Patent Application
20200369419
The object of the present invention is an apparatus and a relative packaging process capable of simultaneously performing multiple packaging cycles. In particular, the finding refers to apparatuses and processes using a base support or tray, intended to house at least one product, and at least one plastic film, intended to be coupled with the base support in order to enclose the product itself in a package. The finding can have application in vacuum packaging or in controlled atmosphere packaging of products of various type.
In the packaging field, apparatuses and relative methods are known for the packaging, e.g. vacuum or in controlled atmosphere, of products such as meat and fish, cheese, treated meats, prepared meals and similar foods.
The vacuum packaging process—also termed vacuum skin packaging (VSP)—is essentially a thermoforming process which provides for arranging product within or above a rigid or semi-rigid support, for example defined by a flat tray, or by a tub or by a cup. The support and the relative product are arranged within a vacuum chamber, in which a thermoplastic film is welded to an upper edge of the support; subsequently, the air present in the package is extracted so that the thermoplastic film can adhere to the product arranged inside the support.
The process of packaging in controlled atmosphere or modified atmosphere—also termed modified atmosphere packaging (MAP)—instead provides for, before the hermetic closure of the support by means of a plastic film, the evacuation of air between the space present between the support and the plastic film and the injection of gas with a controlled composition.
Sophisticated apparatuses and processes were conceived and developed for automatically transferring a plurality of supports in a packaging apparatus where a plastic film portion is fixed to the supports on which the products to be packaged have been previously loaded, so as to efficiently and rapidly obtain a high number of packaged products. For example, such type of known apparatuses and processes is described in the following patent applications WO 2014/060507 A1 and WO 2014/166940 A1. Even if the solutions described in the abovementioned patent applications are highly-developed and allow efficiently forming quality packaged with high productivity, such solutions were designed for large productions and therefore are adapted to be used if it is desired to simultaneously make a large number of identical packages. In connection with a high degree of automation and productivity, several of the apparatuses described in the abovementioned applications have a complex structure and non-negligible size: such apparatuses hence requiring considerable investments of capital and availability of ample spaces for their installation. In addition, apparatuses with a high degree of automation require high standards in terms of production quality and maintenance, otherwise there will be a reduction in terms of reliability since failure—even of only one component—can cause a complete machine stoppage, with the need for intervention only by highly-qualified technical personnel for the restoration of the operative conditions. Additionally, it should be indicated that the large-size automated packaging apparatuses generally have poor flexibility of use: such apparatuses cannot be easily adapted to small production batches or to packaging of products on supports of different geometries.
Hence, in order to be able to sustain small productions of packages, packaging apparatuses are presently employed with manual operation, for which the steps of loading the tray in the machine, the closing of the machine for the packaging step and the step of unloading the package are manually performed by an operator. These apparatuses are conceived for making one package at a time and therefore can be suitable for formats of various size; in addition, if small batch productions are requested in limited time periods, two more manually-actuated apparatuses can be side-by-side in order thus meet the needs that might be required from time to time.
Even if the manually-actuated apparatuses are structurally simple, relatively inexpensive and have a certain flexibility of use, the Applicant has also indicated that these can be improved with regard to several aspects.
Object of the present invention is therefore that of substantially resolving at least one of the drawbacks and/or limitations of the preceding solutions.
A first objective of the present invention is to provide a plant and a packaging process characterized by high operating flexibility: capable of being adapted to small and large production batches and, optionally, capable of making packages of different shapes and sizes.
A further object of the present invention is to provide a compact packaging plant, attainable with limited investment and simultaneously capable of high productivity, considerably greater than that typical of the known manual apparatuses. In particular, one object of the present invention is to provide a packaging plant which, even if compact and attainable with limited investment, has a degree of automation such to reduce the manual interventions to a minimum. A further object of the present invention is to provide plant and a packaging process capable of creating packages of vacuum type or in modified atmosphere. Then, an object of the present invention is to provide a plant and a packaging process capable of safely operating, without compromising the appearance of the final packaged product.
These and yet other objects, which will become more apparent from the following description, are substantially achieved by a packaging plant and process according to what is expressed in one or more of the accompanying claims and/or the following aspects, taken alone or in any combination with each other or in combination with any one of the appended claims and/or in combination with any of the other aspects or features described below.
In a 1st aspect, a plant (100) is provided for packaging products (P) arranged on a support (4), said plant (100) comprising:
In a 2nd aspect in accordance with the 1st aspect the transfer device (30) comprises:
In a 3rd aspect in accordance with the preceding aspect the tract (T1), when the transfer device (30) is in said operative condition, extends above the conveyor (20), in which the displacement element (32) is configured for being moved above the conveyor (20) itself.
In a 4th aspect in accordance with the 2nd or 3rd aspect the displacement element (32) is movable along the tract (T1) of the guide (31) at least between:
In a 5th aspect in accordance with any one of the aspects from the 2nd to the 4th, the guide (31) comprises a first and a second end portion, in which said second end portion is arranged at at least one respective packaging apparatus (1). In a 6th aspect in accordance with any one of the aspects from the 2nd to the 5th, the guide (31) comprises a first and a second end portion, in which only the second end portion of the guide (31) is placed at a respective packaging apparatus (1).
In a 7th aspect in accordance with any one of the aspects from the 2nd to the 6th, the displacement element (32) is selectively movable, optionally by translation, with respect to the guide (31) at least between:
In an 8th aspect in accordance with any one of the aspects from the 2nd to the 7th, the displacement element (32) comprises:
In a 9th aspect in accordance with the preceding aspect in which the contact portion (32b), at least in the loading position, faces the conveyor (20) and is adapted to intercept the at least one support (4), optionally moving, on said conveyor (20).
