High-speed twin aseptic pack packaging machine for liquid products

Abstract

HIGH-SPEED TWIN ASEPTIC PACK PACKAGING MACHINE FOR LIQUID PRODUCTS A high-speed aseptic pack packaging machine (100) for forming a plurality of sealed packages (P1, P2) filled with a pourable food product comprising a plurality of independent transfer paths (200PP, 220PP), a plurality of strip applicator units (9, 59), a plurality of vertical heads (200, 220), a plurality of final folder assembly (290, 300), an output feed (400), a plurality of service units (201, 221), an integrated PLC (320) and an HMI panel (500); wherein, an integrated pneumatic air panel (202) and an integrated water panel (208) are provided in any one of the service units (201 or 221) and an integrated hydraulic power pack (222) is provided in the service unit (221 or 201) not having the integrated air panel (202) and the integrated water panel (208) of the aseptic pack packaging machine (100). FIG. 1

Description

FIELD OF THE INVENTION

[001] The present invention relates to a packaging machine for filling liquid and other pourable foodproducts. More particularly the invention relates to a continuous high speed vertical form-fill-sealmachine with a center seal strip for vertical sealing, an induction sealing arrangement for crosssealing of the pack, with a compact structure, enhanced rate of production and lower powerconsumption.BACKGROUND OF THE INVENTION

[002] Milk and Juices are usually packaged in containers or packs. These types of packs are normallyproduced on fully automatic packaging machines, which advance a web of packaging substratethrough a sterilization unit. Then, the sterilized web is enclosed and advanced within an isolatedclosed area which has a sterile environment for the packaging and filling of the product. When apack or container is formed from a packaging web substrate, the web is folded and sealed verticallyto form a tube, which is further fed downwards for product filling and cross sealing.

[003] Said tube is filled with the desired liquid food product and divided into individual pack byrepeated cross seals at a predetermined distance from each other. These packs are separated fromthe tube by a cut along the cross seals and desired shape on top and bottom of the pack is given bya folder assembly, generally a parallelepiped by folding along the creased lines formed inthe packaging web.

[004] The machine described above produces a single line of tube at a time. Since an aseptic packpackaging machine of this segment produces N number of packs per hour and to make productiondouble, it is required to have two separate machines with all utilities individually provided to eachmachine. This idea is not very economical since it requires a large area to install two machines andtwo sets of utilities to operate both the machines.

[005] Thus, there is a need for a packaging machine which has a higher production rate, whichsignificantly reduces manufacturing cost of machines and power consumption. The conventionalmachine has a speed of approx. 10,000 packs / hour.

[006] The main advantage of the present invention is to provide a packaging machine capable ofproducing approx. 20,000 packs / hour while consuming less power and space. Another advantageof the present invention is to provide a packaging machine capable of producing approx. 50,000packs / hour. The footprint of the present invention saves significant floor space.OBJECT OF THE PRESENT INVENTION

[007] It is an object of the present invention is to provide an aseptic pack packaging machine havingat least a pair of vertical heads which can be operated separately or simultaneously.

[008] It is another object of the present invention is to provide an aseptic pack packaging machinewhich can save air and energy consumption.

[009] It is another object of the present invention is to provide an aseptic pack packaging machinewith a small footprint and higher productivity.

[0010] It is another object of the present invention is to provide an aseptic packaging machine withthe capability of packing different volume sizes or same volume size, simultaneously or a singlevolume size on any one of the vertical heads.

[0011] It is another object of the present invention to provide an aseptic packaging machine whichcan use the same type of laminate on plurality of vertical heads or different type of laminates withdifferent packaging on either vertical head.

[0012] It is another object of the present invention to provide a packaging machine capable ofproducing approx. 20,000 packs / hour while consuming less power and space.

[0013] It is another object of the present invention to provide a packaging machine capable ofproducing approx. 50,000 packs / hour while consuming less power and space.

[0014] It is another object of the present invention to provide a packaging machine capable of nonaseptic packaging for products which are self-sterilizable like alcoholic beverages etc. by changinga few components of the pack packaging machine.

