Patent Grant
7178310
This invention is generally directed to a system for encasing materials, such as poultry or other materials, in plastic bags. The poultry industry sells fowl either as whole dressed birds or as cut-up parts. A consumer can buy a whole dressed chicken, can buy one dressed chicken cut up into parts, or can buy a package of, for example, just legs or just wings. In the two latter situations, the chicken parts are placed on a disposable tray, typically styrofoam, in order to hold the parts together. Some poultry producers place whole dressed birds on these trays also.
The prior art method to encase the product is a heat-seal process. The tray and product are wrapped in a clear plastic material which is then exposed to heat, shrinking the wrapping material and sealing the package. The advantage to the heat-sealing process is that it wraps the product very tightly. In the case of products such as poultry, a tighter package presents a better appearance to consumers. There is an increased marketing advantage to more tightly wrapped packages. Accordingly, the tighter the package can be wrapped, the more advantageous the system.
The disadvantage to the heat-sealing system is that the heat-sealed packages tend to leak. The packaging for any material encased by this method that has any liquid will, sooner or later, leak that liquid. “Leakers” are a problem both for the sellers such as grocery stores and for consumers, as the leaked fluid must be cleaned from the display case, refrigerator, or anywhere else it spilled. Chicken blood in particular is a problem, as it may contain bacteria and must be cleaned quite thoroughly.
A solution to the leaking problem is to use plastic bags to encase the products. A plastic bag that is clipped provides a better sealed package than one subjected to the heat-sealing process. Clipped bags are accordingly less likely to leak.
It is difficult, however, to place an object, such as a chicken, in a bag the exact same size as the chicken. Using a bag larger than the chicken eases the bagging process. The larger bag detracts from the appearance of the package, however, as the chicken is not tightly wrapped. There is also an increased cost to using larger bags.
It is also difficult to place a tray containing a chicken into a bag, since the parts must remain upright until securely wrapped. It is also mechanically difficult to place material on a tray into a bag and also maintain a tight fit, because of the relatively rigid structure of the tray. The use of a larger bag eases the process of placing the loaded tray into the bag, but the material on the tray will then likely fall off the tray later, such as during loading or in transit, defeating the whole purpose of using a tray. Accordingly, trayed chicken, whether whole or cut-up parts, is generally not bagged in the poultry industry.
Additionally, there is a manufacturing and marketing advantage to wrapping a whole chicken in a properly hocked position. A hocked chicken has the thighs of the legs held in close proximity to the sides of the carcass of the chicken. However, the legs of chickens tend to stick outward, up and away from the body, after slaughter. This position makes it difficult to encase a chicken, especially in a bag, and presents an unpleasing appearance to consumers. Consumers looking at a raw chicken in a grocery case will tend to respond more favorably to a chicken wrapped in a hocked position, as opposed to a chicken wrapped in an unhocked position.
Various methods have been used in the prior art to hold the legs of a chicken in a hocked position for presentation to consumers. Traditionally, of course, the legs were tied together with string. Other devices have been described. For example, U.S. Pat. No. 4,293,977, Poultry Trussing Device, describes the use of a bent wire device to hold the legs together. U.S. Pat. No. 5,279,519, Chicken Hock Device, describes the use of a plastic device to hold the legs together. These solutions add another step to the process, and accordingly increase the capital, labor, and material costs of encasing a chicken for market.
Additionally, marketers of products usually wish to display their trade names, trade dress, or logos on the packaging. Marketers sometimes also wish to display other information, such as warnings or instructions, on the packaging. It is less expensive to preprint the packaging material. Adding one or more labels after packing adds an extra cost. Printing directly onto the package after packing is very expensive. Accordingly, the use of preprinted packaging material is desired. Forcing a chicken or a tray of chicken parts into a very tight plastic bag, however, causes random distortion of the printing on the bag, disfiguring the preprinted information. Similarly, the heat-sealing process described above causes severe distortion of any printed information on the wrapping material.
Consequently, for heat-sealed packages, one or more separate labels must be used for any information such as brand identification or cooking instructions. This placement of separate labels, of course, adds an additional cost.
One method presently known to the poultry industry to preprint information on the packaging of whole dressed chickens is to use bags slightly larger than the average chicken. As described above, however, the use of larger bags presents a less appealing appearance to consumers and increases material costs.
A method presently known to encase a chicken in a very tight bag without distortion of the printed material is to shrink the bag with heat after the chicken is in the bag. This method requires specialized, expensive wrapping material.