In a 10th aspect in accordance with the 8th or 9th aspect in which, in the active condition of the displacement element (32), the contact portion (32b) is arranged at a minimum distance from the conveyor (20) less than a minimum distance between the contact portion (32b) itself and the conveyor (20) in the inactive condition of the displacement element (32).
In an 11th aspect in accordance with any one of the aspects from the 2nd to the 10th, the tract (T1) of the guide (31) is rectilinear and extends across the conveyor (20) up to at least one packaging apparatus (1).
In a 12th aspect in accordance with any one of the preceding aspects the conveyor (20) comprises an operative tract (21) extending along a plane and configured for moving the supports (4) along said advancement path (A).
In a 13th aspect in accordance with the preceding aspect in which at least one part of the tract (T1) of the guide (31), in particular the entire tract (T1), extends parallel to the lying plane of the operative tract (21) of the conveyor (20).
In a 14th aspect in accordance with the 12nd or 13rd aspect the operative tract (21) of the conveyor (20), optionally the lying plane of said operative tract (21), in use conditions of the packaging plant (100), extends horizontally.
In a 15th aspect in accordance with any one of the aspects from the 2nd to the 14th, the guide (31) of the transfer device (30) comprises a rectilinear bar arranged, in use conditions of the packaging plant (100), above the conveyor.
In a 16th aspect in accordance with any one of the aspects from the 2nd to the 15th the tract (T1), optionally rectilinear, of the guide (31) is tilted with respect to the advancement path (A) of the conveyor (20) by an angle comprised between 10° and 80°, optionally comprised between 20° and 70°.
In a 17th aspect in accordance with any one of the aspects from the 2nd to the 16th the plant comprises a plurality of transfer devices (30) operating at the advancement path (A) of the conveyor (20), each transfer device (30) being configured for moving at least one support (4), optionally moving, on the conveyor (20) at a respective packaging apparatus (1).
In an 18th aspect in accordance with the preceding aspect each transfer device (30) is at least partly fixed with respect to the packaging apparatuses (1) and is configured for delivering supports (4) to only one of said packaging apparatuses (1).
In a 19th aspect in accordance with the 17th or 18th aspect the tract (T1) of the guide (31) of each transfer device (30) is rectilinear and tilted with respect to the advancement path (A) of the conveyor (20).
In a 20th aspect in accordance with any one of the aspects from the 17th to the 19th, each transfer device (30) is placed, in use conditions of the plant (100), above the operative tract (21) of the conveyor (20).
In a 21st aspect in accordance with any one of the aspects from the 17th to the 20th, the tracts (T1) of the plurality of transfer devices (30) are parallel to each other.
In a 22nd aspect in accordance with any one of the aspects from the 17th to the 21st, the tracts (T1) of the plurality of transfer device (30) are parallel to the lying plane of the operative tract (21) of the conveyor (20).
In a 23rd aspect in accordance with any one of the preceding aspects, each packaging apparatus (1) comprises:
In a 24th aspect in accordance with the preceding aspect the upper tool (6) and the lower tool (2) are movable with respect to each other at least between:
In a 25th aspect in accordance with the preceding aspect in which the transfer device (30) is configured for moving a support (4) on the lower tool (2) in the spaced condition defined by said lower and upper tools.
In a 26th aspect in accordance with any one of the aspects from the 2nd to the 25th the transfer device (30) is a pusher.
In a 27th aspect in accordance with any one of the aspects from the 8th to the 25th the contact portion (32b) of the transfer device (30) comprises a plate exhibiting a substantially L shape, defining a seat adapted to receive a support (4), said contact portion (32b) being configured for receiving in abutment, within said seat, a support (4) and guiding it in moving outside the conveyor (20) along the tract (T1) of the guide (31).
In a 28th aspect in accordance with any one of the preceding aspects, the plant (100) comprises a control unit (50) connected to the transfer device (30), the control unit being configured for commanding the operative condition of said transfer device (30) in order to enable the transfer of at least one support (4), optionally moving, on the conveyor (20) from said conveyor to a respective of said packaging apparatuses (1).
In a 29th aspect in accordance with the preceding aspect the plant (100) comprises at least one sensor configured for emitting at least one signal representative of at least one among the following parameters:
in which the control unit (50) is connected to said sensor and is configured for:
In a 30th aspect in accordance with the 28th or 29th aspect in which the control unit (50) is further connected to the packaging apparatuses (1) and is further configured for:
In a 31st aspect in accordance with the preceding aspect the control unit (50) is configured for commanding the operative condition of at least one transfer device (30) so that the latter can move at least one support (4) at a packaging apparatus (1) placed in the stand-by condition.
In a 32nd aspect in accordance with any one of the preceding aspects the plant (100) comprises a buffer station for each packaging apparatus (1); each buffer station is configured for receiving at least one support (4), optionally a support (4) bearing a product, from a respective transfer device (30) when the lower and upper tools of the respective packaging apparatus (1) served by said transfer device (30) are at least in the approached condition,
in which each buffer station is configured for enabling the positioning of the support borne by the buffer station itself on a lower tool (2) of a respective packaging apparatus (1) when the latter lower tool (2) is spaced from the upper tool (6).
In a 33rd aspect in accordance with any one of the aspects from the 28th to the 32nd in which the control unit (50) is connected to the plurality of transfer devices (30) and is configured for selectively commanding the operative condition of each transfer device (30) in order to move a support (4) from the conveyor (20) to a respective packaging apparatus (1).
