Machine and method for packaging single-dose soluble products in containers

Abstract

Packaging machine for enclosing single-dose soluble products in containers, wherein a transfer line includes a shaking section to impart a shaking movement to at least one container awaiting transfer to a processing station.

Claims

1. A packaging machine configured to insert single-dose soluble products into containers and to perform one or more operations on the containers, comprising: a filling station configured to fill containers with a plurality of single-dose soluble products, a processing station configured to perform one or more operations on the containers filled in said filling station, and a transfer line configured to transfer said filled containers in a transport direction from the filling station to the processing station, wherein the transfer line includes at least one shaking section configured to impart a shaking movement to at least one of the filled containers awaiting transfer to the processing station, wherein said transfer line comprises a plurality of transport units configured to transport respective filled containers, and wherein said plurality of transport units are selectively actuated with oscillatory movement to impart the shaking movement to the respective filled containers.

2. The machine of claim 1, wherein said shaking section is configured to impart successive shaking phases to at least one of the filled containers awaiting transfer to the processing station at different sections of the transfer line.

3. The machine of claim 1, wherein said shaking section is configured to impart the shaking movement to a plurality of the filled containers awaiting transfer to the processing station.

4. The machine of claim 3, wherein said shaking section is configured to simultaneously impart the shaking movement to a predetermined number of the filled containers awaiting transfer to the processing station.

5. The machine of claim 1, comprising a sensor configured to detect a product distribution geometry inside respective filled containers located in said shaking section and to identify which filled containers to subject to the shaking movement based on the detected product distribution geometry.

6. The machine of claim 1, wherein said plurality of transport units are independently actuated by a linear motor associated with a closed-loop guide.

7. The machine of claim 1, wherein said shaking section is located downstream of a curved section of the transfer line.

8. The machine of claim 1, wherein said transfer line is configured to transport said filled containers with their major axes parallel to the transport direction, and wherein said transfer line is configured to impart to said filled containers the shaking movement along a direction parallel to the transport direction.

9. The machine of claim 7, wherein said plurality of transport units are configured to impart the shaking movement to respective filled containers simultaneously with the movement of respective transport units of the plurality of transport units in the transport direction.

10. A method for packaging single-dose soluble products in containers, comprising: filling the containers with a plurality of single-dose soluble products at a filling station, transferring the filled containers in a transport direction from the filling station to a processing station, performing one or more operations on the filled containers at the processing station, during the transferring, performing a shaking phase on at least one of the filled containers awaiting transfer to the processing station, wherein the transferring of the filled containers is carried out by a plurality of transport units transporting respective filled containers along a transfer line, and wherein the plurality of transport units are selectively actuated with an oscillatory movement to impart the shaking phase to the respective filled containers.

11. The method of claim 10, wherein said shaking phase is performed in at least two distinct moments.

12. The method of claim 10, wherein said shaking phase provides for simultaneously shaking two or more filled containers.

13. The method of claim 10, wherein said shaking phase is performed on at least one of said filled containers while being moved along an advancement path.

14. The method of claim 10, comprising a verification phase of a predefined distribution state of said single-dose soluble products in said filled containers by at least one sensor, wherein if the distribution state detected by said at least one sensor does not conform with said predefined distribution state, said shaking phase is performed.

15. The method of claim 10, wherein said at least one sensor is a level sensor configured to detect a filling level of said single-dose soluble products in said filled containers.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The present invention will now be described in detail with reference to the accompanying drawings, provided by way of non-limiting example, in which:

[0020] FIG. 1 is a schematic plan view of a machine according to the present invention,

[0021] FIG. 2 is a schematic perspective view of a transfer line indicated by arrow II in FIG. 1,

[0022] FIG. 3 is a schematic perspective view illustrating a shaking section of the transfer line, indicated by arrow III in FIG. 1,

[0023] FIGS. 4 and 5 are graphs showing possible position/time trends during the shaking phase,

[0024] FIG. 6 is a block diagram showing the sequence of steps of a possible application embodiment of the method according to the present invention, and

[0025] FIG. 7 is a schematic plan view of an embodiment of a machine for packaging single-dose soluble products in containers configured to implement a method according to the present invention.

DETAILED DESCRIPTION

[0026] With reference to FIGS. 1, 10 schematically indicates a machine for enclosing single-dose soluble products in containers.

[0027] The machine 10 includes a container input station 12. The containers 12 may be made of plastic or paper material. The container input station 12 may be fed by a box forming unit 40 configured to form cardboard boxes from flat blanks. The machine 10 includes a filling station 14 configured to fill containers C from the container input station 12 with a plurality of single-dose soluble products, such as single-dose capsules.

[0028] The machine 10 includes a processing station 16 configured to perform one or more operations on containers C filled at the filling station 14. The processing station 16 may be configured to seal containers C from the filling station 14.

