Method and apparatus for compacting product

TECHNICAL FIELD The present invention relates to a method and apparatus for thickening a portion of a product.

Description of the state of the art of the invention [0002] The product often settles after packaging, which makes the packaging appear incomplete. Thus, the packaging often appears full after it has been produced, but after further settling it appears less full. The only example is the traditional elastic bag containing snacks such as potato chips. Such flexible bags are traditionally manufactured and filled in a vertical machine for forming the filling and sealing of packages. Figure 1 shows a part of a traditional vertical machine for filling and sealing packages. First, the product is weighed and weighed on the 101 weight. The 101 scales collect and discharge a specific batch of product. Each batch is the amount of product that will occupy a single bag. Behind the scales 101 there is usually a funnel 102 or a series of funnels, which direct the product. As used herein, the terms "for" and "before" refer to relative points or locations in a process or device. Thus, the event that takes place "behind" occurs later in the process, and follows the events that have occurred "before". Behind the funnel

102 is a cylinder 103 providing the product. The product delivery cylinder 103, in a vertical typewrack for forming and welding packages, is often referred to as a forming cylinder. The packaging foil for the final packaging is wrapped around the product delivery cylinder 103 to form a tube. As soon as the bottom part of the tube is welded, the product is delivered by the product delivery cylinder 103 and the welded tube. Then, the upper part of the tube is welded, severed and separated from the upper foil and the packaging is formed. The device is a very efficient packing device (producing bags) and can achieve bagging speeds of up to 100 bags per minute.

[0003] During transport and handling, the product inside the bag begins to settle, increasing the empty space at the top of the package. The packaging, which stands on the store shelf, after transport and handling, often seems less full than the packaging removed directly from the bag making machine. It causes various problems. First, packaging that looks and feels less full is less attractive to the customer compared to a fuller package. Secondly, many consumers are dissatisfied when, after opening the packaging, they realize that the packaging is only half full. Thirdly, due to the increased empty space after the product settles, the prior art packaging is larger than what is needed at this time in relation to its contents. Such packaging unnecessarily takes up valuable space on the store shelf, in transport trucks, in warehouses and in the consumer's pantry. In addition, production materials such as plastic films are wasted when forming such a package.

[0004] For the above reasons, attempts have been made to reduce the empty space in the package. One trial is disclosed in the jointly owned US Patent Publication No. 2006/0165859, which teaches that a randomly shaped product tends to settle less over time than a uniformly shaped product, and thus discloses the production of a randomly shaped product. However, the disadvantage of this method is that it is not always desirable to produce randomly shaped products.

[0005] Another known method is to partially fill the package with the product, vibrating the package so that the product settles inside the package. Then the additional product is added to the packaging and the process is repeated. Unfortunately, this process is very slow and can not be carried out at high speeds in a traditional vertical machine for forming, filling and sealing packages.

[0006] Document DE-A-3536173 discloses a packaging machine comprising a weighing instrument, a packaging device and a compressor. Document WO-A-96/17773 discloses a vertical machine for forming, filling and sealing packages, with continuous operation, comprising clamping elements and a forming element connected in fluid communication with a source of nitrogen. Document

FR-A-2819945 discloses a filling device having an inlet in fluid communication with a source of nitrogen. Document US-A-3579945 discloses a feed pipe for a machine for forming, filling and welding packages comprising a supply pipe with nozzle openings for a shielding gas.

[0007] Accordingly, one object of the present invention is to provide an apparatus and method that results in increased compaction of the product in the package. In addition, since many packages require the use of a vertical machine for forming, filling and sealing packages, it is desirable that the device and method can be easily adapted for use on such a machine, preferably only after minor modification and without significantly reducing the speed of bagging.

BRIEF DESCRIPTION OF THE DRAWINGS [0008] The novel features of the invention are set out in the accompanying claims. The invention itself, however, as well as the preferred method of its use, its further objects and advantages will be best understood by referring to the following detailed description, exemplary embodiments of the invention shown in the drawing, read in conjunction with the accompanying drawings, in which:

Figure 1 is a perspective view of a prior art filling device;

Figure 2 is a perspective view of a filling device using one embodiment of the invention including a subsidence chamber;

Figure 3 is a top view of a rotary sagging defining device comprising a plurality of subsidence cells in their unloading and receiving positions;

Fig. 4 is a perspective view of a rotatable settlement device comprising a plurality of subsidence cells in their mid-rotation position;

Fig. 5 is a perspective view of a filling device, in one embodiment of the invention including a settling chamber and negative pressure releasing holes;

Fig. 6 is a perspective view of a cylinder providing a product in fluid communication with a nitrogen source, in one embodiment;

Fig. 7 is a perspective view of a filling device, in one embodiment of the invention including an offset receiving funnel;

Fig. 8 is a perspective view of a filling device, in one embodiment of the invention using further sagging devices;

Fig. 9 is a side view of a filling device, in one embodiment of the invention using a horizontal axis of rotation;

Fig. 10 is a side view illustrating a filling assembly comprising a conveyor belt, in one embodiment of the invention;

Fig. 11 is a side view of the chamber in one embodiment of the invention; and

Fig. 12 is a graph of position as a function of time in one embodiment of the invention.

DETAILED DESCRIPTION Several embodiments of the present invention will now be described with reference to the drawings. Unless otherwise stated, similar elements will be marked with identical numerals in all figures.