[0015] Still other objects and advantages will become apparent from a review of the followingdescription of a preferred embodiment of the present invention.SUMMARY OF THE PRESENT INVENTION

[0016] The present invention is directed towards a high speed aseptic pack packaging machinehaving a plurality of machine frames, for forming a plurality of sealed packages filled with apourable food product from packaging laminate, comprising a plurality of transfer paths, a pluralityof strip applicator units, a plurality of vertical heads, a plurality of final folder, an output feed, aplurality of service units, an integrated PLC and a HMI panel for controlling the various units of theaseptic pack packaging machine by a operator.

[0017] To perform a task using pneumatics, there needs to be a way to initiate, monitor, and stopthe process. The electro-pneumatic systems integrate pneumatic and electrical functions into onesystem where the signal or control medium is electrical, and the working medium is compressed air.In this type of system, devices like relays, solenoid valves, limit switches, and PLC are used tointerface electrical control with pneumatic action.

[0018] According to the present invention, an integrated pneumatic air panel and an integrated waterpanel are provided in any one of the service units of the vertical heads and an integrated hydraulicpower pack is provided in the other service unit of the other vertical head not having the integratedair panel (202) and the integrated water panel (208) of the aseptic pack packaging machine.

[0019] According to the present invention the pneumatic air panel is provided for the actuation ofpneumatic cylinders of the machine and the integrated water panel is provided to control flow ofchilled water of temperature 12~20 0C for cooling at various locations in the machine such as to coolcross sealing inductors, servo motors and for sprinkler and water ring air compressor to producesterile air. Further, the integrated hydraulic power pack is provided to actuate the hydraulic cylindersor other components offering high pressure required like in cross sealing. The control signals aregiven by the integrated PLC for the selected vertical head's setup, operation and control.

[0020] Each vertical head comprises a forming and filling unit and a cross sealing jaw unit toadvance the reels of packaging laminate in an independent transfer path for forming packagesrespectively. Each vertical head has its respective forming and filling units, which can operateseparately or simultaneously.

[0021] According to the present invention, a web or laminate is formed into a tube at its respectiveforming and filling unit as it is transferred along a transfer path which comprises a plurality ofbending rollers, a sterilization bath unit, a vertical hot air sealing system, whereby the vertical sealingsystem comprises a hot air nozzle which comes into contact with the laminate during sealing by hotair and pressing, in the vertical direction, along the transfer paths thereby forming a tube. The tubeis further fed along a vertical advancing direction for product filling and cross sealing.

[0022] The cross-sealing jaw unit of each vertical head of the present invention is a pair of crosssealing jaws, each vertical head has its respective jaws, which open and closes, and moves withsequential and cyclic manner in the vertically downwards transfer direction of the formed tube oflaminate up to a desired fixed length which is correlated with sealing time of laminate. Two pairs ofguide pillars are mounted on the main body of the packaging machine and help the cross-sealingjaws configured with induction heating means, to move in fixed condition while sealing the laminatein a direction parallel to the web transfer route is configured for sealing the moving web inlongitudinal direction to form tube from the web.

[0023] The cross-sealing jaws press laminate tube by moving towards each other and move awayfrom each other in sequential and cyclic manner. The cross-sealing jaws cyclic movement is drivenby an actuating means. The actuating means may be mechanical, electrical, pneumatic, rotary,hydraulic or any other actuating mechanism known in the art. The cyclic motion generated by theservo driven motor, mounted on the main body of the packaging machine, the cross-sealing deviceto move along with the sealed web downwards in closed condition and then moving upward slightlyto make the brick shape and again come down in the direction of web. The operating velocities ofthe devices are accelerated, decelerated, and again accelerated to make the desired pack.

[0024] According to the present invention, each vertical head is provided with a capability ofpackaging different volume sizes simultaneously, or same volume sizes simultaneously or any onehead can also be operated individually using the integrated air panel, integrated water panel and theintegrated hydraulic power pack, with the help of the HMI panel by the operator.

