Patent Application
20240281759
The present invention relates to a stock management system and method in a filling plant for the packaging of pourable food products into composite packages.
As is known, many liquid or pourable food products, such as fruit juice, UHT (ultra-high-temperature treated) milk, wine, tomato sauce, etc., are distributed and marketed in composite packages made of a multilayer composite packaging material.
A typical example is the parallelepiped-shaped package for pourable food products known as Tetra Brik Aseptic™, which is made by sealing and folding a laminated strip packaging material. The packaging material has a multilayer structure comprising a carton and/or paper base layer, covered on both sides with layers of heat-seal plastic material, e.g. polyethylene. In the case of aseptic packages for long-storage products, the packaging material also comprises a layer of oxygen-barrier material, e.g. an aluminum foil, which is superimposed on a layer of heat-seal plastic material, and is in turn covered with another layer of heat-seal plastic material forming the inner face of the package eventually contacting the food product.
Composite packages of this sort are normally produced within fully automatic filling (or, also denoted as, packaging) plants, which at least form the composite packages starting from a web of multilayer composite packaging material (wound from a reel) and fill the composite packages with the pourable food product.
A typical filling plant comprises at least a filling machine, which forms the composite packages from the multilayer composite packaging material and fills the composite packages with the pourable food product. Additionally, filling plants may also comprise downstream equipment, receiving the composite packages treatment from the filling machine and executing additional treatments on the composite packages; the downstream treatment equipment may for example comprise one or more of a buffer unit for temporarily buffering the composite packages; an application unit for applying e.g. straws on the composite packages; a grouping unit, e.g. a palletizer unit, for grouping a plurality of composite packages together in a storing unit (such as a pallet).
It is known that in a filling plant, various different types and formats of composite packages can be filled with various kind of pourable food products.
Proper management of warehouse stocks, for example of packaging material reels from which the packaging material web is wound, so as to optimize productivity and minimize waste, is therefore a commonly felt need in such filling plants.
In particular, the present Applicant has realized that it is generally difficult to track and prevent possible wastes of packaging material, e.g. with partially used or totally unused reels having an expired best before date, which cannot be used for the filling operations and have to be properly disposed of.
Moreover, for safety and quality reasons, it is a commonly felt desire to have proper traceability of the packaging materials used for the filling or packaging operations. The present Applicant has realized that it is generally a difficult task to provide the desired traceability of the used packaging materials.
Even though known filling plants operate satisfyingly well, the present Applicant has therefore realized that a need is felt for an improved solution for warehouse stock management.
It is therefore an object of the present solution to provide an improved system and method for stock management in a filling plant, which allows to solve at least part the above-mentioned inconveniences.
According to the present solution, a stock management system and method are therefore provided, according to the appended claims.
A non-limiting embodiment of the present invention will be described by way of example with reference to the accompanying drawings, in which:
Multilayer composite packaging material may comprise at least a layer of fibrous material, such as e.g. a paper or cardboard layer, and at least two layers of heat-seal plastic material, e.g. polyethylene, interposing the layer of fibrous material in between one another. One of these two layers of heat-seal plastic material defines an inner face of the composite packages 2 eventually contacting the pourable food product packaged within the same composite packages 2.
Multilayer composite packaging material may also comprise a layer of gas- and light-barrier material, e.g. aluminum foil or ethylene vinyl alcohol (EVOH) film, in particular being arranged between one of the layers of the heat-seal plastic material and the layer of fibrous material. Preferentially, multilayer composite packaging material may also comprise a further layer of heat-seal plastic material being interposed between the layer of gas- and light-barrier material and the layer of fibrous material.
According to the specific embodiment disclosed and shown in reference to
Filling machine 6 is operatively coupled to the packaging material reel 5 and is configured to process the web 4 so as to obtain composite packages 2 and to fill the same composite packages 2 with a pourable food product, which is received from an inlet duct 8 (fluidically coupled, in a way not shown here, to a tank or similar storage element).
In more detail, web 4 may comprise a succession of connected blanks. In particular, the blanks are defined by a succession of repeated patterns provided on web 4 of multilayer composite packaging material, preferentially each pattern defining at least partially the aesthetical appearance of the finalized composite package 2. Alternatively, multilayer composite packaging material may be provided in the form of single package blanks, which, in use, are singularly formed and filled.