In a 34th aspect in accordance with any one of the aspects from the 28th to the 33rd in which the control unit (50) is connected to the conveyor (20) and is configured for adjusting the movement speed of the latter and therefore the movement speed of the supports (4) along the advancement path (A), in which the control unit (50) is further configured for adjusting the movement speed of the displacement element (32) along the tract (T1) of the guide (31), in which the control unit (50) is configured for commanding a movement speed of the displacement element (32) along the tract (T1) of the guide (31) so that a component of said speed, parallel to the operative tract of the conveyor, is substantially equal to the movement speed of the conveyor (20), optionally substantially equal to the movement speed of the supports (4) along the advancement path (A).
In a 35th aspect a packaging process is provided for packaging at least one product (P) by using a packaging plant (1) according to any one of the preceding aspects.
In a 36th aspect in accordance with the preceding aspect, the process comprises the following steps:
In a 37th aspect in accordance with the preceding aspect the step of displacing the support comprises moving the displacement element (32) along the guide (31) of at least one transfer device (30), in which the guide (31) has a tract (T1) transverse to the advancement path (A) of the supports (4) on the conveyor (20).
In a 38th aspect in accordance with the 36th or 37th aspect the step of displacing at least one support (4) comprises:
In a 39th aspect in accordance with any one of the aspects from the 35th to the 38th, the process comprises a packaging step for packaging at least one product (P), said step comprising at least the following sub-steps:
In a 40th aspect in accordance with any one of the aspects from the 35th to the 39th, the process comprises at least one step of monitoring operative conditions of the plant, in which said monitoring step, performed by the control unit, comprises at least one sub-step of determining at least one selected in the group of the following parameters representative of at least one between the following operative conditions:
as a function of the operative conditions, the process provides for commanding the operative condition of at least one transfer device (30) so that the latter can move at least one support (4) at a packaging apparatus (1).
Several embodiments and several aspects of the finding will be described hereinbelow with reference to the enclosed drawings, provided only as a non-limiting example in which:
It should be noted that in the present detailed description, corresponding parts illustrated in the various figures are indicated by the same reference numerals. The figures may illustrate the object of the invention by representations that are not in scale; therefore, parts and components illustrated in the figures relating to the object of the invention may relate solely to schematic representations.
The terms upstream and downstream refer to a direction of advancement of a package—or of a support for making said package—along a predetermined path starting from a starting or forming station of a support for said package, through a packaging station or apparatus and then up to a package unloading station.
Product
The term product P means an article or a composite of articles of any kind. For example, the product may be of a foodstuff type and be in solid, liquid or gel form, i.e. in the form of two or more of the aforementioned aggregation states. In the food sector, the product may comprise: meat, fish, cheese, treated meats, prepared and frozen meals of various kinds.
Control Unit
The packaging plant described and claimed herein comprises at least one control unit designed to control the operations performed by the plant. The control unit can clearly be only one or be formed by a plurality of different control units according to the design choices and the operational needs.
With the term control unit it is intended an electronic component which can include at least one selected in the following group: a digital processor (e.g. comprising at least one selected in the group among: CPU, GPU, GPGPU), a memory (or memories), an analog circuit, or a combination of one or more digital processing units with one or more analog circuits. The control unit can be “configured” or “programmed” to perform some steps: this can be done in practice by any means that allows configuring or programming the control unit. For example, in the case of a control unit comprising one or more CPUs and one or more memories, one or more programs can be stored in appropriate memory banks connected to the CPU or to the CPUs; the program or programs contain instructions which, when executed by the CPU or the CPUs, program or configure the control unit to perform the operations described in relation to the control unit. Alternatively, if the control unit is or includes analog circuitry, then the control unit circuit may be designed to include circuitry configured, in use, for processing electrical signals so as to perform the steps related to control unit. The control unit may comprise one or more digital units, for example of the microprocessor type, or one or more analog units, or a suitable combination of digital and analog units; the control unit can be configured for coordinating all the actions necessary for executing an instruction and instruction sets.
Actuator
The term actuator means any device capable of causing movement on a body, for example on a command of the control unit (reception by the actuator of a command sent by the control unit). The actuator can be of an electric, pneumatic, mechanical (for example with a spring) type, or of another type.
Support
With the term support, it is intended both a flat support and a tray comprising at least one base and at least one lateral wall emerging from the external perimeter of the base and optionally a terminal flange emerging radially outward from an upper perimeter edge of the lateral wall. The external flange can extend along a single main extension plane or it can be shaped; in the case of shaped external flange, the latter can for example have multiple portions extended along main extension planes that are different from each other, in particular parallel but offset from each other. The portions of the shaped external flange can be radially offset. The support defines an upper surface on which the product P can be placed and/or a volume within which the product can be housed. The tray can comprise an upper edge portion radially emerging from a free edge of the lateral wall opposite the base: the upper edge portion emerges from the lateral wall according to a direction moving outward from the volume of the tray itself.
The flat support can be of any shape, for example rectangular, rhomboidal, circular or elliptical; analogously the tray with lateral wall can have a base of any shape, for example rectangular, rhomboidal, circular or elliptical. The support can be formed by means of a specific manufacturing process separate from the packaging process or it can be made in line with the packaging process.