[0025] The present invention can use the same type of laminate on either or both the vertical headsand different types of laminates with different printed matter, on each head.

[0026] Thus, the present invention provides an improved aseptic pack packaging machine for liquidproducts, with higher production rate, space saving structure while meeting all the technicalrequirements, saving air and energy consumption. Further, the present invention also provides apackaging machine capable of non-aseptic packaging for products which are self-sterilizable likealcoholic beverages etc. by changing a few components of the aseptic pack packaging machine.BRIEF DESCRIPTION OF THE DRAWINGS

[0027] FIG. 1 shows an isometric view of an aseptic pack packaging machine in accordance with anexemplary embodiment of the present invention;

[0028] FIG. 2 shows an exploded isometric view of various units in accordance with an exemplaryembodiment of the present invention;

[0029] FIG. 3 shows paper paths for both the vertical heads in accordance with an exemplaryembodiment of the present invention;

[0030] FIG. 4 shows an integrated pneumatic air panel with an integrated water panel and anintegrated hydraulic power pack in accordance with an exemplary embodiment of the presentinvention;

[0031] FIG. 5 shows an isometric view of the integrated pneumatic air panel in accordance with anexemplary embodiment of the present invention;

[0032] FIG. 6 shows an isometric view of the integrated water panel in accordance with anexemplary embodiment of the present invention;

[0033] FIG. 7 shows an isometric view of the integrated hydraulic power pack in accordance withan exemplary embodiment of the present invention.DETAILED DESCRIPTION OF THE PRESENT INVENTION

[0034] For a thorough understanding of the invention, reference is to be made to the followingdescription in connection with the above-mentioned drawings. Although the invention is describedin connection with exemplary embodiments, the invention is not intended to be limited to the specificforms set forth herein. It is understood that various omissions and substitutions of equivalents arecontemplated as circumstances may suggest or render expedient, but these are intended to cover theapplication or implementation without departing from the spirit or scope of the invention. Further,it will nevertheless be understood that no limitation in the scope of the invention is thereby intended,such alterations and further modifications in the figures and such further applications of theprinciples of the invention as illustrated therein being contemplated as would normally occur to oneskilled in the art to which the invention relates.

[0035] In other instances, detailed descriptions of well-known methods, layout and procedures, anddevices are omitted so, not to obscure the description of the present invention with unnecessarydetail. Also, it is to be understood that the phraseology and terminology used herein is for the purposeof description and should not be regarded as limiting. Further, reference herein to "one embodiment"or "an embodiment" means that a particular feature, characteristic, or function described inconnection with the embodiment is included in at least one embodiment of the disclosure.Furthermore, the appearances of such phrase at various places herein are not necessarily all referringto the same embodiment. The terms "a" and "an" herein do not denote a limitation of quantity, butrather denote the presence of at least one of the referenced item. The terms "pack" and "package"used herein have the same meaning.

[0036] Further, "plurality" can be more than one, two, three or more, however, the preferredembodiment of the present invention is explained with respect to "two transfer paths for forming thepackages" for understanding.

[0037] For reference purposes and to explain the preferred but not limited embodiment of the presentinvention, reference numerals in brackets separated by the commas (_, _) are used to refer to therespective unit of the vertical heads of the machine.

[0038] Further, many of the mechanisms which are to be described are identical on the other verticalhead. Now different embodiments of the present invention will be described in light of the drawingsof the present invention.

[0039] FIG. 1 & 2 show an assembled and exploded view of an aseptic pack packaging machine(100) having a plurality of machine frames (110, 120), for liquid products in accordance with thepresent invention. The aseptic pack packaging machine (100), comprising a plurality of transferpaths (200PP, 220PP), a plurality of strip applicators (9, 59), a plurality of vertical heads (200, 220),a plurality of final folder units (290, 300), an output feed (400), a plurality of service units (201,221), an integrated PLC (320) and an HMI panel of the aseptic pack packaging machine (100). Thefinal folder units (290, 300) to give desired shape to plurality of packages (P1, P2). Further, theoutput feed (400) is provided for the vertical heads (200, 220) to collect the final packages (P1, P2).The HMI panel (500) is provided to digitally control the operations and set parameters on themachine.