[0010] In general, the present invention relates to a method and apparatus for thickening a portion of a product and increasing the density of the product inside the package. Compacting refers to the density of the product inside the package. The aim is to form and compact the intermediate product portion, which is then discharged to the packaging device and finally to the packaging. An additional object, in one embodiment of the invention, is to ensure that increased compaction remains during the packaging operation. Applicants have found that the formation and compaction of the intermediate portion and subsequent insertion of said portion into the package result in increased product thickening. The product portion refers to the collected product charge.

[0011] Due to the resulting increased product compaction in the packaging machine, there is less subsidence during the next transport, handling and display of the package for sale. Thus, the apparatus and the method of the present invention ensure that the package displayed on the store shelf will more closely resemble the packaging seen in the packaging machine. The packaging machine used in this description refers to any packaging device. The method and apparatus are to be used in a wide range of packaging machines, including, without limitation, a vertical machine for forming, filling and sealing packages, and a horizontal machine for forming, filling and sealing packages, a packaging device for containers in a boxed sack system. bag-in box, BiB),

The end packs described herein may include traditional flexible packaging associated with snack type products, vertical packaging, box packaging, packaging in a "bag-in-box" container, and other packaging products containing the product that is settling.

[0012] The device and method can be used to increase the concentration of a variety of products, including food products such as chips, pretzels (cookies), cookies, pasta, nuts, flakes and seeds. Similarly, the present invention also applies to individually wrapped products, such as individually-wrapped mints or other candies that are subject to settling.

The device and the method also work with respect to other different dry products, including dog food, cat food, animals, etc.

[0013] Figure 2 is a perspective view of a filling device using one embodiment of the invention including a subsidence chamber. In Figure 2, the sagging device 207 is located between the scales 101 and the cylinder 103 supplying the product of a vertical machine for forming, filling and sealing packages.

The weight 101 may comprise practically any weight known from the prior art. For example, the weight 101 may be a statistical weight. As shown in the figure, the weighing funnel 101 has a receiving funnel 102. The receiving funnel 102, or a series of funnels, receives and guides the product into the packaging machine behind it. As used herein, the receiving funnel 102 applies to any device located downstream of the balance, but before a sagging device that collects and directs the product. The receiving hopper 102 may be attached to the balance and form part of the weight 101 and may comprise vertical or oblique walls. For example, a metal detector located between the scales 101 and the receiving funnel 102 can be used to monitor the presence of foreign bodies. Specialists in this field will notice that the receiving funnel 102 is not necessary in all embodiments of the invention. Behind the receiving funnel 102 and the scale 101 there is a device 207 causing settling.

[0014] As illustrated, the sagging device 207 includes a single subsidence chamber 204, a vibrator 208, and a gate 206. The term sagging device used in the present description refers to a device that receives and captures a quantity of product to create from it an intermediate portion of the concentrated product. The subsidence chamber 204 is a separate chamber that receives and maintains the product. The subsidence chamber 204 can have four vertical walls and an open top and bottom.

[0015] Applicants have discovered that collecting the product fed from the balance and holding the product for some time in the subsidence chamber 204 facilitates settling of the product and increases the thickening of the product. Increasing the settling of the product during packaging results in a reduction in settling after product formation. The subsidence chamber 204 may be shaken or vibrated (vibrated) with a vibrator 208 to facilitate and accelerate the settling of the product. The necessary time and amount of external energy, such as vibrations required to facilitate settling of the product depend on many factors including, without limitation, product geometry, size and geometry of the settling chamber, portion size, and the desired level of compaction. Specialists in this field of technology will be able to determine the amount of timeand the energy required to achieve the desired level of compaction. The settlement chamber can also be used for other motions such as vertical, horizontal, rotary, vibratory and mixtures thereof to facilitate settling of the product, resulting in increased compaction. The vibrator 208, which is optional, may include any device that vibrates (oscillates) the subsidence chamber 204. The vibrator 108 may be located at various locations in the sagging device 207.

[0016] Applicants have discovered that the geometry of the subsidence chamber

204 affects the shape of the packaged portion as well as the shape of the final package, especially if the end packaging is a traditional flexible bag. The shape of the cross-section of the subsidence chamber 204 may be substantially similar to the desired shape of the product portion. For example, the subsidence chamber 204 may have a substantially oval cross-section to mimic the substantially oval cross-section of a conventional elastic bag. Other cross sections including, without limitation, circular and square cross-section may be used.

[0017] The height of the sagging chamber 204 can be varied according to the desired size and the shape of the intermediate product portion, which ultimately determines the size and shape of the finished product. For example, the size of the subsidence chamber 204 can be approximately a multiple of 0.5 to 2.5 times the height of the final package, and in one embodiment the settling chamber 204 has an approximate height of 1.25 the height of the final package. The size of the chamber depends on a variety of factors, including the required subsidence size. The height of the subsidence chamber 204 can be selected to fit properly between the weight and the packaging device, without lifting the scale.

[0018] In one embodiment, the bottom of the settlement subsidence 201 has a larger opening than the top of the subsidence chamber. For some products susceptible to hovering of the product in the chamber, the larger exit diameter reduces to a minimum the product hanging in the chamber. This helps the product maintain its compact shape and causes its faster and more effective discharge.

[0019] At the bottom of the subsidence chamber 204 is a gate 206. The gate 206 may comprise a plurality of gate types, including sliding gates and swinging gates. For example, the gate 206 may be a sliding gate that allows a quick and efficient discharge of the product from the subsidence chamber 204.

[0020] Behind the gate 206 is a cylinder 103 providing the product. In some embodiments of the invention, there is an intermediate funnel 209 that directs the product discharged from the gate 206 into the product delivery cylinder 103. Intermediate funnel 209 may include one or more funnels that may include straight or oblique walls.