The support can be at least partly made of paper material, optionally exhibiting at least 50% by weight, preferably at least 70% by weight, of organic material comprising one or more of cellulose, hemicellulose, lignin, lignin derivatives. The paper material in question extends between a first and a second main extension surface. The sheet paper material employed for making the support can, in an embodiment variant thereof, be covered for at least one part of the first and/or second main extension surface by means of a plastic material covering, e.g. film for food use. If the covering is arranged so as to cover at least part of the first extension surface, the same covering will come to define an internal surface of the support. On the other hand, if the covering is arranged on the second main extension surface, the same covering will come to define an external surface of the support. The covering can also be thermally treated such that it can act as an engagement and fixing element for portions of the support, as will be better described hereinbelow. The covering can also be employed for defining a sort of barrier to water and/or humidity useful for preventing the weakening and loss of structurality of the support with consequent uncontrolled deformation of the paper material forming the latter component. The covering can be applied to the paper material (as specified above on the internal and/or external side of the support) in the form of a so-called coating or lacquer deposited as a solution or sprayed whose thickness is generally comprised, in a non-limiting manner, between 0.2 μm and 10 μm. Alternatively, the covering can comprise a plastic film, e.g. a polythene coating, applicable by means of a lamination process on one or both sides (internal and/or external sides) of the paper material defining the support. If the covering is applied by means of lamination, the values of the plastic film (covering) can for example vary between 10 μm and 400 μm, in particular between 20 μm and 200 μm, still more particularly between 30 μm and 80 μm, of covering material (i.e. polythene). The plastic covering material can be selected, by way of example, among the following materials: PP, PE (HDPE, LDPE, MDPE, LLDPE), EVA, polyesters (including PET and PETg), PVdC.
The support can alternatively be at least partly made of single-layer and multilayer thermoplastic material. The support can have gas barrier properties. As used herein, this term refers to a film or sheet of material that has an oxygen transmission rate of less than 200 cm3/(m2*day*bar), less than 150 cm3/(m2*day*bar), less than 100 cm3/(m2*day*bar) when measured in accordance with ASTM D-3985 at 23° C. and 0% relative humidity. Gas barrier materials suitable for single-layer thermoplastic containers are for example polyesters, polyamides, ethylene vinyl alcohol (EVOH), PVDC and the like. The support can be made of multilayer material comprising at least one gas barrier layer and at least one heat-sealable layer to allow sealing the covering film on the surface of the support. The gas barrier polymers which can be employed for the gas barrier layer are PVDC, EVOH, polyamides, polyesters and mixtures thereof. Generally, a PVDC barrier layer will contain plasticizers and/or stabilizers as known in the art. The thickness of the gas barrier layer will preferably be set in order to provide the material of which the support is composed with an oxygen transmission rate at 23° C. and 0% relative humidity less than 50 cm3/(m2*day*atm), preferably less than 10 cm3/(m2*day*atm), when measured in accordance with ASTM D-3985. In general, the heat-sealable layer will be selected from polyolefins, such as ethylene homo- or copolymers, propylene homo- or copolymers, ethylene/vinylacetate copolymers, ionomers and homo- or co-polyesters, e.g. PETG, a glycol-modified polyethylene terephthalate.
Additional layers, such as adhesive layers, for example to make the gas barrier layer better adhere to the adjacent layers, may preferably be present in the material of which the support is made and are selected based on the specific resins used for the gas barrier layer.
In the case of a multilayer structure, part of this can be formed as a foam. For example, the multilayer material used for forming the support can comprise (from the outermost layer to the layer of contact with the more internal foods) one or more structural layers, typically made of a material such as expanded polystyrene, expanded polyester or expanded polypropylene, or of cardboard, or sheet for example polypropylene, polystyrene, poly(vinyl chloride), polyester; a gas barrier layer and a heat-sealable layer. A frangible layer that is easy to open can be positioned adjacent to the heat-sealable layer in order to facilitate the opening of the final package. Mixtures of polymers with low cohesion that can be used as frangible layer are for example those described in the document WO99/54398. The overall thickness of the support can for example be 5 mm, optionally comprised between 0.04 and 3.00 mm, still more optionally between 0.15 and 1.00 mm.
The support can be entirely made of paper material (optionally covering made of plastic material film) or it can be entirely made of plastic material. In a further embodiment variant, the support is at least partly made of paper material and at least partly of plastic material; in particular, the support is made of plastic material at its interior and externally covered at least in part in paper material.
The support can also be employed for defining so-called “ready-meals” packages; in such configuration the supports are made such that they can be inserted in an oven for heating and/or cooking the food product placed in the package. In such embodiment (supports for ready-meals packages), the support can for example be made of paper material, in particular cardboard, coated in polyester or it can be entirely made with a polyester resin. For example, supports suitable for ready-made packages are made of the following materials: CPET, APET or APET/CPET, expanded or non-expanded. The support can also comprise a hot-weldable layer of a low melting material on the film. This hot-weldable layer can be co-extruded with a PET-based layer (as described in the patent applications No. EP1529797A and WO2007/093495) or it can be deposited on the base film by means of deposition with solvent means or by means of extrusion coating (e.g. described in the documents U.S. Pat. No. 2,762,720 and EP 1 252 008 A). In a further embodiment variant, the support can be at least partly made of metal material, in particular of aluminum. The support can also be at least partly made of aluminum and at least partly of paper material. In general, the support can be made of at least one of the following materials: metal, plastic, paper.
Film
A film made of plastic material, in particular polymeric material, is applied to the supports (flat supports or trays), so as to create a fluid-tight package housing the product. If desired, a vacuum package is attained, the film applied with the support is typically a flexible multilayer material comprising at least one first external thermo-weldable layer capable of welding to the internal surface of the support, optionally a gas barrier layer, and a second external heat-resistant layer. If it is desired to make a package under controlled atmosphere (MAP) or a package under natural atmosphere (non-modified atmosphere), the film applied with the support (film made of plastic, in particular polymeric material) is typically single-layer or multilayer, having at least one thermo-weldable layer and possibly capable of heat-shrinking under the action of heat. The applied film can also comprise at least one gas barrier layer and optionally an external heat-resistant layer.
Material Specifications
The term paper material means paper or cardboard; in particular, the sheet material that can be used to make the paper layer can have a weight of between 30 and 600 g/m2, in particular of between 40 and 500 g/m2, even more particularly between 50 and 250 g/m2.