[0040] According to the present invention each vertical heads (200, 220) comprising a plurality oftube forming and filling units (250, 260) to form plurality of tubes (T1, T2) from a plurality of reel(R1, R2) of packaging laminate (1, 51), a plurality of cross sealing jaw units (270, 280) to crosssealing the plurality of tubes (T1, T2) to form plurality of packages (P1, P2). Each cross sealing jawunit (270, 280) comprises a pair of Forming and cross sealing assembly (A, A') and (B, B')respectively for forming and cross sealing of the tube |(T1, T2) using an induction sealing. Further,each Forming and cross sealing assembly (A and A') of cross sealing jaw unit (270) comprises apair of cross sealing jaws i.e. front and rear cross sealing jaws (27, 27') for cross sealing the tube(T1). Similarly, each Forming and cross sealing assembly (B and B') of cross sealing jaw unit (280)also comprises a pair of cross sealing jaws i.e. front and rear cross sealing jaws (77, 77') for crosssealing the tube (T2). The rear cross sealing jaws (27, 77) have an inductor for heating by inductionfor heat sealing and front cross sealing jaws (27' 77') comprise a polymer pad for cushioning effect.

[0041] FIG. 3 shows a schematic view of paper path (200 PP, 220 PP) for forming the packs (P1,P2) from plurality of reel (R1, R2) of packaging laminate (1, 51) loaded on un-winders, accordingto an embodiment of the present invention. Two independent transfer paths (200PP, 220PP) forlaminate (1, 51) lead to forming the packages (P1, P2). Both the reels of packaging laminate (1, 51)may be same or different in terms of structure, printing or width, based on the requirement.

[0042] Further, the plurality of forming and filling units (250, 260) comprise vertical hot air sealingdevices (not shown in figure) comprising a hot air nozzle with a guide for Longitudinal seal (LS)strip (7, 57) for vertical sealing by hot air and pressing, in the vertical direction, along the transferpath (200PP, 220PP) to form the laminate tube (T1, T2).The cross sealing jaw units (270, 280) crossseals the tubes (T1, T2) to form the pack (P1, P2) by means of induction heating and pressing. Theprocess is explained later in detail.

[0043] FIG. 4 shows the preferred but not limited configuration of the present invention, the serviceunit (201) comprises the integrated pneumatic air panel (202) and the integrated water panel (208)and the other service unit (221) comprises the integrated hydraulic power pack (222), to feedlaminate (1, 51) and control various operations along both or any one of the transfer paths (200PP,220 PP).

[0044] FIG. 5 shows a front and an isometric view of the integrated pneumatic air panel (202) ofthe present embodiment. The integrated pneumatic air panel (202) of the present invention isconfigured preferably but not limited, in the service unit (201). The integrated pneumatic air panel(202) comprises at least one or a combination of the plurality of an air filter, regulator & lubricatorunit (203), a plurality of solenoid valves (204), a plurality of flow meters (205), a plurality ofpressure regulators (206), a plurality of pressure gauges (207) and other circuitry components inaccordance with the present invention. The integrated pneumatic air panel (202) is provided foractuation of various pneumatic cylinders and other components for the operation of the aseptic packpackaging machine (100). Pneumatic air is supplied by the pneumatic air panel (203) to actuate thepneumatic cylinders and other pneumatically operated devices to perform various operations alongthe transfer paths (200PP, 220PP) from laminate roll (R1, R2) feeding till discharge of final asepticpacks (P1, P2). This pneumatic air is also used in the LS nozzles (23, 73) for hot air vertical sealing.