Accordingly, there is a need for an apparatus and method of encasing material such as poultry, including whole dressed birds and whole dressed birds on trays, in a properly hocked position, in order to provide a pleasing appearance to consumers and to ease the process of putting the bird into a bag. Additionally, there is a need for an apparatus and method of encasing material such as poultry, including whole dressed birds and whole dressed birds on trays, in tightly wrapped bags, in order to provide a pleasing appearance to consumers, to prevent “leakers”, to lower costs, and to provide and maintain printing on the packaging. The present invention meets these needs.
A general object of the present invention is to provide a method and apparatus for encasing poultry in a properly hocked position, tightly in plastic bags, in order to present a more pleasing appearance to consumers.
Another object of the present invention is to minimize the amount of packaging material needed to encase poultry in a properly hocked position in plastic bags.
Another object of the present invention is to minimize the cost of packaging material for encasing properly hocked poultry.
Briefly, and in accordance with the foregoing, the present invention discloses an apparatus and a method to stretch a plastic bag, grasp poultry such as a whole chicken or a whole chicken on a tray, by the legs, push the poultry into the bag while maintaining the legs in a properly hocked position, and eject the material and bag from the apparatus for clipping to seal the bag. The pusher assembly of the present invention, by maintaining the poultry in a properly hocked position, allows the use of smaller bags, by reducing the cross-section of the poultry as it is pushed into the bag. The apparatus and method of stretching the bag before inserting the chicken allow the bag to contract around the material and therefore encase the material very tightly. The use of a plastic bag with a clip closure provides for a very tight seal. Finally, the use of plastic bags with a memory agent allows the plastic to expand and then contract around the material very tightly and very evenly Because the bags contain a memory agent and are stretched evenly, they will contract back around the material with minimal distortion of the printed information on the bag.
The organization and manner of the structure and operation of the invention, together with further objects and advantages thereof, may best be understood by reference to the following description, taken in connection with the accompanying drawings:
a is a top view of the pusher assembly of the preferred embodiment of the present invention, showing the components in a first, or open, position.
b is atop view of the pusher assembly of the preferred embodiment of the present invention, showing the components in a second, or closed, position
a is a sectional view of the pusher assembly of the preferred embodiment of the present invention, shown as section A—A of
b is a sectional view of the pusher assembly of the preferred embodiment of the present invention, shown as section A—A of
a is a perspective view of the pusher assembly of the preferred embodiment of the present invention, showing the components in a first, or open, position.
b is a perspective view of the pusher assembly of the preferred embodiment of the present invention, showing the components in a second, or closed, position.
a is another perspective view of the pusher assembly of the preferred embodiment of the present invention, showing the components in a first, or open, position.
b is another perspective view of the pusher assembly of the preferred embodiment of the present invention, showing the components in a second, or closed, position.
While the invention may be susceptible to embodiments in different forms, there is shown in the drawings, and herein will be described in detail, a specific embodiment with the understanding that the present disclosure is to be considered an exemplification of the principles of the invention, and is not intended to limit the invention to that as illustrated and described herein. For example, the present disclosure describes the method and apparatus as used to encase chickens and chicken parts, but the same method and apparatus can be used for other poultry and for other material without departure from the invention.
A perspective view of an apparatus 20 is shown in
A bag carriage 22 is located at the rear of the rigid frame 24. The bag carriage 22 is shaped, in cross-section, like an inverted “U”. It has a flat horizontal surface 22a, and two sides 22b and 22c extending downward. The sides 22b and 22c ride on rails (not shown) on the inside of the rigid frame 24, but any means of attachment can be used, so that the bag carriage 22 slides inside the rigid frame 24 from the rear 24b towards the front 24a and back again. Additionally, the bag carriage 22 has two air jets 44 located under its horizontal surface and facing to the rear of the rigid frame 24. These air jets 44 are connected to a standard compressed air supply (not shown).
The bag carriage 22 preferably includes a bag platform 26. The bag platform 26 is generally rectangular in shape and is mounted so that the rear edge of the bag platform 26 is positioned under the horizontal surface 22a of the bag carriage 22. The bag platform 26 is attached to the bag carriage 22 by any suitable means (not shown) so that the bag platform 26 travels front 24a to rear 24b along with the bag carriage 22. Additionally, however, the bag platform 26 has means, not shown, to raise it and lower it independently between its first, lower position and a second, raised position. Any suitable hydraulic or mechanical system can be used to accomplish this raising and lowering. The upward movement of the bag platform 26 is stopped by the airjets 44 located at the underside of the horizontal surface 22a of the bag carriage 22. The bag platform 26 includes two apertures, not shown, in its flat horizontal surface for attaching a stack of bags 32.
