A method, apparatus and program product utilize a torque control algorithm constrained by a speed window to control the dispense rate of a packaging material dispenser when wrapping a non-cylindrical load with packaging material. In particular, a dispenser motor of the packaging material dispenser that is controlled by a VFD may be driven to maintain a substantially constant torque, while also constrained to operate within a speed window that is based at least in part on a rate of relative rotation between the packaging material dispenser and the load.

Embodiments of product handling systems facilitate transfer of individual product items from incoming bulk form into dedicated trays for inspection, sorting, selection, and packaging. Inspection may comprise interrogation of product items within a tray by electromagnetic (e.g., optical, hyperspectral) or other (e.g., physical, acoustic, gas sensing, etc.) techniques. Prior to packaging, product items disposed within the tray may be stored in a moveable carousel responsible for controlling environmental factors such as temperature, humidity, illumination, ambient gases, product-to-product interactions, and/or others. Movement of product items from a carousel's transfer station to an outside staging position may be accomplished using robots and/or conveyor belts. Embodiments may allow rapid, low-cost consumer selection of specific individual product items based upon their accompanying metadata (e.g., source, identifier), in combination with the results of inspection (e.g., visual appearance). Embodiments may receive product items pre-packaged in tray format to expedite inspection, sorting, selection, and packaging.

Embodiments of product handling systems facilitate transfer of individual product items from incoming bulk form into dedicated trays for inspection, sorting, selection, and packaging. Inspection may comprise interrogation of product items within a tray by electromagnetic (e.g., optical, hyperspectral) or other (e.g., physical, acoustic, gas sensing, etc.) techniques. Prior to packaging, product items disposed within the tray may be stored in a moveable carousel responsible for controlling environmental factors such as temperature, humidity, illumination, ambient gases, product-to-product interactions, and/or others. Movement of product items from a carousel's transfer station to an outside staging position may be accomplished using robots and/or conveyor belts. Embodiments may allow rapid, low-cost consumer selection of specific individual product items based upon their accompanying metadata (e.g., source, identifier), in combination with the results of inspection (e.g., visual appearance). Embodiments may receive product items pre-packaged in tray format to expedite inspection, sorting, selection, and packaging.

A packaging method includes feeding products, ordered into two rows, into a first ring winding unit of extensible film and winding the products in a first film having a first rotation direction to form a continuous packaging or bundle; feeding the wound products to a second ring winding unit of extensible film in a second film having a second rotation direction opposite to the first rotation direction to form a continuous packaging or bundle with two layers of film; and feeding the continuous packaging or bundle into a cutting unit, which moves in synchrony with, and cuts, the continuous packaging or bundle transversely into finished groups of products. A ring winding machine is provided at each of the two ring winding units, obtaining a continuous winding also when the film becomes exhausted in at least one of the two ring winding machines. A packaging machine is also provided.

An orbital wrapping apparatus for wrapping a cargo in a stretch film is provided and generally includes a base frame, a circular ring assembly mounted on the base frame, a stretch film dispenser mounted on the circular ring assembly, and a cutting assembly mounted to the base frame and extending through an opening defined by the circular ring assembly. The stretch film dispenser includes a roll of stretch film dispensing the stretch film by rotation of the circular ring assembly, a subframe fixed to the circular ring assembly and the roll of stretch film is mounted on a loading assembly attached to the subframe, and a first feed roller and a second feed roller are mounted to a portion of the subframe that is movable between a first position adjacent to an axis extending through the first and second end caps and a second position spaced further apart from the axis. The cutting assembly is adapted to cut and hold the stretch film.

A packaging machine using extensible film for products fed in groups or individually includes a conveyor feeding the product, a product positioning unit, a film winding unit and a discharge conveyor positioned at the outlet of the winding unit. The winding unit is a ring winder having a ring rotating with respect to guiding rolls, positioned on a supporting frame, and arranged on a plane perpendicular to the advance direction of the products. A shelf is provided beneath the winding unit, cantilevered for extending in the advance direction of the products, and connects the feeding conveyor with the winding unit. A vacuum-effect gripping unit is positioned beneath the shelf for gripping the film and carries a cutting unit. The vacuum-effect gripping unit and the cutting unit can be moved alternatingly and selectively from a withdrawn rest position of the shelf to an extended position for gripping and cutting the film.

A method, apparatus and program product perform automatic load profiling to optimize a wrapping operation performed with a stretch wrapping machine. Automatic load profiling may be performed, for example, to determine a density parameter for a load that is indicative of load stability such that one or more control parameters may be configured for a wrapping operation based upon the density parameter. Automatic load profiling may also be performed, for example, to detect a load with a nonstandard top layer, e.g., a load with a top or slip sheet, a load with an easily deformable top layer, a load with a ragged top surface topography and/or a load with an inboard portion, such that a top layer containment operation may be activated during wrapping to optimize containment for the load.

An orbital stretch wrapping apparatus is provided and includes a base frame, a circular ring mounted on the base frame and rotatable with respect to the base frame about an axis of rotation, a stretch film dispenser mounted on the circular ring and rotatable with the circular ring about the axis of rotation, the stretch film dispenser having a subframe fixed to the circular ring, a roll of stretch film mounted to the subframe and rotatable with respect to the subframe, a first feed roller mounted to the subframe and rotatable with respect to the subframe, a second feed roller mounted to the subframe and rotatable with respect to the subframe, and a brake member connected to the first feed roller and the second feed roller.

An orbital wrapping apparatus for wrapping a cargo in a stretch film comprises a base frame, a circular ring assembly mounted on the base frame and rotatable with respect to the base frame about an axis of rotation, a stretch film dispenser mounted on the circular ring assembly and rotatable with the circular ring assembly about the axis of rotation, and a cutting assembly mounted to the base frame and extending through an opening defined by the circular ring assembly. The stretch film dispenser has a roll of stretch film dispensing the stretch film by rotation of the circular ring assembly. The cutting assembly is adapted to cut and hold the stretch film.

A method, apparatus and program product perform automatic load profiling to optimize a wrapping operation performed with a stretch wrapping machine. Automatic load profiling may be performed, for example, to determine a density parameter for a load that is indicative of load stability such that one or more control parameters may be configured for a wrapping operation based upon the density parameter. Automatic load profiling may also be performed, for example, to detect a load with a nonstandard top layer, e.g., a load with a top or slip sheet, a load with an easily deformable top layer, a load with a ragged top surface topography and/or a load with an inboard portion, such that a top layer containment operation may be activated during wrapping to optimize containment for the load.