[0045] Further, compressed air flows through multiple devices, components, pipes, and fittings thatcan add particulates, oil, and moisture. Even though the compressor includes an air dryer, filter,water separator and regulator, the air should still be prepared at the machine before it is used. Thiscompressed air is supplied to the air filter, regulator & lubricator assembly or FRL (203) in theintegrated pneumatic air panel (202) where it filters the air and the pressure of the air is alsoregulated.

[0046] According to another embodiment, sterile air, nitrogen or any inert gas can also be used.

[0047] The pneumatic air panel (202) comprises a plurality of solenoid valves (204), which arecontrolled by the integrated PLC (320). The flow meters (205) are provided to read the flow of airthrough the circuit to set and monitor operation of the machine (100). Further, the integratedpneumatic air panel (202) comprises the pressure regulators (206) which further comprises thepressure regulators (206) having pressure switch and pressure regulators (206) having precisionpressure regulators with pressure switch and precision valves to reduce and regulate the pressure ofthe air through multiple circuits, as per desired value.

[0048] According to the preferred but not limited embodiment of the present invention, six lines areprovided to install six air pressure regulators at the desired pressure level in each line.According to the present invention, the desired pneumatic pressure for the actuation of the pneumaticcomponents is approx. 6 bar.

[0049] Further, according to another embodiment of the present invention, the integrated pneumaticair panel (202) comprises of valves assemblies, which may work on Ethernet / Profibus protocols / Interface. Further a plurality of prepositional regulators may be provided which may be connectedthrough IOT based application for remote monitoring and maintenance purpose.

[0050] According to the present invention, the integrated pneumatic air panel (202) of service unit(201) of the vertical head (200) is designed in such a way that any or both the vertical heads (200,220) of the aseptic pack packaging machine (100) can be operated individually as wellsimultaneously as per the requirement and can be selected by the HMI panel (500).

[0051] In a preferable embodiment of the invention, the integrated pneumatic air panel (202) isprovided for the various compressed air-based operations along both or any one of the transfer paths(200PP, 220PP).

[0052] FIG. 6 shows a front and an isometric view of the integrated water panel (208) in accordancewith the present invention. The integrated water panel (208) is configured, preferably but not limited,in the service unit (201). Further, the integrated water panel (208) is configured preferably alongwith the integrated pneumatic air panel (202).

[0053] The integrated water panel (208) comprises a plurality of solenoid valves (209), a pluralityof flow meters (210), a plurality of pressure gauges (215), a plurality of ball valves (211), a pluralityof strainers (212) and other circuitry components in accordance with an embodiment of the presentinvention.

[0054] The integrated water panel (208) is provided to control flow of chilled water of temperature12~20 0 10 C for cooling at various locations in the machine such as to cool cross sealing inductors,servo motors and for sprinkler and water ring air compressor to produce sterile air in the asepticpack packaging machine (100).

[0055] The integrated water panel (208), as shown in FIG. 6, is provided with filters to remove dirt,and other particulate contamination from water for circulation.

[0056] The integrated water panel (208) provides flow control in different circuits by using theplurality of solenoid valves (209). The solenoid valve (209) uses an electrical coil which actuates orenergizes the selected valve for the designated operation.

[0057] The plurality of flow meters (210) are provided to check the flow rate of the water in a circuit.The plurality of pressure regulators (214) are provided to regulate the pressure of the water indifferent circuits to maintain pressure as per the requirement.

[0058] FIG. 7 shows an isometric view of the integrated hydraulic power pack (222) of the presentinvention. According to preferred but not limited embodiment of the present invention, theintegrated hydraulic power pack (222) is provided in the service unit (221). The integrated hydraulicsystem (222) is provided to operate any one or both the vertical heads (200, 220) of the aseptic packpackaging machine (100).

[0059] The integrated hydraulic power pack (222) comprises hydraulic pump and motor, pressurerelief valve, solenoid valves or actuators and other circuitry components, to provide high pressurehydraulic fluid to drive cylinders through connecting hoses or pipes during the cross sealing by crosssealing jaw units (270, 280) and other operations as required, which is controlled by the integratedPLC (320) of the machine (100).