PVDC is any vinylidene chloride copolymer in which a prevalent amount of the copolymer comprises vinylidene chloride and a lower amount of the copolymer comprises one or more unsaturated monomers copolymerizable therewith, typically vinyl chloride and alkyl acrylates or methacrylates (for example methyl acrylate or methacrylate) and mixtures thereof in different proportions.
The term EVOH includes saponified or hydrolyzed ethylene-vinyl acetate copolymers and refers to ethylene/vinyl alcohol copolymers having an ethylene co-monomer content preferably composed of a percentage of from about 28 to about 48 mole %, more preferably from about 32 and about 44 mole % of ethylene and even more preferably, and a saponification degree of at least 85%, preferably at least 90%.
The term polyamides is meant to indicate homo- and co- or ter-polymers. This term specifically includes aliphatic polyamides or co-polyamides, e.g. polyamide 6, polyamide 11, polyamide 12, polyamide 66, polyamide 69, polyamide 610, polyamide 612, copolyamide 6/9, copolyamide 6/10, copolyamide 6/12, copolyamide 6/66, copolyamide 6/69, aromatic and partly aromatic polyamides or copolyamides, such as polyamide 61, polyamide 6I/6T, polyamide MXD6, polyamide MXD6/MXDI, and mixtures thereof.
The term polyesters refers to polymers obtained from the polycondensation reaction of dicarboxylic acids with dihydroxylic alcohols. Suitable dicarboxylic acids are, for example, terephthalic acid, isophthalic acid, 2,6-naphthalene dicarboxylic acid and the like. Suitable dihydroxylic alcohols are for example ethylene glycol, diethylene glycol, 1,4-butanediol, 1,4-cyclohexanodimethanol and the like. Examples of useful polyesters include poly(ethylene terephthalate) and copolyesters obtained by reaction of one or more carboxylic acids with one or more dihydroxylic alcohols.
The term copolymer means a polymer derived from two or more types of monomers and includes terpolymers. Ethylene homo-polymers include high density polyethylene (HDPE) and low density polyethylene (LDPE). Ethylene copolymers include ethylene/alpha-olefin copolymers and unsaturated ethylene/ester copolymers. The ethylene/alpha-olefin copolymers generally include copolymers of ethylene and one or more co-monomers selected from alpha-olefins having between 3 and 20 carbon atoms, such as 1-butene, 1-pentene, 1-hexene, 1-octene, 4-methyl-1-pentene and the like. Ethylene/alpha-olefin copolymers generally have a density in the range of from about 0.86 g/cm3 to about 0.94 g/cm3. It is generally understood that the term linear low density polyethylene (LLDPE) includes that group of ethylene/alpha-olefin copolymers which fall in the density range of between about 0.915 g/cm3 and about 0.94 g/cm3 and in particular between about 0.915 g/cm3 and about 0.925 g/cm3. Sometimes, linear polyethylene in the density range between about 0.926 g/cm3 and about 0.94 g/cm3 is referred to as linear medium density polyethylene (LMDPE). Lower density ethylene/alpha-olefin copolymers may be referred to as very low density polyethylene (VLDPE) and ultra-low density polyethylene (ULDPE). Ethylene/alpha-olefin copolymers can be obtained with heterogeneous or homogeneous polymerization processes. Another useful ethylene copolymer is an unsaturated ethylene/ester copolymer, which is the copolymer of ethylene and one or more unsaturated ester monomers. Useful unsaturated esters include vinyl esters of aliphatic carboxylic acids, in which esters have between 4 and 12 carbon atoms, such as vinyl acetate, and alkyl esters of acrylic or methacrylic acid, in which esters have between 4 and 12 carbon atoms. Ionomers are copolymers of an ethylene and an unsaturated mono-carboxylic acid having the carboxylic acid neutralized by a metal ion, such as zinc or, preferably, sodium. Useful propylene copolymers include propylene/ethylene copolymers, which are copolymers of propylene and ethylene having a percentage by weight content mostly of propylene and propylene/ethylene/butene ter-polymers, which are copolymers of propylene, ethylene and 1-butene.
Packaging Plant 100
Reference number 100 overall indicates a packaging plant, adapted to make packages comprising at least one product P.
As schematically illustrated for example in
The conveyor 20 comprises an operative tract 21 extending along a plane and configured for moving the supports 4 along an advancement path A (
Regarding the structure, the conveyor 20 can comprise a belt (condition illustrated in the enclosed figures) moved by means of one or more motors, e.g. electric. Alternatively, the conveyor 20 can comprise a roller (condition not illustrated), always moved by means of electric motors.
The plant 100 further comprises a plurality of packaging apparatuses 1, schematically shown in
Each packaging apparatus 1 is configured for receiving at least one support 4 bearing a product P and for engaging a portion of a film 5a with said support 4 in order to make at least one package 40. In detail, each packaging apparatus 1 comprises at least one lower tool 2 configured for receiving and sustaining one or more supports 4 and an upper tool 6 configured for engaging a film portion 5a with at least one support 4 for making at least one package 40; the upper tool 6 and the lower tool 2 are movable with respect to each other at least between a spaced condition and an approached condition. In detail, in the spaced condition the lower tool 2 and the upper tool 6 are configured for enabling the positioning of at least one film portion 5a and a support 4 bearing the product between said tool, i.e.
interposed between the lower tool 2 and the upper tool 6. In the approached condition, the upper tool 6 and the lower tool 2 are configured for enabling the engagement of the film portion 5a with the support 4 in order to make the package 40. In more detail, each of the packaging apparatuses 1 comprises at least one heating device associated with the upper tool 6 which is configured for heating at least one film portion 5a before or during a packaging step of the product P, in order to enable the heat-sealing of said film with the support 4. The heating device comprises a heat-sealing plate configured for contacting the film 5a, heating it and pressing it against the support 4, in particular against a perimeter closure flange of the support and exerting a contact pressure between said film 5a and the support 4.