Each composite package 2 may extend along a longitudinal axis, having a longitudinal seam portion (extending along the respective longitudinal axis) and a pair of transversal sealing bands, in particular a transversal top sealing band and a transversal bottom sealing band. In particular, each composite package 2 may have a substantially parallelepiped structure.
Furthermore, each composite package 2 may comprise at least two transversal walls (being transversal to the respective longitudinal axis) and being disposed at opposite sides of composite package 2 and a plurality of lateral walls extending between the transversal walls.
More specifically, one respective transversal wall of each composite package 2 may define a bottom wall and the other respective transversal wall defines a top wall. In particular, the bottom wall may define a support surface adapted to be placed on a (horizontal) plane, such as e.g. a shelf within a distribution point, and the top wall is opposed to the bottom wall.
In a known manner (not detailed nor shown herein), the filling plant 1 may also comprise a pourable food product conditioning device for conditioning the pourable food product. The pourable food product conditioning device may be connected to filling machine 6 so as to direct the pourable food product to the filling machine 6 via the inlet duct 8.
In more detail, filling machine 6 may comprise at least:
In more detail, the package forming unit may comprise at least:
In even more detail, the forming device may comprise a plurality of pairs of one respective operative assembly and one respective counter-operative assembly, each operative assembly and each counter-operative assembly being configured to form and transversally seal and cut in cooperation the tube for forming one respective composite pack.
Additionally, the forming device may also comprise a conveying unit configured to advance the operative assemblies and the counter-operative assemblies along respective conveying paths. The respective operative assemblies and the respective counter-operative assemblies of each pair are configured to cooperate with one another for forming and transversally sealing and cutting the tube when advancing along respective operative portions of the respective conveying paths.
Moreover, each pair of one respective operative assembly and one respective counter-operative assembly comprises at least one respective transversal sealing unit configured to transversally seal, in use, the tube.
Additionally, filling machine 6 may also comprise:
As shown in
Moreover, filling plant 1 comprises a control device 10, for example including a PLC (Programmable Logic Controller) or similar processing and computing unit, configured to control general operation of the same filling plant 1 and in particular to set operational parameters of the filling machine 6 and downstream processing equipment 9.
The control device 10 is operatively coupled, e.g. via the Internet and/or an internal network, to a central server 12, e.g. a cloud server or a physical server at the plant site (which can also be accessed by an external network), where operating data and information relating to the filling plant 1 are received and stored in a database (DB) 14.
As shown in the same
The operator 15 may also communicate with the central server 12 via a fixed computer 18 (or similar processing apparatus), provided with a suitable graphical user interface; in a manner not shown, the computer 18 may also be part of the control device 10 of the filling plant 1.
The same operator 15 is also able to interact with the control device 10, either directly or through the mobile device 16.
The filling plant 1 moreover comprises a storage or warehouse 20, where packaging material is stored, when not in use in the filling machine 6 and/or downstream processing machine 9. In particular, packaging material reels 5 are stored grouped on pallets (or similar grouping or storing units) 22, of which only one is shown, as an example, in
According to an aspect of the present solution, a stock management system in the filling plant 1 envisages provision on each pallet 22 of a first identification or tag element 24, which is configured to be detected (read) in a contactless (or wireless) manner and is configured to store first stock information relating to the pallet 22 and its content, in particular relating to all the packaging material reels 5 which are carried by the same pallet 22.
First tag element 24 is physically arranged on the pallet 22, coupled thereto at any suitable position, so as to be accessible for reading.
First tag element 24 may be of a passive or active type, for example being a radio tag or beacon, in particular a RFID (Radio Frequency Identification) tag having (in a known manner here not discussed in detail) a communication antenna and a storing unit for storing the first stock information. According to different embodiments, the first tag element 24 may be a NFC (Near Frequency Communication) tag or a BLE (Bluetooth Low Energy), Wi-Fi or UWB (Ultra Wideband) beacon.
As an alternative, or in addition, the first tag element 24 may include an image code (such as a 2D or 3D barcode, a QR code or similar) and/or an image, to convey at least part of the first stock information; the same image code may also be printed or otherwise applied on the pallet 22.