As shown in
A bag-stretching unit 28 has left-side and right-side components, including a left base guide 46, a right base guide 48, a left finger 50, a right finger 52, a left arm 54, and a right arm 56. The relation of the left and right components to each other and to the rigid frame 24 can be adjusted.
As shown in
Similarly, a right sizer 68 includes a right screw adjuster 68A, a right sizer mount 68B, and a right bracket 72. The right screw adjuster 68A is connected to the rigid frame 24, so that rotation of the right screw adjuster 68A causes it to move toward the left 24c or the right 24d relative to the rigid frame 24. The right sizer mount 68B is connected to the right screw adjuster 68A so that the right screw adjuster 68A rotates within the right sizer mount 68B, but moves the right sizer mount 68B toward the left 24c or the right 24d of the rigid frame 24 as the right screw adjuster 66A moves. The right sizer mount 68B is attached to the right bracket 72, which is connected to a right arm 56. The right arm 56 is adjusted toward the left 24c or the right 24 of the rigid frame 24 as hereinafter described, by rotation of the right screw adjuster 68A.
In the preferred embodiment, the adjustable sizers 66 and 68 are screw-type adjusters. However, any kind of adjusting mechanism can be used to adjust the distance between the left arm 54 and the right arm 56. In the preferred embodiment the user can adjust the distance, grossly or finely, between the right arm 56 and the left arm 54 to allow for differences in sizes of trays, variations in sizes of bags, variations in sizes of material to be bagged and variations in stretchability of bags from different vendors or suppliers.
A left height adjuster 74 is connected to the frame 24 and to the left piston 62. A right height adjuster 76 is connected to the frame 24 and to the right piston 64. The height of the left piston 62 is adjusted by rotating the left height adjuster 74 and the height of the right piston 64 is adjusted by rotating the right height adjuster 76. By adjusting the height of the left piston 62, which articulates with the left arm 54, the user can adjust the degrees of arc through which the left arm 54 travels, thereby adjusting the height to which the left finger 50 will reach. Similarly, by adjusting the height of the right piston 64, which articulates with the right arm 56, the user can adjust the degrees of arc through which the right arm 56 travels, thereby adjusting the height to which the right finger 52 will reach. In the preferred embodiment, the left and right height adjusters 74, 76 are screw-type adjusters but any type of height adjustment can be done without departing from the spirit of the invention.
The left arm 54 connects to a left mounting bracket 78, and rotates about a left axle 58. The left mounting bracket 78 is connected to the frame 24. Similarly the right arm 56 connects to a right mounting bracket 80, and rotates about a right axle 60. The right mounting bracket 80 is connected to the frame 24.
The left adjustable base guide 46 is an elongated member, with an angled cross-section. The left adjustable base guide 46 is positioned above the frame 24, is essentially parallel to the top surface of the frame 24, and extends from near the front of the frame 24 to beyond the rear of the frame 24. As shown in
The right adjustable base guide 48 is an elongated member, with an angled cross-section. The right adjustable base guide 48 is positioned above the frame 24, is essentially parallel to the top surface of the frame 24, and extends from near the front of the frame 24 to beyond the rear of the frame 24. As shown in
All edges of both the left adjustable base guide 46 and the right adjustable base guide 48 are rounded to allow plastic to slide over those edges. Additionally, the rear ends of the base guides 46 and 48 are tapered for the same purpose.
A left finger 50 is pivotally attached to the left arm 54 through a rod 51. A right finger 52 is pivotally attached to the right arm 56 through a rod 53. The left finger 50 and the right finger 52 are elongated members that extend rearward of the left arm 54 and the right arm 56, respectively. Each finger 50, 52 is generally rectangular in cross-section. The edges of each finger 50, 52, however, are rounded to allow plastic to slide over those edges more easily. Additionally, the round rods 51, 53 provide a rounded surface which will also contact the plastic during the stretching process to be hereinafter described. Both fingers 50 and 52 are tapered at their rear ends.
The left finger 50 and right finger 52 are mounted on the mounting arms 54 and 56 so that the fingers 50 and 52 fit between the base guides 46, 48 when in a first position, as shown in
A ram 30 is positioned near the front of the apparatus 20. The ram 30 is aligned such that upon activation the ram will stroke forward between the base guides 46 and 48. The ram 30 is oriented so that it operates midway between the left adjustable base guide 46 and the right adjustable base guide 48. The ram 30, in the preferred embodiment, is an air piston with a forward and reverse stroke.