The plant 100 further comprises at least one transfer device 30 configured, in at least one operative condition, for transferring at least one support 4 from the conveyor 20 to a respective of said packaging apparatuses 1. The transfer device 30 is configured for transferring the supported supports 4, optionally moving, from the conveyor 20 to one or more packaging apparatuses 1: in this configuration the transfer device 30, in the operative condition, is configured for intercepting the supports, optionally moving, on the conveyor 20. Alternatively, the conveyor 20 can be configured to be stopped for predetermined time instants; the transfer device 30 can be configured for contacting the support 4 on the conveyor 20 during such stop step, i.e. when stopped on the conveyor.
In an embodiment illustrated in
In more detail, each transfer device 30 comprises at least one guide 31 exhibiting a tract T1 transverse to the advancement path A of the supports 4 on the conveyor 20; the guide 31 is fixed with respect to the packaging apparatuses 1, at least when the transfer device 30 is in said operative condition. In particular, the tract T1 of the guide 31 is rectilinear and extends across the conveyor 20 up to at least one packaging apparatus 1. The guide 31 of the transfer device 30 comprises a rectilinear bar arranged, in use conditions of the packaging plant 100, above the conveyor 20. In particular, at least one part of the tract T1 of the guide 31, optionally the entire tract T1, extends parallel to the lying plane of the operative tract 21 of the conveyor 20. The rectilinear tract T1 of the guide 31 is tilted with respect to the advancement path A of the conveyor 20 by an angle comprised between 10° and 80°, optionally comprised between 20° and 70°. In more detail, the guide 31, in particular the bar of the guide 31, extends to entirely cover the width of the conveyor 20. Said guide 31 extends between a first and a second end portion: only the second end portion is arranged at a respective packaging apparatus 1, in particular arranged at the lower tool 2 of the respective packaging apparatus 1. The first end portion of the guide 31 is instead spaced from the respective packaging apparatus 1, in particular arranged at the side of the conveyor 20 opposite the side along which the respective packaging apparatus 1 is arranged. Each transfer device 30 is placed, in use conditions of the plant 100, above the operative tract 21 of the conveyor 20.
As previously mentioned, the plant 100 comprises a plurality of transfer devices 30; in such configuration the tracts T1 of the guides 31 can be parallel to each other (see for example
As is visible from the enclosed figures, the transfer device 30 further comprises at least one displacement element 32 engaged with the guide 31 and configured, at least in the operative condition of the transfer device 30, for being moved along the tract T1 above the conveyor 20. In particular, the displacement element 32 is configured for intercepting at least one support 4 displaced on the conveyor 20, moving it to the respective packaging apparatus 1. The displacement element 32 is configured for being moved along the tract T1 of the guide 31 between a loading position and an outlet position. The displacement element 32, in the loading position, is spaced from a respective of said packaging apparatuses 1 and configured for intercepting one or more supports 4 moving on the conveyor 20: furthermore, in said loading position, the displacement element 32 is placed at an end portion of the guide 31 that is opposite with respect to the respective packaging apparatus 1. The displacement element 32, in the outlet position, is instead placed in proximity to the respective packaging apparatus 1 beside the conveyor 20.
The displacement element 32 is movable with respect to the guide 31 between an active condition and an inactive condition. The displacement element 32, in the active condition and when movable along the tract T1 of the guide 31, is adapted to intercept at least one support 4 arranged, optionally moving, on the conveyor 20. On the other hand, in the inactive condition, the displacement element 32, when movable along the tract T1 of the guide 31, is adapted to avoid contact with the supports 4 placed on the conveyor 20 (optionally moving on the conveyor 20). In fact, in the active condition, the displacement element 32 is arranged at a minimum distance from the conveyor 20 less than a minimum distance between the conveyor 20 and the displacement element 32 when the latter is in the inactive condition. In other words, the minimum distance between the conveyor 20 and the displacement element 32 increases when passing from the active condition to the inactive condition. The active condition is for example shown in
Regarding structure, the displacement element 32 comprises an engagement portion 32a directly constrained to the guide 31 and at least one end contact portion 32b facing the conveyor 20, at least in the loading position. The engagement portion 32a essentially represents the element of connection between the displacement element 32 itself and the guide 31; in the enclosed figures, an engagement portion is illustrated in a non-limiting manner comprising a sliding carriage, below which the contact portion 32b is constrained.
The contact portion 32b instead represents the element adapted to directly intercept the support 4 arranged, optionally moving, on the conveyor 20. In more detail and in accordance with a preferred embodiment, the contact portion 32b of the transfer device 30 comprises, in a non-limiting manner, a plate exhibiting a substantially L shape, defining a seat adapted to receive a support 4. The contact portion 32b is thus configured for receiving in abutment, within said seat, at least one support 4 and for guiding it in moving outside the conveyor 20 along the tract T1 of the guide 31. In this configuration the transfer device 30 acts, in a non-limiting manner, as a pusher; it is however also possible to make a different contact portion 32b that can for example act as a pull element.
The transfer device 30 comprises at least one motor, optionally an electric motor, connected to the displacement element 32 and configured for moving the latter between the loading position and the outlet position. Furthermore, the transfer device 30 can comprise an actuator or a further electric motor configured for moving the displacement element 32 between the active condition and the inactive condition.