In addition, intermediate funnel 209 can have a variety of shapes. For example, the intermediate funnel 209 may have a shape similar to the shape of the subsidence chamber 204.

[0021] In some embodiments, when the process moves further from the receiving funnel 102 to the product delivery cylinder 103, each subsequent further transition point has a larger diameter than the previous transition point. Thus, in such an embodiment, intermediate funnel 209 has a larger diameter than the subsidence chamber 204, but smaller in diameter than the product delivery cylinder 103. This arrangement minimizes the product hinge and any other disturbances of the combined portion.

[0022] Thus, the method of compacting the product portion begins by weighing a quantity of the product on the scale.

Then, the product is directed and received by a settlement device. As soon as the product is in the sagging device, the product is compacted to create a portion of the product. As discussed, this can be achieved by holding the product for some time, or by shaking, rotating and / or vibrating the sagging device. After concentrating the product, the product is discharged into the cylinder supplying the product. It should be noted that the product can be directly discharged into the product delivery cylinder, or it can be discharged into an intermediate funnel or chute before reaching the cylinder supplying the product. A portion of the product is then inserted from the cylinder that delivers the product to the package. As discussed above, the settlement device is located behind the scale and in front of the cylinder supplying the product. In addition, the deposition initiating device may comprise only one subsidence chamber, or the device may comprise more than one subsidence chamber.

[0023] The settlement device 207 may comprise only one subsidence chamber 204. However, the sagging settlement device 207 may comprise more than one subsidence chamber 204. For example, two or more subsidence compartments.

204 may operate in parallel, each inserting its portion of product into a downstream cylinder 103 delivering the product. In other sagging devices, at least two subsidence chambers 204 operate in series, the first chamber being located below the second chamber and the product partially settling in the first chamber before being deposited for further settling in the second chamber. In other settlement devices, one or more subsidence chambers 204 are located on a rotating sagging device. Each subsequent chamber can cause increased settling.

[0024] Figure 3 is a top view of a rotary sagging developing device comprising a plurality of subsidence cells in their unloading and receiving positions.

The rotating settlement device 304 is a device comprising more than one subsidence chamber, said settling chambers being axially rotatable within the sagging device. Figure 3 shows a rotary settlement device 304 comprising eight subsidence chambers 204a-h, positioned above stationary turret 306, gate 305 and vibrator 208. Although the figure shows eight subsidence chambers 204a-h, other amounts of subsidence cells can also be used. Those skilled in the art understand that the number of required settling chambers depends on a number of factors including, without limitation, product geometry, desired size and weight of each serving, and the desired capacity counted in bags per minute, settlement time required, etc.

[0025] In the rotating settlement device 304, settling chambers 204a-h can be arranged in different positions. For example, the centers of each subsidence chamber can be evenly distributed along the revolver table

305. The chambers can be evenly distributed and positioned like the spokes of the wheel on the wagon. As shown in the drawing of the deposition chamber 204, it is arranged at an angle relative to the revolving table 305 to maximize the number of chambers that will fit on the revolving table 305.

[0026] In the embodiment shown in the drawing, the subsidence chambers 204 have open top and bottom so that the product is held inside the subsidence chambers 204 by the presence of the stationary turret table 305. In this embodiment, the subsidence chambers 204 slide and rotate on the revolving table 305 In the revolver table 305 there is an opening 308, located above the gate 306.

The shape of this opening may correspond to the shape of the subsidence chamber 204. The chamber is positioned above the gate

306, and aligned with the opening 308 is referred to as the discharge chamber 204a. The product in the unloading chamber 204a is held by the gate 306. Accordingly, when the gate 306 is opened, by sliding or otherwise, the product descends through the bore 308 in the revolver table 305 and passes through the open gate 306. Those skilled in the art understand that there are other ways to hold the product inside each subsidence chamber such as using a separate gate for each subsidence chamber.

[0027] A cylinder is provided behind and below the gate 306

103 providing the product. The thickened, agglomerated product is discharged from the discharge chamber and into the product delivery cylinder 103, where it is then packaged in a packaging machine.

[0028] The subsidence chambers 204 can be filled at various locations. In one embodiment, the discharge chamber

204a is also the same subsidence chamber that accepts the product, called the receiving chamber. After unloading the product in the unloading chamber 204a, the gate 306 may close.

Next, the discharge chamber 204a will then receive the product.

All of the discharge chambers 204 in turn will then move one space in the order in which the product in the settling chamber settles and becomes more compact.

Reception and unloading does not take place simultaneously.

[0029] However, figures 3 and 4 show a device in which the ingestion and discharge does not take place in the same chamber. As shown in Figure 3, the discharge chamber 204a discharges the product and the other chamber, the receiving chamber 204c receives the product from the receiving funnel 102. The discharge and takeover may occur simultaneously. After the discharge chamber 204a discharges its product, it rotates two positions to become the receiving chamber 204c when it receives the product. The discharge chamber 204a can only rotate one space before it becomes the receiving chamber, while the discharge chamber can also rotate a number of positions before it becomes the receiving chamber. The location of the receiving and unloading locations depends on a variety of factors, including, without limitation,

[0030] After the receiving chamber 204c has received its product, it rotates in a clockwise direction through the positions until it becomes the discharge chamber 204a again. Although the example described with the rotation in the clockwise direction has been described, this should not be considered as limiting, since the device can also rotate in the counter-clockwise direction.