[0060] The plurality of actuators is actuated by a low amount of energy, however, these actuatorscontrol a very high pressure in the hydraulic system (222). Thus, the high-pressure hydraulic fluidactuates the hydraulic cylinders or other components offering high pressure required like in crosssealing.

[0061] Further, the integrated hydraulic Power pack (222) is provided to operate cross sealing jaws(270, 280) to perform cross sealing of laminate tubes (T1, T2) and actuate the cutting knife to packs(P1, P2) along both or any one of the transfer paths (200PP, 220PP).

[0062] The advantage of the present embodiment and the integrated hydraulic power pack (222) ofthe present invention as shown in FIG. 7 can be better understood by the following example.

[0063] For example, in the case of two conventional machines, two motors with total 4 HP powerare required for operating both systems. However, according to the present invention (100), thehydraulic power pack (222) requires only one 3 HP motor to operate pair of vertical heads (200,220) of aseptic pack packaging machine (100), thus the present invention saves 1 HP powerrequirement. Further, in a conventional version, filter, check valve, pressure relief valve, pressurereducing valve, manifold & heat exchanger is required in double quantity, each operating foroperating the two separate machines. On the other hand, the aseptic pack packaging machine (100)of the present invention requires components like filter, check valve, pressure relief valve, pressurereducing valve, manifold & heat exchanger etc., only in a single quantity for operating the verticalheads (200, 220) simultaneously as well as individually of the present invention (100). Thus, thepresent invention (100) saves one quantity for each of these components, thus reducing the overallmachine manufacturing, operating and maintenance cost.

[0064] The present invention is directed towards a high-speed aseptic pack packaging machine (100)as shown in FIG. 1 & FIG. 2, to form a plurality of sealed packages (P1, P2) filled with a calibratedquantity of pourable product, from a plurality of reel (R1, R2) of packaging laminate (1, 51) alongthe respective transfer paths (200 PP, 220 PP) according to the present invention.

[0065] FIG. 3 shows the transfer paths (200 PP, 220 PP) for the pair of vertical heads (200, 220) forforming the packs (P1, P2) from the pair of reels (R1, R2) of packaging laminate (1, 51) loaded atrespective un-winders, according to the present invention.

[0066] According to the present invention, the desired vertical head (200, 220) either one or both,are selected as per the requirement through the HMI panel (500) by the operator. Further, the centerstrip which is used for longitudinal seal is LS strip (7, 57).

[0067] According to an embodiment, both the vertical heads (200, 220) are operating. Each paperpath (200PP, 220 PP) of the present invention comprises a plurality of forming and filling unit (250,30 260) which are configured to advance the respective reel (R1, R2) of packaging laminate (1, 51)with a plurality of rollers like a paper guide roller (2, 52), a power feed roller (3, 53), a dancing roller(4, 54), another bending roller (5, 55) to advance and bend the reel of packaging laminate (1, 51)and a pair of marking units (6, 56) to print the details.

[0068] Further the paper path (200PP, 220 PP) of the respective vertical heads (200, 220) comprisesa strip applicator (9, 59) which further comprises a Longitudinal seal (LS) strip reel (7, 57) toperform the vertical sealing and a splicing unit (8, 58) for continued uninterrupted supply of the LSstrip (7, 57), which apply the LS strip, preferably made of LDPE or LLDPE, along the one edge ofthe packaging laminate (1, 51) from the inside by the induction sealing method. Only a half widthof the LS-strip (7, 57) seals with the edge of the packaging laminate (1, 51) and the other half willbe sealed to the other edge later, when the packaging laminate (1, 51) is formed into a tube (T1, T2).A plurality of bending rollers (10, 60), (11, 61) to advance the packaging laminate and then thepackaging laminate (1, 51) of reels (R1, R2) are fed through an aseptic chamber for sterilization.