[0029] The machine 10 includes an output station 18 for discharging sealed containers C. The output station 18 may include a conveyor belt 42 that receives sealed containers C from the processing station 16 and feeds them in an output direction.

[0030] With reference to FIGS. 1-3, the machine 10 includes a transfer line 20 configured to intermittently transfer containers C in a transport direction A from the container input station 12 to the output station 18 through the filling station 14 and the processing station 16.

[0031] The transfer line 20 includes a shaking section 22 configured to impart a shaking movement to at least one container C awaiting transfer to the processing station 16.

[0032] During high-speed intermittent transport and/or along curved sections from the filling station 14 to the processing station 16, the single-dose soluble products inside the containers are subject to inertial forces that may cause localized accumulations of capsules that could protrude beyond a maximum filling level of the container. Products protruding beyond the maximum filling level may fall outside the containers or may be crushed and damaged, even to the point of breakage, during the container sealing phase. Product damage could lead to performance degradation during use, resulting in end-consumer dissatisfaction. Product breakage during production phases would cause inefficient machine stoppages due to spillage of product contents, e.g., detergent, resulting in work area contamination.

[0033] Shaking containers C awaiting transfer to the processing station 16 allows for more uniform product distribution inside the containers, prevents product accumulations inside the containers, avoids the risk of product spillage during container transfer to the processing station 16, and the risk of product damage during the container sealing phase.

[0034] The shaking section 22 may be configured to impart successive shaking phases to at least one container C awaiting transfer to the processing station 16 at different sections of the transfer line 20.

[0035] Subjecting containers C to successive shaking phases improves product settling and uniformity degree inside containers C. Containers C can be oscillated repeatedly, thus allowing for lower oscillation intensity settings.

[0036] The shaking section 22 may be configured to impart a shaking movement to a plurality of containers C awaiting transfer to the processing station 16.

[0037] In particular, the shaking section 22 may be configured to impart a shaking movement to all containers awaiting transfer to the processing station 16.

[0038] The shaking section 22 may be configured to simultaneously impart a shaking movement to a predetermined number of containers C awaiting transfer to the processing station 16.

[0039] A position may be established beyond which all containers begin to oscillate. Before this position, the containers may be held stationary while waiting. This allows reducing the energy consumption of the machine 10.

[0040] In one possible embodiment, the machine 10 may include a sensor 24 configured to detect a product distribution geometry inside respective containers located in the shaking section 22.

[0041] The sensor 24, which may be an optical sensor, allows identifying which containers C to subject to a shaking movement based on the detected product distribution geometry.

[0042] The sensor 24 enables selecting which containers to shake for leveling the products inside them. This allows oscillating only the containers requiring product leveling, thereby reducing the machine's energy consumption.

[0043] With reference to FIG. 3, the transfer line 20 may include a plurality of transport units 26 movable along a closed-loop guide 28 and configured to transport respective containers C. The transport units 26 may be independently actuated by a linear motor 30 associated with the closed-loop guide 28.

[0044] The linear motor 30 independently activates the transport units 26 that carry containers C along the transfer line 20.

[0045] The transport units 26 may be selectively actuated with oscillatory movement to impart shaking to respective containers C. Thus, the same units that transport containers C can also produce the shaking of containers C. This avoids the introduction of external elements dedicated to producing the shaking movement.

[0046] The actuation of the transport units 26 by a linear motor 30 allows controlling the oscillations of each container C independently from other containers C.

[0047] The shaking section 22 may be located downstream of a curved section 32 of the transfer line 20. Indeed, it is very likely that high-speed movement of containers along a curved section will lead to product accumulations inside the containers due to centrifugal force. The arrangement of the shaking section 22 downstream of a curved section 32 of the transfer line 20 allows leveling the product accumulations generated by centrifugal force.

[0048] With reference to FIG. 3, the transfer line 20 may be configured to transport containers C with their major axes X parallel to the transport direction A. The transfer line 20 may be configured to impart to containers C a shaking movement along a direction parallel to the transport direction A. Thus, the container shaking movement occurs along the major axes of containers C, i.e., between the two most distant walls of containers C in the direction of their longer sides. This gives the products more space to level out inside containers C.

[0049] In a possible embodiment, the transport units 26 may be actuated to impart a shaking movement to respective containers C when the containers C are stationary in waiting positions, such as in buffer positions or in queue. In this case, the movement profile of the containers during the shaking phase is illustrated in FIG. 4, with the position of containers C oscillating around a waiting position (position in the graph).

[0050] In a possible embodiment, the transport units 26 may be actuated to impart a shaking movement to respective containers C simultaneously with the movement of containers C in the transport direction A. In this case, the movement profile of the containers during the shaking phase is illustrated in FIG. 5, where the position of containers C oscillates during their movement in the transport direction A.