[0031] When the subsidence cells rotate, the product becomes more compact. The vibrator 208 may vibrate the product inside the subsidence chambers 204 to facilitate settling of the product. The vibrator 208 may be located at various locations, including without limitation, on a stationary turret 305, attached to chambers 204 or otherwise attached to a rotating device 304 causing settlement or other supporting structure.

[0032] As shown in Figures 3 and 4, the receiving funnel

102 may be located at the top of the rotating sagging device 304. The receiving funnel 102 directs the product to the receiving chamber. As noted above, the receiving funnel 102 may be located immediately below the weight 101 or may be located below the second funnel or a series of funnels.

[0033] Figure 4 is a perspective view of a rotary shedding device comprising a plurality of subsidence chambers at a position in the middle of rotation. Figure 4 also shows an opening 308 located on the stationary table 305. As shown in the drawing, the chambers are in a half-circle, so that the chambers do not take or unload the product. However, the product may be taken and / or unloaded during rotation.

However, it may be desirable that the compact portion is kept in its compact state after forming this portion.

[0034] In Figure 4 a stationary upper plate is shown

409. The top plate 409 is intended to ensure that the product inside the subsidence cells 204 does not escape the subsidence chambers 204. In addition, the upper plate 409 is to inhibit the external elements from entering the developing device and protect them from being packed. The top plate 409 is not necessary in all embodiments of the invention, and those skilled in the art understand what process conditions warrant the use of such a top plate.

[0035] As shown in the drawing, intermediate funnel 209 and the product delivery cylinder 103 are shown behind the opening 308. In Figure 4, the product delivery cylinder 103 is part of the bag forming apparatus in a vertical machine for forming, filling and sealing packages. The product delivery cylinder 103 may be directly connected to the rotatable device 304. The product delivery cylinder 103 may also not be directly connected to the rotatable device 304. The product delivery cylinder 103 may be separated from the rotating device 304 by a slot or may be connected via another device such as a funnel intermediate 209.

[0036] The product in the package may contain product only from one subsidence chamber. In this case, the quantity of the product received in the receiving chamber is equal to the quantity of the product in the final packaging.

[0037] The final package may also contain two portions of the product. For example, the package may comprise a product of at least two different subsidence cells, or the package may contain two portions of product from the same chamber. In this case, the first portion may first be formed and unloaded and then successively the second portion may be formed in the same chamber and then discharged.

[0038] Applicants have discovered that in some products compaction is further increased when two or more smaller portions are compacted separately and then added to a single package. For example, if the final product is to contain two portions of the product, then these portions formed in two different compartments will be both put in one package. Referring again to Figure 3, in such an embodiment of the invention, the single package will contain a product discharged from the discharge chamber 204a as well as a product from the chamber 204h located one behind the discharge chamber 204a. Thus, the product from both chambers 204a / 204h can be discharged into a vertical machine for forming, filling and sealing packages to be packaged in a single package.

[0039] The height of each chamber can be selected so that existing devices can be upgraded by adding batch compaction without, for example, lifting the weight. As an example, in one embodiment as a result of using the multi-cartridge method, the subsidence cells may have a shorter height because the height decomposes into a plurality of chambers and, as a result, the weight does not have to be moved. This results in reduced capital costs for the modernization of the existing machine.

[0040] Applicants have found that after inducing subsidence, the portion maintains its shape and compaction when it is packaged. This causes less settling after packaging, giving the consumer a fuller package that more closely resembles the appearance of the filled bag in the packaging machine.

As discussed previously, the increased settling during packaging reduces settling after packaging, which provides a number of advantages. One such advantage is the possibility of using a relatively smaller package for the same product weight.

This results in reduced production costs because less material is needed to make the package. In addition, this results in reduced transport costs because more packages can fit in a given volume. In addition, it allows the presentation of more packages on the store shelf, as smaller packages take up less space. Likewise, a smaller package allows the consumer to store the same amount of product in a smaller space, thereby freeing the valuable pantry surface.

[0041] As discussed, the device and method give the possibility of packaging the same amount of product in a relatively smaller package. This smaller package may have reduced height, width or combinations thereof compared to the previous packaging. In one embodiment, the package width does not change, and only the height dimension changes. This embodiment minimizes the modifications required for the packaging machine.

[0042] The following examples show the efficacy of one embodiment of the present invention and are for illustrative purposes only. Accordingly, the following examples should not be considered as limiting.

Control Test [0043] A test was carried out using chips with a product weight of 609.5g (21.5 fl oz). Wheat chips were thin wafers with ridges. The subsidence device was not used for the control sample. The bags had a width of 30.5 cm (12 inches), a total height of 47.63 cm (18.75 inches) and a usable height of 45.09 cm (17.75 inches) after deducting one inch on top and bottom weld. An empty space was measured in each package and the level of fullness of each bag was calculated. The empty space was measured by measuring the average level of the product in the package. The packaging removed from the packaging machine, which was a vertical machine for forming, filling and sealing packages, had an average of approximately 86% of the filling, and had an average product level of 38.74 cm (15.25 in). Then, to determine the condition of the packages after being on the store shelf, the packages were subjected to a simulated sales process, which included simulating the transport, carrying and displaying of a typical packaging on the store shelf. After simulation, the empty space was measured and it was calculated that the fullness level of each capsule was approximately 78% on average, with a product level of 35.18 cm (13.85 inches).

Thus, the level of fullness of packaging decreased on average by about 8% after simulation of stay on the store shelf, and the product level decreased by an average of 3.6 cm (1.4 inches).