According to an aspect of the present solution, the first stock information stored in the first tag element 24 include an identification (e.g. a EAN, European article number, identification code, a serial number or any unique identifier) of the pallet 22 and moreover information about each packaging material reel 5 carried by the pallet 22, which comprise one or more of the following: a production order; an identification (e.g. EAN) code; a best before date; a number of packages that can be produced, for the respective packaging material reel 5 (other information and parameter can also be included in the first tag element 24, the above list being exemplary and not exhaustive).
According to a further aspect of the present solution, the stock management system in the filling plant 1 moreover envisages provision on each packaging material reel 5 of a respective second tag element 26 (only one of which is shown in
Also the second tag element 26 may be of a passive or active type, for example being a radio tag or beacon, in particular a RFID tag, or a NFC tag or a BLE, Wi-Fi or UWB beacon, having (in a known manner here not discussed in detail) a communication antenna and a storing unit for storing the second stock information.
As an alternative, or in addition, also the second tag element 26 may include an image code and/or an image (such as a 2D or 3D barcode, a QR code or similar), to convey at least part of the second stock information.
The second tag element 26 is physically arranged at any suitable location on the packaging material reel 5 (e.g. at a core thereof), so as to be accessible for reading.
According to an aspect of the present solution, the second stock information stored by the second tag element 26 include an identification (e.g. a EAN identification code) of the packaging material reel 5 and one or more of the following: a production order; a best before date; a number of packages produced, packages wasted, or packages left (i.e. a counter of the packages that may still be produced using the specific packaging material reel 5); and an indication of the filling machine (s) 6 that used the packaging material for the packaging operations.
In particular, the number of packages left is a variable counter, which is updated based on the actual use of the packaging material reel 5 in the filling plant 1 for the packaging operations.
The identification (e.g. EAN) code of the packaging material reel 5 may be indicative of the specific multilayer composite packaging material and/or composite packages 2 to be formed from the specific multilayer composite packaging material.
Identification code may also be indicative of one or more of the following: a volume of the finalized composite packages 2 (formed from multilayer composite packaging material and filled with the pourable food product); a volume of the pourable food product filled within the finalized composite packages 2; the pourable food product and its characteristics (such as the kind of the pourable food product); recipe information; details of the multilayer composite packaging material; the repeated pattern printed on multilayer composite packaging material; a type and/or format of finalized composite packages 2; the name of the producer, commissioner or distributor of composite packages 2; indications about the target market.
According to a possible embodiment, the information content in the first tag element 24 can be written/updated automatically, as soon as each packaging material reel 5 is placed on the pallet 22; for example, a wireless communication can be implemented between the first and second tag elements 24, 26, which is activated by their proximity when the packaging material reels 5 are placed in the pallet 22.
Alternatively, information content may be written with the intervention of an operator 15, who, using a dedicated function on a handheld device (e.g. the same mobile device 16), is able to scan the second tag elements 26 of the packaging material reels 5 that are included in the pallet 22 and then cause the whole data to be written in the first tag element 24 of the same pallet 22 (as the first stock information).
In particular, writing/updating of the first tag element 24 in the pallet 22 can be implemented both in the converting factory (i.e. after the packaging material reels 5 have been assembled and arranged in the pallet 22 for shipping to a customer) and at the customer site (i.e. at the filling or packaging plant 1), in case the customer would like to store different packaging material reels 5 (for example, partially used reels) on a specific pallet 22 by doing a reset/update of the information stored on the “built-in” first tag element 24.
As shown in the same
In addition, or as an alternative, the first tag element 24 of the pallets 22 that are stocked in the warehouse 20 may be read by the operator 15, with a suitable reader (e.g. a RFID tag reader) or with the same portable or mobile device 16, in case it is configured for reading the first tag element 24 (for example, in case the first tag element 24 includes a barcode or QR code).
As shown in the same
Control device 10 may be configured to set operational parameters of the same filling machine 6, as a function of the identification code of the packaging material reel 5 included in the second tag element 26.
These operational parameters may include one or more of the following: operational parameters of the conveying device, such as an advancement speed of web 4; operational parameters of the tube forming device; operational parameters of the sealing device such as a sealing power; operational parameters of the filling device such as a flow rate; operational parameters of the package forming unit such as a sealing power of the transversal sealing units, an advancement rate of the operative assemblies and counter-operative assemblies, a hit position at which, in use, operative assemblies and/or counter-operative assemblies start to contact the tube; operational parameters of the sterilization device.