The plant can also comprise at least one buffer station interposed between the conveyor 20 and at least one packaging apparatus 1 and configured for receiving at least one support 4, optionally a support bearing a product, when the lower tool 2 is in the packaging position, optionally also when the station is in the stand-by position. The buffer station is then configured for enabling the positioning of the support 4 borne by the same buffer station on the lower tool 2. In other words, the buffer station allows the transfer device 30 to position a support 4 at, in particular nearby, a packaging apparatus 1 also when the latter has the lower tool 2 in packaging position: in this manner, when the lower tool 2 has terminated the packaging step and unloaded the respective package, the support 4 is immediately ready to be positioned on the lower tool 2, consequently without having to await the arrival of a support 4 from the conveyor 20. The buffer station can comprise an abutment plane at which the support 4, coming from the conveyor 20, awaits the arrival of the lower tool: the transfer device 30 is then configured for completing the displacement of the support 4 from the buffer station to the lower tool 2 of the relative packaging apparatus.
Also illustrated in the enclosed figures is a lower tool movable between:
Indeed, when in the packaging position and in use conditions of the plant, the lower tool is vertically aligned with the upper tool and they define a sort of virtual size with vertical extension. The lower tool, when in the loading position, is arranged at least in part outside of said virtual size. The lower tool in the loading position is substantially superimposed on the buffer station. In fact, when the lower tool moves from the packaging position to the loading position, it is configured for automatically receiving the support from said buffer station.
In one embodiment, the buffer station can be associated with the lower tool. In particular, the lower tool can be connected to a catenary, optionally with closed path, which is configured for following the movement of the lower tool between the packaging position and the loading position. In particular, the catenary, when the lower tool is in the packaging position, is configured for defining a plane adapted to receive in abutment at least one support 4 (buffer station). The plane defined by said catenary is configured for being reduced when the lower tool 2 reaches the loading position, such that the support 4 is arranged at said lower tool 2. During the reduction of the catenary, the packaging device 30 is configured for maintaining the position of the displacement element 32, such that said displacement element 32 can prevent a displacement of the support 4 during the movement of the catenary: in this manner the displacement element 32 is configured for enabling the unloading of the support on the lower tool when this reaches the loading position.
In a further embodiment, the buffer station is defined by a base engaged with the lower tool 2 and movable together with the latter. The base is abutted against an upper portion of the lower tool 2.
In one embodiment, the plant comprises a control unit 50 connected to the transfer device 30 and in particular to the plurality of devices 30; the control unit 50 is configured for commanding the operative condition of the transfer device 30 so as to allow the transfer of at least one support 4, optionally moving on the conveyor 20, from the conveyor 20 to one of the packaging apparatuses 1. The control unit 50 is configured for controlling, in particular for defining, the position of the displacement element 32; in more detail, the control unit 50 is configured for commanding the movement of each displacement element 32 between the loading position and the outlet position, as well as commanding the active and inactive conditions thereof. The control unit 50 is configured for commanding the active condition of at least one displacement element 32 of a transfer device 30 during the commanding of a movement of said element 32 from the loading position to the outlet position; in more detail, the control unit 50 is configured for commanding the active condition of a displacement element 32 when the latter is moved in the direction of a relative packaging apparatus 1 (condition illustrated in
The control unit 50 is further configured for managing the electric motors and/or actuators which allow the movement of the displacement element 32 of each device 30 in order to control the displacement of the elements 32 both for the movement between the active and inactive conditions and for the movement between the loading and outlet positions.
As described above, also the conveyor 20 is moved by means of one or more electric motors; the control unit 50 is connected to said electric motors and is configured for commanding, in particular adjusting, the speed of the conveyor in order to command the speed of the supports 4 along the advancement path A. The conveyor 20 is moved by means of an electric motor connected to the control unit 30 which is configured for adjusting the rotation speed of said motor in order to set or vary the speed of the conveyor 20 and therefore the movement speed of the supports along the advancement path A.
The control unit 50 is further configured for synchronizing the movement of the conveyor 20 with the transfer device 30; in particular the unit 50 is configured for synchronizing the movement of the displacement element 32, between the active condition and the inactive condition, with the movement of the conveyor 20.
The plant 100 can comprise at least one sensor configured for emitting at least one signal representative of the presence of a support 4 within a specific passage section of the conveyor 20; in particular, the sensor is configured for emitting at least one signal representative of the relative position of a support 4 placed on the conveyor 20 with respect to at least one respective packaging apparatus 1. The plant 100 can also comprise a further sensor configured for emitting at least one signal representative of the movement speed of the conveyor 20, in particular the advancement speed of the supports 4 along the advancement path A of the conveyor 20.
The control unit 50 is connected to the transfer device 30, to the conveyor 20 and optionally to at least one of said sensors and is configured for commanding the operative condition to the transfer device 30 as a function of the signals received from said sensors and/or as a function of the movement speed of the conveyor 20 so that a specific transfer device 30 can intercept at least one support 4 moving on the conveyor 20 in order to move it to a relative packaging apparatus 1.
The control unit 50 can be connected to each of the packaging apparatuses 1 and is configured for receiving a monitoring signal from each of these; as a function of the monitoring signal, the control unit is configured for determining an operative parameter of each packaging apparatus 1 representative of at least one between a stand-by condition and a packaging condition. In detail, in the stand-by condition, the lower and upper tools are in the spaced condition and the lower tool is adapted to receive at least one support 4. In the packaging condition, the lower and upper tools are in the approached condition and configured for making at least one package 40.
As a function of the monitoring signal and therefore as a function of the operative conditions of the packaging apparatuses 1, the control unit 50 is configured for commanding the operative condition of at least one transfer device 30 so that the latter can move at least one support 4 to a packaging apparatus 1 placed in the stand-by condition.