Single batch [0044] In the next test, a non-rotating sagging device was used, comprising a single settling chamber similar to the chamber of Figure 2, using a single batch method where each package contained a single batch of product. The settlement device had subsidence chambers having a substantially oval cross-section and a width of 30.5 cm (12 inches). A smaller bag was used due to the settlement of the product. The smaller bag was 30.5 cm (12 inches) wide and 42.55 cm (16.75 inches) high, with a usable space of about 40.75 cm (15.75 inches). In the packaging machine, the packages were approximately full 86% and had a product level of about 34.42 cm (13.55 inches). Thus, the settlement device reduced the same amount of product in a bag with the same width from a product level of 38.74 cm (15.25 inches) to a product level of 34.42 cm (13.55 inches) in the packaging machine. After simulating the stay on the store shelf, the packages were approximately full in 82% and had a product level of about 32.64 cm (12.85 inches). Thus, the level of fullness of the packaging decreased only by about 4% and resulted in a more complete bag compared to the control sample. In addition, the product dropped only by about 1.8 cm (0.7 in), which is about half the fall that occurred in the control sample. the packages were approximately full in 82% and had a product level of about 32.64 cm (12.85 inches). Thus, the level of fullness of the packaging decreased only by about 4% and resulted in a more complete bag compared to the control sample. In addition, the product dropped only by about 1.8 cm (0.7 in), which is about half the fall that occurred in the control sample. the packages were approximately full in 82% and had a product level of about 32.64 cm (12.85 inches). Thus, the level of fullness of the packaging decreased only by about 4% and resulted in a more complete bag compared to the control sample. In addition, the product dropped only by about 1.8 cm (0.7 in), which is about half the fall that occurred in the control sample.

Sample with multiple batches [0045] In the next test, the same device was used using the multi-batch method, in which the final package contains two product portions. Thus, in this embodiment, the subsidence chamber formed and unloaded one portion of the product and then the same sagging chamber then formed and unloaded the second portion of the product into the same package as the first product portion discharged. The sample with multiple batches also used bags of the same size as in the case of a single batch. The packaging machine had approximately 87% fill and had product levels of around

34.67 cm (13.65 inches). After simulating the stay on the store shelf, the packages were approximately full in 83% and had a product level of about 33.40 cm (13.15 inches). Thus, compared to the single batch method, the multi-batch method gave a more complete bag both in the packaging machine and after simulations of staying on the store shelf.

[0046] Both in the single batch and two batch trials, a smaller package was formed that contained the same amount of product as the larger pellet in the control sample, but which required less material for its production.

Correspondingly, compaction of the product results in reduced production costs, reduced transport costs, and an increase in the number of packages available for a similar size of retail space, packaging that requires less storage space and packaging that appears more complete to the retail consumer.

[0047] Referring again to Figure 3, applicants will now discuss the effect of the gate speed 306 on compacting a portion of product. Applicants have found that slow moving gate 306 reduces the densification of product portions, while fast-acting gate 306 allows portions to stay compact. As used herein, the term fast-acting gate means a gate that is completely open in less than about 50 milliseconds. There are various ways to minimize the impact that gate 306 has on the concentration of the product portion. In one embodiment, the gate speed 306 is increased. In another embodiment, the gate 306 is completely open in such a short time as about 40 milliseconds. As discussed, this fast-acting 306 gateway works, to minimize the reduction in compaction. In one embodiment, the length of the gate

306 is increased. This allows the gate 306 to increase in speed before the opening 308 is opened. Furthermore, as shown, the gate 306 and the hole 308 are arranged such that the shortest distance in the opening 308 is in the same direction in which the gate 306 is opened. The fast-acting gate 306 can be used in any device described in the present description.

[0048] Referring now to Figure 5, Figure 5 is a perspective view of a filling device using one embodiment of the invention including a settling chamber and vacuum relief openings. Figure 5 is similar to Figure 2 except that Figure 5 also shows vacuum relief recesses 510. Figure 5 shows a sagging device 207 located downstream of the weighing 101 and upstream of the product delivery roller 103, in which the product delivery cylinder 103 includes a forming collar 511, and wherein the product delivery cylinder 103 includes vacuum relief ports 510 extending above the forming collar 511. As discusses in one embodiment of the invention, a compact product portion is formed prior to placing said product in the product delivery cylinder 103. This compact portion creates a negative pressure in the product delivery cylinder 103 as it descends inside the product delivery cylinder 103. This phenomenon did not occur in the prior art, because the product was sufficiently distributed to prevent the formation of a vacuum. In addition, there was no sliding gate 206 there to cut off the air flow and thus create a negative pressure. However, this compact portion creates a negative pressure above the portion inside the product delivery cylinder 103 when the product delivery cylinder 103 is sealed. In one embodiment, the product delivery cylinder 103 is sealed when the upper gate 206 is closed. This vacuum reduces the speed at which a portion of the product may fall. To minimize the vacuum created, the vacuum relief recesses 510 are positioned above the forming collar 511 that directs the packaging material.

Vacuum releasing openings 510 allow air to be drawn into the product delivery cylinder 103 and the vacuum is removed. Vacuum relief ports 510 may include a single opening or may include two or more apertures. In one embodiment, the openings have dimensions of about 3 mm (about 1/8 inch) to about 6 mm (about 1/4 inch).