Operation of the apparatus will now be described. To begin the size of the bag to be packed is selected. The size of the bag to be used will be determined in part by the size of the item to be placed in the bag, and the ability of the bag to stretch. The size of the bag 32A is selected to form a very tight wrap around the material to be encased. In the preferred embodiment, a 7.25-inch bag forms a very tight wrap around a standard whole dressed chicken sold in the poultry industry. Different sized bags can be used for different sizes of poultry, different sizes of trays, or different material altogether. A stack of bags 32 of a preselected size is then loaded on the bag platform 26 using the wicket 42.
Next, the distance between the left base guide 46 and the right base guide 48 is adjusted using the left sizer 66 and the right sizer 68. The base guides 46, 48 are designed to accommodate either a tray or a whole bird. The angular cross-section allows a tray, containing either a whole bird or cut-up parts, to slide on and between the base guides 46, 48. The design of the guides also permits a whole bird to slide on and between the guides 46, 48. The height of the left and right arms 54, 56 is adjusted using the left and right height adjusters 74, 76, so that, when the arms 54, 56 are raised to a second position as hereinafter described, the fingers 50, 52 will be in a second position slightly above the height of the material to be packaged.
The arms 54, 56 begin in a first position. In this first position, the pistons 62, 64 are at extension, causing the arms 54, 56 to be rotated inward, causing the fingers 50, 52 to move downward and inward
The bag carriage 22 begins in a first position in which the front 35 of the bag 32A is positioned slightly rearward of the base guides 46, 48. The bag platform 26 is raised from a first position to a second position. In the second position, the stack of bags 32 contacts the air jets 44 at the point of the opening 38 of the top-most bag 32A. At this point the top-most bag 32A is now at nearly the same height as the bag carriage 22. Air is forced through the jets 44 to lift the top of the first bag 32A above the left and right base guides 46, 48. Next the bag carriage 22 is moved forward, allowing the left base guide 46 and the right base guide 48 to pass over bottom 34 of the bag 32A and through the opening 38 of the bag 32A. As the bag carriage 22 moves, the top 36 of bag 32A slides over the left base guide 46, the right base guide 48, the left finger 50, and the right finger 52, the latter two of which are, at this time, in a first position wherein the left finger 50 and the right finger 52 are generally positioned between two base guides 46 and 48. The bag carriage 22 will continue to be moved forward to a second position until the base guides 46, 48 reach the rear end 37 of the bag 32A. Other devices, such as suction cups or a mechanical device, could also be used for opening the bag 32A.
The pistons 62, 64 then retract to pull down on the arms 54, 56, causing the arms 54, 56 to rotate about their axles 58, 60. In turn, the fingers 50, 52 move upward and outward until the fingers 50, 52 reach a second position. The second position of the fingers 50, 52, which was preset as described above, was selected so that the fingers 50, 52 are positioned slightly above the top of the material to be packaged. The rotation of the arms 54, 56, by moving the fingers 50, 52 rotationally through arcs, causes the bag 32A to stretch evenly about its circumference. The bag 32A is now stretched and ready to receive material as shown in
The item to be packed, for example, a whole dressed chicken or chicken parts on a tray, is placed on and between the base guides 46, 48. In the preferred embodiment, the item will be loaded from the right side of the apparatus. The stopping plate 47, mounted on the left side of the apparatus, will prevent the material from going over the edge of the left base guide 46. The apparatus 20 may be used as part of an automated system, for example, one in which trays of items are conveyed automatically to the location between the base guides 46 and 48. In the event that material is misguided by a user or a conveyor, and misses the intended area between the base guides 46, 48, the stopping plate 47 will retain the material and prevent it from going over the side of the base guide 46.
The ram 30 pushes the material into the now-stretched bag 32A. Continuation of the stroke of the ram 30 pushes the material and bag 32A off the base guides 46, 48 and the fingers 50, 52. As the bag 32A comes off the base guides 46, 48 and the stretching fingers 50, 52, the stretched plastic contracts back to its original size, and contracts around the material in the bag 32A. Because the plastic contains memory agent, the plastic will contract with minimal distortion of any printed information on the bag 32A. The contraction of the plastic will cause the bag 32A to wrap very tightly around the material, presenting the tight appearance that is pleasing to consumers and thereby conferring a marketing advantage upon products packaged by this method.
In the preferred embodiment, as the ram 30 pushes the now-encased material out the rear of the apparatus 20, it falls onto a conveyor belt (not shown), which carries the bagged material down the line for closure and clipping of the bag to form a tight seal. The now-encased material can be handled manually or by other mechanical methods.
When the bag carriage 22 moves horizontally to its original position, the bag support platform 26 also moves horizontally back to its original position also. The apparatus 20 is now ready for the next cycle. The ram then returns to its original position.