[0051] With reference to FIG. 6, the present invention relates to a method for packaging single-dose soluble products 12 in containers 10, comprising a filling phase 110 where containers 10 are filled with defined quantities of single-dose soluble products 12 and at least one processing phase 130, subsequent to the filling phase 110, where one or more operations are performed on the filled containers 10. By defined quantities is meant a desired number of single-dose soluble products 12. For example, containers 10 may be filled with a desired number of single-dose soluble products 12 equal to ten products, preferably fifteen products, even more preferably twenty products. The operations performed on containers 10 in the processing phases 130 following the filling phase 110 may include, for example, quality control on the filling status of containers 10, or sealing of the filled containers 10.

[0052] The method includes at least one shaking phase 120 where at least one of said filled containers 10 is shaken before performing the subsequent processing phase 130 so that the single-dose soluble products 12 arrange themselves in containers 10 according to a predefined distribution state. Indeed, before shaking the filled containers 10, the single-dose soluble products 12 inside them may be arranged in a distribution state different from the predefined one. For example, before shaking, the single-dose soluble products 12 may be arranged inside containers 10 in a non-uniform and disordered manner, accumulating locally inside containers 10. In other words, before shaking, the filling level profile reached by the single-dose soluble products 12 might differ from the predefined one. For example, the filling level profile before shaking might differ from a substantially flat one. Performing shaking on filled containers 10 before the subsequent processing phase 130 advantageously ensures that the single-dose soluble products 12 contained therein are arranged according to a predefined distribution state and that the filled containers 10 are prepared for the subsequent processing phase 130. This is particularly advantageous because it allows performing the correction action for the arrangement of single-dose soluble products 12 while the next filled container 10 is in the processing phase 130, thus optimizing timing. Moreover, performing this shaking phase 120 before the subsequent processing phase 130 reduces the risk of jams or breakage of single-dose soluble products 12 due to their anomalous arrangement inside containers 10 on which the processing phase 130 is performed. In possible embodiments, the method may provide that the shaking phase 120 of filled containers 10 is performed in at least two distinct moments. Shaking filled containers 10 in at least two distinct moments allows performing an overall shaking of longer duration compared to shaking performed in a single moment, thus ensuring that the single-dose soluble products 12 arrange themselves inside containers 10 according to the predefined distribution state. Moreover, if the distribution state of single-dose soluble products 12 inside containers 10 is altered between one moment and another, performing shaking in at least two distinct moments allows restoring the predefined distribution state previously obtained.

[0053] According to possible embodiments, shaking may be performed at two distinct points along the conveying system 18. For example, shaking of containers 10 may be performed during the filling phase 110 of containers 10 at the filling station 20 and then subsequently, before the filled containers 10 reach the subsequent processing station 22. Shaking filled containers 10 at at least two distinct points along the conveying system 18 allows performing an overall shaking of longer duration compared to shaking performed at a single point, thus ensuring that the single-dose soluble products 12 arrange themselves inside containers 10 according to the predefined distribution state. Moreover, if the distribution state of single-dose soluble products 12 inside containers 10 is altered between one point and another along the conveying system 18, performing shaking at at least two distinct points allows restoring the predefined distribution state previously obtained.

[0054] According to possible embodiments, two or more shakings may be performed on the same filled container 10 at different instants in time. Shaking filled containers 10 at at least two different instants in time allows performing an overall shaking of longer duration compared to shaking performed at a single instant, thus ensuring that the single-dose soluble products 12 arrange themselves inside containers 10 according to the predefined distribution state. Moreover, if the distribution state of single-dose soluble products 12 inside containers 10 is altered between one instant and another, performing shaking at distinct instants in time allows restoring the predefined distribution state obtained at a previous instant in time.

[0055] According to possible embodiments, two or more shakings may be performed on the same filled container 10, stationary in the same position along the advancement path PA, at different instants in time. A filled container 10 may remain stationary in the same position along the advancement path PA while waiting for the subsequent processing station to become available. Performing shaking on filled containers 10 while stationary in the same position along the advancement path PA thus allows effectively utilizing moments that would otherwise be unproductive.

[0056] In possible embodiments, the method may provide that the shaking phase 120 occurs simultaneously on two or more filled containers 10. This way, it is possible for single-dose soluble products 12 to arrange themselves according to a predefined distribution state simultaneously in two or more filled containers 10, obtaining a significant benefit on the overall execution times of packaging the single-dose soluble products 12. This simultaneous shaking of two or more filled containers 10 may occur regardless of whether there are one or more filled containers 10 on each mobile element of the conveying system 18. In this way, the method allows, for example, performing the shaking phase 120 simultaneously on multiple filled containers 10.