[0049] The openings do not have to start in the first section with a length of 7.62 cm (3 inches) of the product delivery cylinder 103. Applicants have found that certain products having edges or corners may engage with openings 510 and thereby interfere with the product flow. To remedy this problem, the product may be allowed to gather momentum in the cylinder section 103 providing a product that does not include openings before entering the product into the cylinder section 103 providing the product having openings 510. The openings 510 may be sized to minimize catching of the product. on holes 510. As shown,

Figure 5 does not include an intermediate funnel 209, however, other embodiments include an intermediate funnel 209. Such an intermediate element allows the product to pick up momentum, which also may reduce the likelihood of engagement or gripping on the openings 510.

[0050] Vacuum openings 510 can be used in any packaging machine including a product delivery cylinder 103 that includes a collar 1510. In one embodiment, the packaging machine includes a vertical machine for forming, filling and sealing packages, having a weight and a cylinder supplying the product.

[0051] Those skilled in the art understand that many products such as potato chips are often purged with nitrogen to extend their shelf-life. Thus, the packaged product is purged with nitrogen to remove air. Previously, the nitrogen spigot was located inside the product delivery cylinder 103 to supply nitrogen to the molded package. This was achieved by means of a pipe stub or a tube running inside the cylinder 103 supplying the product. This was also achieved using a cylinder 103 providing a product comprising two concentric tubes, the inner tube allowing the product to flow, and the outer tube acting as a port for allowing nitrogen to flow. In yet another embodiment,

However, applicants have discovered that in these embodiments, at least a portion of the cross-sectional area of ​​the product delivery cylinder 103 has been devoted to supplying nitrogen. Thus, the use of a nitrogen nozzle changes the available cross-section of the product supplying cylinder 203, which affects the thickening of the product. To compensate for the sacrifice of the section field loss per nitrogen stub, in one embodiment, the area of ​​the cylinder 103 supplying the product must be changed. A change in this area has a negative effect on product concentration. In one embodiment, increasing the field of the product delivery cylinder 103 reduces densification of the product. Applicants have discovered a novel and non-obvious way of eliminating or minimizing the need for a separate nitrogen nozzle.

[0052] As noted above, the vacuum-releasing holes 510 disposed in the product delivery cylinder 103 suck air into the product delivery cylinder 103. Applicants have discovered that by placing a sheath or a nitrogen source 611 over the vacuum releasing openings 510, nitrogen is sucked into the cylinder 103 delivering the product instead of air. Figure 6 is a perspective view of a cylinder providing a product in fluid communication with a nitrogen source. The nitrogen source 611 is in fluid communication with the outer periphery of the product delivery cylinder 103. In this way, nitrogen is injected into the cylinder 103 supplying the product from the outer periphery of the cylinder 103 delivering the product.

[0053] For example, a nitrogen blanket is placed around vacuum relief recesses 510. The vacuum relief portions 510 may be in fluid communication with the nitrogen source 611. The product delivery cylinder 103 is in fluid communication with the nitrogen source 611. The nitrogen source may be connected through one or more tubes to the product delivery tube 103 so that the nitrogen from the nitrogen source 611 may be sucked in to the tube 103 providing the product.

Nitrogen flow rates of from about 2 to about 12 cubic feet per minute may be used.

[0054] As discussed above, the sump device 207 can be installed without adjusting the height or positioning of the balance 101. Often, moving or adjusting the balance 101 or the welding machine is excessively expensive. Thus, instead of moving the scale 101 or the welding machine, an offset receiving funnel 102 can be used. Figure 7 is a perspective view of a filling device including an offset receiving funnel. As can be seen, the shifted receiving funnel 102 receives a product from a scales 101 that is vertically displaced from the product delivery cylinder 103. The product delivery cylinder 103 can be offset from a weight of 101 from about 10 to 20 cm (4 and 8 inches). The wall of the receiving funnel 102 can be inclined at an angle greater than 45 degrees to the horizontal. The height and shape of the displaced receiving funnel 102 can be adjusted to receive and grip the product discharged from the scales 101 without moving the scales 101 or the welding machine. The packaging machine may be a vertical machine for forming, filling and welding packages comprising a scales 101, a product supplying cylinder 103, located downstream of the scales 101, and a receiving funnel 102 located downstream of the scales 101 and upstream of the product delivery cylinder 103, where the receiving funnel 102 is a shifted receiving funnel .

[0055] Figure 8 is a perspective view of the filling device in one embodiment using further settling chambers. As shown in the drawing, the product goes to the first subsidence chamber 204a. The product is then inserted into the second subsidence chamber 204b and then into the third subsidence chamber 204c. Two or more successive subsidence chambers 204a-c may be used. Each subsidence chamber may be vibrated (vibrate) or otherwise compact the product. The subsidence cells 204a-c may operate as discussed previously. Each subsidence chamber 204a-c may include a gate 206 as discussed herein. The amount, alignment and time in each subsidence chamber 204 a c can be adjusted depending on the product being compacted, as well as the desired compaction ratio. Subsidence cells 204a

- c can be vertically aligned so that the product from the upper sinking device is received from the lower settlement device. At least two subsidence chambers may lie substantially in the same vertical plane. As shown in Figure 8, subsidence chambers 204a

- c are basically in the same vertical plane. The subsidence cells 204a-c may also not be in the same vertical plane. Thus, the subsidence chambers 204a-c may be stepped to receive the product from the scale 101 and arrange a portion in the product delivery tube 103 that is vertically offset relative to the weight 101. The device may include a scale 101, a product delivery cylinder 103, at least one device establishing a settlement, wherein the at least one sagging device is located between the balance 101 and the product delivery cylinder 103, and wherein the sagging device comprises at least two settling chambers, and wherein the at least two settling chambers are vertically aligned.