In the preferred embodiment, 7.25-inch bags can be used for standard whole birds instead of the 8.75-inch bags formerly used in the poultry industry, at a cost savings of approximately 15 percent. Because of the adjusting mechanisms, the apparatus 20 and method can be used for any size material with any suitably-sized bags.
The addition of a memory agent to polyethylene has been found to allow the plastic to expand in the stretching process and then to contract back around the encased material with minimal distortion. The use of polyethylene bags with three to six percent ethylene vinyl acetate (EVA) has been found to provide the best memory and therefore the least distortion of printed matter, but any suitable memory agent that meets this function will suffice.
The ram 30 of the present invention has a novel pusher assembly 200 attached to the front side of ram 30. Pusher assembly 200 is illustrated in
As ram 30 makes a forward stroke and encounters a whole chicken 202, left grabber 210 and right grabber 212 grasp the legs 204, 206 and hold them in the proper hocking position until chicken 202 has been pushed completely into bag 32A. When ram 30 withdraws, grabbers 210, 212 automatically release legs 204, 206.
Pusher assembly 200 is make of a body 214 with a base portion 216, a connecting portion 218, and a top portion 220, which define a left slot 222 and a right slot 224.
Left grabber 210 is made of a left swing gate 230, a left swing plate 232, and a left clamp 234. A gate axle bolt 236 extending from top portion 220, through left slot 222, and into base portion 216 holds left swing gate 230 in left slot 222 and allows left swing gate 230 to rotate about gate axle bolt 236, from a first position as shown in
Right grabber 212, in mirror image to left grabber 210, is made of a right swing gate 250, a right swing plate 252, and a right clamp 254. A gate axle bolt 256 extending from top portion 220, through right slot 224, and into base portion 216 holds right swing gate 250 in right slot 224 and allows right swing gate 250 to rotate about gate axle bolt 256, from a first position as shown in
Both swing gates 230, 250 have extending shoulders 270, 272 respectively, that extend in the direction to the rear 24b of frame 24. Both swing plates 232, 252 have extending shoulders 274, 276 respectively, that extend in the direction to the front 24a of frame 24. Accordingly, rotation of the swing gates 230, 250 toward the rear 24b, as shown by directional arrows 278, 280 in
When the clamps 240, 260 are in their first positions 290, 292, as shown in, for example,
Preferably, left clamp 234 and right clamp 254 each have an arcuate inner surface, to facilitate grabbing the legs 204, 206 of a chicken, as will hereinafter be described.
As ram 30 and pusher assembly 200 make a forward stroke, pusher assembly 200 encounters a chicken 202 placed between guides 46, 48. Legs 204, 206 each enter left chamber 294 and right chamber 296, respectively, as shown in
The rotation of clamps 234, 254 causes the arcuate inner surfaces to contact the legs 202, 204 of the chicken 200. The clamps 234, 254 thereby grasp legs 204, 206, holding them in a proper hocking position. As ram 30 continues its forward stroke, the chicken 202 is pushed into bag 32A as described above. When the chicken 202 is completely in the bag and ram 30 begins its reverse stroke, the pressure of legs 204, 206 against swing gates 230, 250 is relieved.
Swing plates 232, 252 are biased toward their first positions, as shown in
While preferred embodiments of the present invention are shown and described, it is envisioned that those skilled in the art may devise various modifications of the present invention without departing from the spirit and scope of the appended claims.
This patent application in a continuation-in-part of U.S. patent application Ser. No. 10/435,912, filed May 12, 2003 now U.S. Pat. No. 6,895,726, issued on May 24, 2005 which was a continuation of U.S. patent application Ser. No. 10/046,143 filed Jan. 15, 2002 now abandoned, which claims the benefit of U.S. Provisional Patent Application No. 60/261,969, filed Jan. 16, 2001.
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|---|---|---|---|
| 3254472 | Clark et al. | Jun 1966 | A |
| 4069643 | Young et al. | Jan 1978 | A |
| 4241562 | Meyer | Dec 1980 | A |
| 4270336 | Altenpohl et al. | Jun 1981 | A |
| 4464882 | Van Ginkel et al. | Aug 1984 | A |
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| 5692360 | McDonald et al. | Dec 1997 | A |
| Number | Date | Country | |
|---|---|---|---|
| 20050155330 A1 | Jul 2005 | US |
| Number | Date | Country | |
|---|---|---|---|
| 60261969 | Jan 2001 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 10046143 | Jan 2002 | US |
| Child | 10435912 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 10435912 | May 2003 | US |
| Child | 11080869 | US |