[0057] In possible embodiments, the method may provide that the shaking phase 120 is performed on filled containers 10 while they are being moved along the advancement path PA. This way, the method allows performing shaking and movement of filled containers 10 in parallel, obtaining a significant benefit on the overall execution times of packaging the single-dose soluble products 12.

[0058] In possible embodiments, the method may include a verification phase 140 of the distribution state of single-dose soluble products 12 inside containers 10 by at least one sensor 14.

[0059] In possible embodiments, the method may include a verification phase 140 of the distribution state of single-dose soluble products 12 inside containers 10 by at least one sensor 14, wherein if the distribution state detected by the sensor 14 does not conform to a predefined distribution state, the shaking phase 120 is performed. This way, the method allows selectively subjecting only those filled containers 10 to shaking where the single-dose soluble products 12 are arranged in a distribution state different from the predefined one. This selective shaking, limited only to filled containers 10 where the single-dose soluble products 12 are arranged differently from the predefined state, enables energy savings compared to situations where all containers 10 are subjected to shaking. For example, the sensor 14 may be a level sensor configured to detect the filling level reached by single-dose soluble products 12 inside containers 10 during the filling phase 110.

[0060] In possible embodiments, filled containers 10 may be subjected to shaking if the sensor 14 detects that the single-dose soluble products 12 inside them are arranged in a distribution state different from the predefined one. Indeed, according to the present invention, filled containers 10 may be subjected to shaking when the sensor 14 detects a filling coefficient lower than a predetermined first threshold value and, alternatively or in combination, that the level reached by single-dose soluble products 12 inside containers 10 is higher than a predetermined second threshold value.

[0061] In possible embodiments, the method may provide that the shaking phase 120 is performed by independently movable carts 16. This way, it is possible to shake filled containers 10 selectively. Selective shaking of filled containers 10 also allows diversifying the shaking phases 120 for different filled containers 10. For example, it is possible to diversify the oscillation amplitudes of the vibration applied to filled containers 10. Similarly, the duration of shaking phases 120 may be diversified for different filled containers 10. In possible applications, thanks to independently movable carts 16, the shaking phase 120 may be performed at different times and/or at different positions along the advancement path PA. All these differentiation modes may be considered alternatively or in combination.

[0062] The method may provide that one or more filled containers 10 are waiting to reach a subsequent processing station 22 because the latter is still engaged in performing the processing phase 130 on at least one other filled container 10. Performing shaking on filled containers 10 waiting along the advancement path PA to reach a subsequent processing station 22 allows effectively utilizing moments that would otherwise be unproductive.

[0063] In possible embodiments, the method may provide that the shaking phase 120 is performed on one or more filled containers 10 while they are waiting for a processing phase 130 to be completed on at least one other filled container 10. This aspect advantageously allows utilizing idle times of filled containers 10 waiting to position themselves at processing stations occupied by other containers 10 to perform one or more respective shaking phases 120 for each waiting filled container 10.

[0064] The distribution of single-dose soluble products 12 inside containers 10 may be influenced by the shape of the advancement path PA of containers 10 in the automatic machine 11. In particular, single-dose soluble products 12 inside containers 10 may be subject to inertial forces and/or undesired stresses generated by the movement of filled containers 10 along the advancement path PA. Such undesired inertial forces may be generated, for example, by the movement of filled containers 10 along curved sections of the advancement path PA. According to possible embodiments, these undesired inertial forces could also compromise the predefined distribution state of single-dose soluble products 12 inside containers 10 obtained, for example, through a previous shaking phase 120.

[0065] In possible embodiments, the method may provide that the shaking phase 120 is performed on at least one of the filled containers 10 after passing at least one curved section along the advancement path PA. This way, the method advantageously allows obtaining the predefined distribution state of single-dose soluble products 12 in containers 10 altered due to the shape of the advancement path PA and the consequent alteration of the distribution state.

[0066] In possible embodiments, the method may provide that the shaking phase 120 is performed along a shaking direction passing through the two opposite side walls of containers 10 that are farthest apart. This way, the method advantageously allows utilizing the larger dimension of container 10 to arrange the single-dose soluble products 12 contained therein according to the predefined distribution state. Indeed, by exploiting the larger dimension of container 10, single-dose soluble products 12 have more space to move during shaking to arrange themselves according to the predefined distribution state compared to the space they would have along the remaining dimensions of container 10.

[0067] In possible embodiments, one or more shaking phases 120 may be performed on filled containers 10 between two successive processing phases 130.

[0068] In possible embodiments, the method may include two distinct filling phases 110 of containers 10.

[0069] In possible embodiments, the method may include at least a first and a second filling phase 110.

[0070] Naturally, while maintaining the principle of the invention, construction details and embodiments may be widely varied without thereby departing from the scope of the invention as defined by the following claims.