[0056] The size and shape of each settling chamber can be the same or the size and shape can vary. As an example, the first subsidence chamber 204a is larger than the subsequent subsidence chambers 204b, c. Each chamber located behind a given chamber may have a smaller size than the chamber located directly in front of it.

[0057] Figure 9 is a side view of the filling device in one embodiment using a horizontal axis of rotation. While Figures 3 and 4 showed sagging devices along the vertical axis of rotation, Figure 9 shows a horizontal axis of rotation. The device may comprise at least two settling chambers which are rotatable vertically along a horizontal axis within the settlement device. In this case, the deflecting devices 204a-h can function as the previous sagging devices discussed herein. The first device 204a that causes subsidence can take the product. The product becomes more compact when the sagging device 204a rotates to the unloading position shown by the sump device 204e. At this time, a compact portion is discharged from the device 204e causing settling. The product can be held inside the device 204a - h causing settling via an independent cover or gate 206, which can be removed during unloading. The sidewalking devices 204 may be surrounded by a fixed wall 913 that acts as a cover and prevents the product from escaping from the sap nosing device 204. The device may comprise a fixed wall 913 as well as a gate 206 that can be opened in the unloading position. which acts as a cover and prevents the product from getting out of the device 204 causing settlement. The device may comprise a fixed wall 913 as well as a gate 206 that can be opened in the unloading position. which acts as a cover and prevents the product from getting out of the device 204 causing settlement. The device may comprise a fixed wall 913 as well as a gate 206 that can be opened in the unloading position.

[0058] Figure 10 is a side view of a filling assembly comprising a conveyor belt. In this filling unit, the product becomes more compact when it is lifted vertically along the endless belt conveyor. The settlement device 204 can operate as described previously. Slaughterhouse devices can be vibrated. Accordingly, until the product is at the end of the conveyor belt it is already sufficiently compacted. Then gate 206 is opened to unload the product. In this way, in one embodiment, the at least one sagging settlement device can comprise at least one settling chamber connected to an endless conveyor that vertically displaces at least one subsidence chamber.

[0059] Instead of sealing the package, the partial package may first be filled with the product. The packaging is formed without a top seal, forming a partial package and then filled with a portion of the product. Then, the packaging is interacted to increase the concentration of the product inside the unopened package. This interaction may comprise any of the methods discussed above with reference to the sagging device, and includes vibration, agitation, movement, etc. In this way, the product in a partial package settles. The final seal is then produced on the partial packaging to create a final package. The package may be welded to obtain a reduced package. The final weld may be placed such that the average packing density is increased.

[0060] The package may be welded with the first weld after filling. The package is then subjected to an interaction to increase compaction, as discussed above. The bag is then re-sealed with the final seal, resulting in a relatively smaller package. The excess of packaging material and the first weld can then be cut off from the packaging and removed.

[0061] Figure 11 discloses a side view of a chamber in one embodiment of the invention. The chambers 204 may have a uniform diameter, either the upper part or the lower part may have a larger diameter. The chamber 204 has an upper section V1, which has a larger diameter than the lower section V2. As shown in the drawing, the upper section V1 has a conical cross-section, while the lower section V2 has a cylindrical cross-section. As can be seen in the figure, section V1 and bottom section V2 meet at neck 1101. If a product is to be suspended in the chamber to stop product flow, product hanging in the chamber is likely to occur at neck 1101. It may be desirable for the product to flow to and was stored in the lower section V2. However, to get the right capacity, if the product is hanging in the chamber, in one embodiment, the volume of the upper section V1 is the same as the volume of the lower section V2. Thus, if a certain degree of product hinge occurs in the neck 1101, the upper section V1 can store the batch without spilling the product.

[0062] Referring to Figure 3, another embodiment of the invention will now be discussed. One or more chambers 204 can be monitored by means of a sensor. The sensor may be any sensor known in the art. The sensor can be a digital or analog sensor that monitors the product level. The sensor may contain a photocell. The sensor can be placed on or above any chamber. As an example, the sensor can be located above the discharge chamber 204a. The sensor can determine if the product level is too high, which would indicate that the product has hovered in the chamber. The sensor can then transmit this information and the packaging machine can operate accordingly. The packaging machine can stop to allow vibrations in the chamber or otherwise cause the product to settle. The packaging machine can use a blast of air, nitrogen, etc. to remove product hanging in the chamber and force the product to settle. The sensor may also be located upstream of the discharge chamber 204a. As an example, the sensor may be located above any of the upper chambers 204c-h.

[0063] Similarly, the sensor can be used to determine if the product level is too low. This would indicate that the weight 101 is malfunctioning and does not contain enough product. In addition, if the product level is too high, this may indicate a further malfunction of the balance 101. Thus, the use of sensors can be used to monitor the performance of balances 101 and eliminate or reduce the need for inspection of packages.

[0064] Furthermore, the sensor can also be placed in the discharge chamber 204a or downstream of the discharge chamber 204a to ensure that the entire product has been discharged. For example, the sensor may be located above the chamber 204b after the discharge chamber 204a. If the product remains in this chamber 204b then a failure occurred and the previous bag was not properly filled. This can eliminate or reduce the need to inspect the bags to ensure that they have the correct weight.

[0065] The sensors may also be arranged along the height of the chamber 204. These sensors may also monitor the product level in the cavity 204. These sensors can be attached to one or more cavities 204. These sensors can monitor the change in product level over time. Thus, a sensor or sensors can be used to determine the degree of filling and discharge. If the degree of discharge is lower than desired, then it may mean that the product has been hanging. In addition, if the degree of discharge is less than desired, it may mean that part of the product will be in the final weld, which may lead to an incorrect weld. This gives the opportunity to eliminate the inspection of final packaging.