Moreover, due to the fact that packaging material information are saved on the second tag element 26, an interlock functionality with actual filling machine data may be implemented to prevent the use of wrong packaging material reels 5 in the filling machine 6. For example, use of packaging material with expired best before date, or with characteristics that do not match with the product order, can be automatically prevented and avoided by the control device 10.
Control device 10 may also be configured to allow for a modification of one or more of the above operational parameters by the operator 15, after the automatic setting of the same operational parameters. In this manner, the operator 15 may have the possibility to correct and/or optimize some of the operational parameters; such a modification may also be possible during the formation and filling of composite packages 2.
More specifically, at least some or all of the operational parameters may define production conditions of all or at least some portions of the filling plant 1. Additionally or in alternative, at least some or all of the operational parameters may define a quality control protocol for determining and/or controlling the quality of composite packages 2, a test plan for assessing, in use, hygienic information during the formation and the filling of composite package 2, a cleaning-in-place protocol, a sterilization-in-place protocol.
Operation of the stock management system in the filling plant 1 thus envisages reading of the first stock information stored by the first tag element 24 on the pallets 22, in order to retrieve the information relating to the packaging material available in the filling plant 1.
In particular, reading of the first tag element 24 on the pallets 22 is performed (automatically by the gate 28, or with the intervention of the operator 15) when the pallets 22 are first received by the customer and introduced in the filling plant 1, e.g. in the warehouse 20. Stock information relating to every packaging material reel 5 (like production order, EAN code, best before date, number of packages that may be produced, etc.) included in the pallet 22 are therefore retrieved and conveniently transmitted to the central server 12 and stored in the database 14.
Moreover, further reading of the first tag element 24 may be performed periodically on the pallets 22 that are stored in the warehouse 20, so as to have updated information on the available packaging material, in particular regarding any remained or leftover packaging material reels 5 (i.e. packaging material reels 5 that have been only partially used for past production orders).
The operator 15, accessing the central server 12 (e.g. via the software application on the mobile device 16) is thus able to monitor the resources available, schedule the future productions and the provisioning of new packaging material. Advantageously, when planning or starting a new production, the application may provide to the operator 15 the list of the available (new or only partially used) packaging material reels 5 suitable for that production. This allows to ensure that all available packaging material reels 5 are used, avoiding any waste of material; time and cost saving optimization criteria may also be implemented by the application to automatically determine and provide to the operator 15 the lists of packaging material reels 5 to be used.
Moreover, at the converting factory (or producer) side, accessing the information stored in the database 14 in the central server 12 allows to understand if the pallets 22 have been properly delivered, the receiving time and the proper location of the customer site. In case of any misalignment, such as a packaging material reels 5 being delivered to the wrong site, or with an expired best before date, this can be detected immediately. In case the customer is paying only the number of packages produced or only the good packages (independently from the number of packaging material reels 5 received and used), this also allows the converting factory to be sure that the customer received specific packaging material reels 5 and to track possible packaging material waste (with partially used and/or totally unused reels).
In addition, operation of the stock management system in the filling plant 1 envisages that the filling machine 6 detects (reads) the second tag element 26 on the currently used packaging material reel 5 and automatically logs data regarding filling operations and transmit these data to the central server 12, for storing in the database 14 in association with the same packaging material reel 5 (logging of data can be performed at regular intervals or at certain occasions, e.g. at midnight, at each change of speed or volume of product, etc.).
In particular, and as schematically shown in
As previously discussed, at the end of a reel usage (or at any other desired time, e.g. after each packaging material splice), the second tag element 26 of the packaging material reel 5 having been used is advantageously updated, in particular with respect to the package count, reflecting the total number of packages produced and wasted (other information may also be updated or written, such as the above discussed start and end of production and an identifier of the corresponding filling machine 6).
In particular, a usage rate of the packaging material reel 5 can be determined, as follows:
where the number of target packages corresponds to the total number of packages that are estimated to be produced starting from the full reel.
In particular, a packaging material reel 5 can be considered ‘complete’ (or fully used/completely utilized) if the usage rate is higher than a certain usage rate threshold, e.g., ≥98%; while the packaging material reel 5 can be considered as ‘partially used’ when the usage rate is comprised within a certain usage rate range, e.g. between 0.1% and 98%.