In general, the control unit 50 is configured for synchronizing the movement of the transfer device 30, the movement of the upper and lower tools of each of the packaging apparatuses 1, the movement of the displacement element 32 from the active condition to the inactive condition, the movement of the displacement element 32 from the loading position to the outlet position and vice versa. In this manner, the control unit can manage the plurality of transfer devices 30 so that these can correctly serve the supports to the packaging apparatuses 1.
Furthermore, the control unit 50 is configured for commanding the maintenance of the position of the displacement element 32 at the buffer station of a relative packaging apparatus, optionally while awaiting the arrival of the lower tool in the loading position. In particular the control unit 50 is configured for synchronizing the movement of the transfer device 30, when the displacement element 32 is at said buffer station, with the movement of the lower tool 2 of the respective packaging apparatus 1.
Packaging Process
Also forming the object of the present invention is a process of packaging by using a plant 100 in accordance with any one of the enclosed claims and/or in accordance with the above-reported detailed description.
The process comprises a step of moving supports 4 along the predetermined advancement path by means of the conveyor 20. The supports 4 moving along said path 4 can be of the type bearing at least one product P or, alternatively, they might not have the product. The product P can be arranged on the support 4 before or during the movement of the supports 4 themselves on the conveyor 20. The positioning of the products P on the supports can be performed manually by an assigned operator (condition schematized in
The process further comprises a step of displacing at least one support 4, optionally moving on the conveyor 20, from the conveyor 20 towards a packaging apparatus 1 by moving the displacement element 32 along the guide 31 of at least one transfer device 30. In more detail, said displacing step provides for the action manto of at least one transfer device 30 so that the latter can intercept a support placed on the conveyor 20 in order to move it within a respective packaging apparatus 1. As described above, the plant 100 comprises a plurality of apparatuses 1 and an equal number of transfer devices 30; the step of displacing the supports from the conveyor 20 to the packaging apparatus can provide for the simultaneous actuation of a plurality of devices 30 so that each of these can move a respective support 4 in a specific apparatus 1.
The step of displacing each transfer device 30 comprises the following sub-steps:
During the movement of the displacement element 32 from the loading position to the outlet position, the displacement element 32 intercepts one or more supports 4, optionally moving, on the conveyor 20: the displacement element 32 is capable of intercepting the support 4 since it is arranged in the active condition illustrated for example in
Following the interception step, the displacement element 32 moving along the tract T1 of the guide 31 moves the support 4 outside the conveyor and to a respective packaging apparatus 1; in particular, the displacement element 32 arranges the support directly on the lower tool of the packaging apparatus 1.
Once the support 4 (optionally the support 4 bearing the product P) was loaded on the packaging apparatus, the process provides or a step of repositioning the displacement element 32 during which the latter is moved from the outlet position to the loading position: in this manner, the transfer device 30 can then perform a new operative condition for moving a further support 4 from the conveyor 20 to the apparatus 1. During such step of repositioning the displacement element 32, the latter is initially brought to the inactive condition and then moved from the outlet position to the loading position, always along the tract T1 of the guide 31: in this manner, the end contact portion 32b is spaced from the conveyor and configured for being moved above the latter, avoiding the contact with the supports 4. The step of repositioning is schematically illustrated in
The process can comprise a step of monitoring operative conditions of the plant 100 performed by means of the control unit 50; such monitoring step comprises at least one sub-step of determining at least one parameter selected in the group of the following parameters representative of at least one between the following operative conditions:
As a function of the operative conditions, the process provides for commanding the operative condition of at least one transfer device 30 so that the latter can move at least one support 4 to a packaging apparatus 1 placed in the stand-by condition. In fact, by means of the monitoring step, the control unit 50 is capable of establishing if one or more packaging apparatuses 1 are in the stand-by condition and therefore capable of receiving a support 4. Alternatively or in combination, the control unit 50, due to the monitoring step, is capable of recognizing a support 4 moving on the conveyor 20 and optionally detecting the relative position thereof with respect to an apparatus 1 and/or a movement speed along the advancement path A. As a function of these further operative conditions, the control unit 50 is configured for defining the operative condition of one or more transfer devices 30 in order to determine which support 4 moving on the conveyor 20 must be loaded on a specific packaging apparatus 1.
As described above, the tract T1 of the guide 31, along which the displacement element 32 is moved, is transverse to the advancement path A of the supports; if the displacement of the supports by the transfer device 30 is performed during the movement of the supports 4 along the path A, the control unit can calculate and/or adjust the movement speed of the conveyor 20 and therefore advancement speed of the support 4 along the path A and manage the movement speed of the displacement elements 32 so that the movement speed of the supports 4 on the conveyor 20 is substantially identical to the component of the movement speed of the displacement elements 32 parallel to the advancement path A; in this manner, the control unit 50 can ensure the extraction of a first support 4 from the conveyor 20 without the same being able to impact against an adjacent second support placed immediately upstream or downstream of the first support with respect to the advancement path of the supports 4.
Once the loading of the support 4 has been performed, in particular of the support bearing the product 4, on the lower tool of an apparatus 1, the process provides for performing a packaging step during which:
The step of packaging can be of known type and also provides for at least one of the following steps:
At the end of the packaging step, the lower and upper tools are once again arranged in the spaced or distal condition so as to allow the extraction of the package 40 from the apparatus. Once the package 40 is extracted, the apparatus 1 is once again in the stand-by condition and can receive a new support 4 for making a new package.
| Number | Date | Country | Kind |
|---|---|---|---|
| 102017000143920 | Dec 2017 | IT | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/IB2018/059417 | 11/28/2018 | WO | 00 |