The sensor or sensors can also be used to monitor settling. They can also be used to determine the correct bag size for the batch. For example, a sensor may be used to ensure that the size of the pouch is large enough to accommodate the compacted batch.

Referring again to Figure 3, the chambers 204a -h can rotate, stop, vibrate and rotate again. During the rotating step, the chambers 204a-h rotate from one position to a second position. For example, the discharge chamber 204a rotates to a discharge position (as shown in the drawing). When it rotates to the discharge position its speed increases to the point where it can be held for some time before the velocity is reduced to zero. Then, in one embodiment, the subsidence chambers 204 a - h are subjected to a holding period. In one embodiment, during the holding period of the chamber 204a -h they are not rotated but remain approximately in the stationary position. During this holding period, the product may be discharged from the discharge chamber 204a. At the same time, the product can be received by the receiving chamber 204c. After the stopping period, the chambers 204 a - h can be subjected to a vibration (vibration) step, which causes the product to additionally settle. The oscillation step may include oscillating the chambers 204a-h. The vibrationing step may include setting the chambers 204 to oscillate forward and backward to induce settling of the product. Each individual chamber 204 can rotate forward and backward on its own axis to promote settling. Thus, as an example, the chamber 204 rotates along the revolver table 305, but also rotates along its own axis. The chamber 204 can rotate around an axis located in its center. The chamber 204 can rotate less than about 360 degrees before changing directions.

[0067] Figure 12 is a graph of position as a function of time for one filling device. Line 1201 shows a filling device having only forward movement. As you can see, the position of the revolver table slowly changes over time as the turret rotates between positions. When the turret speed increases, its position changes faster over time.

Then the revolver table begins to slow down to its stop when it reaches its desired position. In this embodiment, the turret table is constantly moved with its always increasing position. Later, the chamber can be stopped and subjected to a vibration step, as discussed above.

[0068] Line 1202 shows another filling device having forward and backward movement as a function of time. In this filling device the chamber is continuously rotated between the positions, however the chamber experiences forward and backward movements. This backward movement is referred to as superimposed movement because it is superimposed on forward motion. In one embodiment, this applied motion helps in settling the product during the turning step.

[0069] The stopping step may comprise vibration of the chamber. This oscillation may include high frequency oscillations but low amplitude. This ensures that the gate 206 of the chamber 204 properly aligns with the cylinder 103 providing the product.

[0070] It is understood by those skilled in the art that actual speed, stop time and vibration time is a function of bag size and product geometry. These factors can be adjusted to maximize the best settling rate relative to an acceptable number of product cracks. For example, although aggressive vibration and rapid rotation increase settling, it can also lead to increased product cracking. Velocity, stop time and velocity and vibration time can be adjusted to maximize settling at an acceptable number of product cracks.

[0071] The methods described herein have led to many surprising benefits. One advantage is that the product loading cycle to the packaging has been significantly reduced. The loading cycle (product for packaging) refers to the time elapsed since the first product enters the package until the last product enters the package. As the state of the art revealed a loosely packaged product, this product was very distributed, which led to a long cycle of loading the product into the package. A product with low bulk density tends to have a long time of falling as it falls from the balance to the packaging device, which results in a long product loading cycle to the packaging. The product loading cycle to the packaging influences the speed at which the bags can be molded and filled. Thus, the speed in the prior art was limited, because the packaging machine had to wait for the whole product to be put into a partial package. Reducing the product loading cycle to the packaging increases the speed of bag forming and filling.

[0072] As an example, a 57g (2 oz.) Bag containing Sunchips, produced by Frito-Lay North America, Plano, Texas, could have been previously carried out at speeds of 70 bags per minute. However, using the methods and devices described herein, in particular the sagging device, as well as the vacuum relief openings used therein, speeds of up to 100 bags per minute have been achieved. Similarly, 28 g (1 ounce) bags containing Sunchips were made at 150 bags per minute using the methods and devices described herein, compared to the traditional rate of 100 bags per minute, with no method or devices described herein. Thus, the methods and devices described herein allow for the production of bags at significantly increased speeds.

[0073] Due to the partially reduced product loading cycle into the package, in one embodiment the doctor strips and the sagging devices can be eliminated. As described above, previously, due to the long cycle of loading the product into the packaging, it was common for the crumbs or crumb to get into the product portion. The scraper strips are used to wipe the final welds before welding to remove these crumbs as well as push each product out of the welding area. Again, because the product loading cycle to the packaging is reduced, the product is delivered as a compact portion. Applicants have discovered that by using the devices and methods described herein, the need for the use of doctor strips has been eliminated.

[0074] Similarly, applicants have discovered that by using the devices and methods described herein, the need for sinking devices has been reduced. Soothing devices were previously used to shake the bag before filling, in particular for low-density products. However, nowadays, when a compact portion is delivered to the packaging, the sagging device is no longer needed. Reducing instruments such as doctor strips and settlement devices reduces capital costs and operating costs. In addition, since scraper blades and settlement devices are not needed, a more versatile packaging machine can be used for a variety of products instead of specific packaging machines for specific products.

[0075] Although the invention has in particular been shown and described in relation to a preferred embodiment, it is understood by those skilled in the art that various changes in form and details may be made without departing from the scope of the invention.

Frito-Lay North America, Inc.

Proxy:

76P40208PL00

EP 2 490 941 B1