Based on the count of the remaining packages on a specific packaging material reel 5, it is also possible to print an updated physical label to be applied on a partially used reel, with the updated count of packages 10 remained for that specific reel.
By merging the second stock information read from the second tag elements 26 placed on each packaging material reel 5 with the data automatically logged by the filling machine 6 relating to the filling operations, the stock management system thus allows to understand if a specific reel has been used, on which machine has been used, the date and time of the reel utilization(s) and number of produced packages and packages wasted for every reel.
It is noted that this information can also be used, e.g. during a root cause analysis in case of a lack of sterility in the filled composite packages 2. Advantageously, reading of the second tag element 26 provides the operator 15 with full and immediate traceability of the packaging operations (even when the central server 12 is off-line).
Moreover, the first stock information read by scanning the first tag element 24 placed in the pallet 22 of packaging material reels 5 merged with information related to usage of every packaging material reel 5 allows for example to:
Moreover, the stock managing system, based on the knowledge of the presence of partially used and unused packaging material reels 5, may provide a notification/alert before their expiration date in order to avoid waste of resources. Thanks to this signaling, customer can potentially decide to adjust production schedule in order to optimize the packaging material usage.
In order to avoid scrapping of partial reels, the stock management system can suggest to the operator 15 that partially used reels with a same identification code or production order of the reel in use are available (so that they can fit the current production/product) and suggest, e.g., to reuse partial reels before using full reels.
In this regard, in the warehouse 20, using a long distance reader (e.g. of the RFID type), possibly embedded in the mobile device 16 of the operator 15, it is possible to understand if a pallet 22 with a specific identification code is present so as to execute desired actions (for example, in order to recall a pallet 22 including a specific packaging material reel 5 with desired identification and product order, or for inventory purposes).
It is underlined that all of the above stock management operations can be implemented at the central server 12 and/or by the software application run at the operator's mobile device 16, based on the data stored in the database 14; the same stock management operations may also be performed at an external processing facility (in case the central server 12 is e.g. located at the customer site).
In particular, the software application on the mobile device 16 of the operator 15 may provide a suitable user interface to perform the stock management operations, providing for example information related to the fully used, partially used and unused packaging material reels 5 in the warehouse 20 (with the count of remaining packages) and suggestions to use specific packaging material reels 5 based on partial usage rates and best before date.
In addition or as an alternative, the above information and notifications can also be provided to the operator 15 through a web-based interface implemented at the central server 12.
The operator 15 with the mobile device 16 is also able to read data directly from the first and second tag elements 24, 26 on the pallets 22 and packaging material reels 5, with the read data possibly being stored and synced on the database 14 in the central server 12.
This report refers to a pallet 22 storing a number of packaging material reels 5, providing identification data and usage rate data for all the reels, based on the actual production data provided by the filling machine 6.
With reference to
In particular, the step of assisting management of the stock of packaging material includes one or more of the following steps:
The advantages of the discussed stock management solution will be clear from the foregoing description.
In any case, it is underlined again that the proposed solution allows to improve management of the stock of packaging material in a filling plant, minimizing wastes and optimizing production.
Moreover, an improved traceability of the packaging material used for the packaging production is provided.
Moreover, using the tag element on the packaging material reels and a corresponding reader on the filling machine allows to automatically log in all the information related to the packaging material. This allows the advantages of: a reduced workload of the operator that can focus on other tasks; preventing mistakes during the insertion done by operator; eliminating the risk that identification information are not inserted causing a lack of traceability information.
Clearly, changes may be made to what described herein without, however, departing from the scope of protection as defined in the accompanying claims.
In particular, it is underlined that the discussed solution may be applied for any additional material and/or consumables used for packaging of the products into the composite packages 2, such as strips, caps, straws, etc.
As an example, the second tag element 26 may be applied to strip bobbins, used (in a known manner) to seal the composite packages 2, with the first tag element 24 being applied in this case to a box or similar housing or storing unit of the same strip bobbins.
| Number | Date | Country | Kind |
|---|---|---|---|
| 21180369.7 | Jun 2021 | EP | regional |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2022/061318 | 4/28/2022 | WO |
