor. Once the group of articles is surrounded by the film on four sides, and an “L-bar” type sealing jaw including a heated knife or cutter is then used to sever and seal the film adjacent to the lateral (left or right) sides and the trailing side of the group of articles, in one embodiment. Other sealing technologies may also be employed, such as a cross bar seal technology, an air knife, among others. Further, a preformed tube of film may be used to envelope the product bundle during a wrap, in one embodiment, as an alternative to wrapping the bundle with a roll or rolls of film 210, 410 and sealing the ends. To illustrate, an elastic tube of film may be preprinted and mechanically opened and stretched to the size of the product bundle and pulled over the product bundle as a first or second wrap. The elasticity of the tube will then cause the bundle to tighten around the product bundle after being mechanically released.
Regardless of the wrapping technique used, in one embodiment, the film placed over, wrapped around, or covering the articles is then usually subjected to a heating process or restricting technology process such that it shrinks over the bundle, thereby temporarily securing the articles together against movement for more efficient distribution as unit.
One example of a machine for forming and shrinking packing films over the product bundle 100 is now described in detail. As shown schematically in
As part of the wrapping machine, a plurality of tensioner or “dancer” rollers 824 are also provided for ensuring that the proper tension is provided on the films 814, 816 as they simultaneously travel toward a product receiving area 826. Just upstream of the last roller 824 in the group and next to the product receiving area 826, a device for severing and sealing the films 814, 816 together is provided. In one embodiment, this device comprises a pair of opposed sealing jaws 828 that are selectively actuated to move in a vertical direction. As illustrated, the jaws 828 are positioned adjacent to the product receiving area 826, with at least one of the jaws including a heated knife, air knife, or wire for severing and sealing the two films 814, 816 together, with the other jaw serving as a stop for the heated knife, air knife, or wire. While this arrangement generally results in a very reliable operation, it is within the broadest aspects of the present disclosure to use another type of cutting device to sever and seal the films 814, 816.
For purposes of illustrating one embodiment of the method, it should be assumed that a seal 830 is already formed between the free ends of the respective films 814, 816, just in advance of the product receiving area 826. At the product receiving area 826, the product bundle (which may be product items positioned in juxtaposition) are advanced toward the seal 30 securing the films 814, 816 together, such as by using a hydraulic, mechanical, or pneumatic ram 832. The foregoing discussion is a non-limiting example utilizing two rolls of packaging films. Various embodiments alternatively wrap the packaging film as a single sheet of film with one seal flange connecting the web or roll as opposed to two seal flanges connecting one single web or roll or two different rolls. Further, in some embodiments, an elastic tube of film may be mechanically opened and stretched to the size of the product bundle and pulled over the product bundle as a first or second wrap. The elasticity of the tube will then cause the bundle to tighten around the product bundle after being mechanically released.
As shown in
As a result of the advancing of the product bundle by the ram 832, the product bundle covered by the current wrap are then advanced onto a conveyor 838, such as one including a driven, endless conveyor belt. In the case of polyethylene film, the conveyor 838 transports the loose bundle into a temperature control device 840, such as a heating or cooling tunnel. In one embodiment, the device 840 initially heats the polyethylene films 814, 816 forming the wrap to the appropriate temperature for setting. In one embodiment, a cooling device, such as a blower 841, then may be used to cool the films 814, 816 such that the wrap substantially shrinks over the bundle of items.
After a first wrap of the product bundle, the bundle 100 is partially or completely covered on four sides. Then, the bundle 100 may be moved or repositioned for a second wrap to be completed in accordance with the present disclosure. Alternatively, in one embodiment, the packaging line includes multiple sealing stations that can include both horizontal and/or vertical seal systems on both planes to fulfill embodiments of the aforementioned methods of sealing/packing the product.
After the second wrap, the bundle 100 is completely covered on four sides with the second wrap and may be covered with unsealed bullseye openings in opposite ends of the second wrap, with the items held closely together in a bundle 100 and generally prevented from moving relative to each other as a result of the shrinking process.
Referring now to
Accordingly, graphics may be printed on the packaging film 910 and be displayable on the 4 sides of the bundle after wrapping (and eventual shrinking). Correspondingly (in further stages 912 and 914), the product bundle 100 may be wrapped with packaging film 920 around the top and bottom faces and corresponding two sides in a second wrap, where the width of the packaging film 920 is minimized to cover the faces and corresponding sides without overlapping and extending over the other sides. In such an embodiment, when desired, graphics or barcodes may be produced on the first and/or second packaging films and maintained as a tight package after undergoing shrinking, as depicted by the packaged bundle 930 (in further stage 916). This is a non-limiting example and in some embodiments the first and/or second packaging film may not undergo a shrinking process.
For a side having a bullseye formation from the outer wrap, a design may be depicted on an inner wrap positioned under the outer wrap and may be visible through the bullseye. Further, for the outer wrap, graphics may also be printed and displayed away from the bullseye. It is noted that the further one moves toward the center of a particular side panel, the more likely the wrap placed over the side panel is going to shrink and distort. Therefore, designs placed near the ends or corners of the side panel are less likely to distort. In addition, mechanisms in a packaging line may be used to retard shrinking. As an example, a side belt conveyor may hold the product bundle and wrap where the design or barcode is printed in a shrink tunnel, such that area being held is not going to get airflow and will therefore retard or prohibit shrinking.
Referring next to
Accordingly, graphics may be printed on the packaging film 1010 and be displayable on the 4 sides of the bundle after wrapping (and eventual shrinking). Correspondingly (in further stages 1012), the product bundle 100 may be wrapped with packaging film 1020 around the top and bottom faces and corresponding two sides in a second wrap, where the width of the packaging film 1020 extends and overlaps the top face and corresponding sides to wrap around the bottom face of the bundle 100. In such an embodiment, when desired, graphics or barcodes may be produced on the first and/or second packaging films and maintained as a tight package after undergoing shrinking, as depicted by the packaged bundle 1030 (in further stage 1016). Further, bullseyes may be formed on opposite sides and the bottom face, in one embodiment. This is a non-limiting example and in some embodiments the first and/or second packaging film may not undergo a shrinking process.
In the embodiment of
Certain embodiments of the present disclosure can be implemented in hardware, software, firmware, or a combination thereof. In various embodiment(s), a method of packaging is implemented in software or firmware that is stored in a memory and that is executed by a suitable instruction execution system, such as in a packaging conveyor system. If implemented in hardware, as in an alternative embodiment, a method of packaging can be implemented with any or a combination of the following technologies, which are all well known in the art: a discrete logic circuit(s) having logic gates for implementing logic functions upon data signals, an application specific integrated circuit (ASIC) having appropriate combinational logic gates, a programmable gate array(s) (PGA), a field programmable gate array (FPGA), etc.
It should be emphasized that the above-described embodiments of the present disclosure are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the present disclosure. Many variations and modifications may be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the present disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure.
This application claims priority to copending U.S. provisional application entitled, “Packaging a Product Bundle,” having Ser. No. 61/536,879, filed Sep. 20, 2011, which is entirely incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 61536879 | Sep 2011 | US |