[0069] Each paper path (200PP, 220PP) comprises a sterilization bath unit (12, 62) and a cover (13,63) for sterilization bath to make the inner environment suitable for sterilization which is performedby applying a sterilizing agent such as hydrogen peroxide or nitrogen peroxide solution or any othermean, which is subsequently evaporated by heating by means known in the art. Sterilization of thelaminate by hydrogen peroxide and system sterilization by sterile air and hydrogen peroxide sprayare required. The flow of sterile air is needed to maintain aseptic conditions and for hot air sealingwhich are fully controlled. An aseptic environment around the sterilized laminate is maintained withan overpressure of heat sterilized air.

[0070] According to the present invention the overpressure in the aseptic environment is preferablyaround +20 to +40 mmWC (1.96 millibar to 3.92 millibar). This pressure is maintained as a positivepressure to avoid entry of the atmospheric air into the chamber.

[0071] Each Transfer route (200PP, 220PP) further comprises a calender roller (14, 64) to smoothenthe packaging laminate (1, 51), an air knife (15, 65) to remove residual sterilizing agent fromlaminate's surface, a bending roller (16, 66) (driven) and another bending roller (17, 67) are providedfor smooth transfer of the laminate (1, 51) along the path (200PP, 220PP).

[0072] A pair of upper forming rings (18, 68), a crease roller (19, 69) provided to ensure the creasesare formed for the pack's (P1, P2) final shape, and a pair of movable forming rings (20, 70) areprovided along each transfer route (200PP, 220PP). Further, the upper forming ring (18, 68), themovable forming rings (20, 70) and a pair of lower forming rings (25, 75) are provided to pinch andfold the respective laminate (1, 51) there between and seal the longitudinal joining edges of thepackaging laminate (1, 51) at respective transfer path (200PP, 220 PP) of vertical heads (200, 220).

[0073] Each transfer route (200PP, 220 PP) comprises a vertical hot air sealing device (not shown),comprises hot air nozzles i.e., a LS Nozzle (23, 73), a LS short stop nozzle (24, 74), through whichhot air is sprayed for sealing, which comes in contact with the edges of the packaging laminate (1,51) during the hot air sealing, in the vertical direction thereby forming a continuous tube (T1, T2).The center seal strip (LS Strip) (7, 57) overlaps the laminate edges along the longitudinal sealing,thus ensure leak proof longitudinal seal and covered cross section of laminate edge inside the formedtube.

[0074] The Filler tubes (21, 71) are provided for each forming and filling unit (250, 260) in thevertical heads (200, 220) to fill the liquid product in the respective tube (T1, T2). Liquid product tobe packaged is supplied by an external product storage tank having conveying system to fill acalibrated quantity of product into the filler tubes (21, 71), at an appropriate over-pressure i.e.approx. +20 to +40 mmWC (1.96 millibar to 3.92 millibar), which is maintained in the asepticchamber through the filtered compressed air coming from integrated pneumatic air panel (202).Further, each transfer path (200PP, 220PP) comprises a pair of divided forming rings (22, 72), todivide each pack (P1, P2) as per the length according to the volume, as set earlier.

[0075] A pair of tube support rollers (26, 76) in each transfer path (200PP, 220PP) are provided tokeep the respective tube in place while the product is filling and tube is moving downwards.

[0076] Now the filled tube (T1, T2) moves downwards along the respective transfer path (200PP,220PP) and comes in the cross sealing assembly (270, 280). Each cross sealing jaw unit (270, 280)comprises a pair of Forming and cross sealing assembly (A, A') and (B, B') for the forming andcross-sealing of the tube (T1, T2) using an induction sealing respectively. Further, each Formingand cross sealing assembly (A and A') of cross sealing jaw unit (270) comprises two cross-sealingjaws (27, 27') as front and rear cross sealing jaws (27, 27'). Similarly, each Forming and crosssealing assembly (B and B') of cross sealing jaw unit (280) also comprises two cross sealing jaws(77, 77') as front and rear cross sealing jaws. The rear cross sealing jaws (27, 77) of (A, A') (B, B')have the inductor for heating by induction for heat sealing and front cross sealing jaws (27' 77') of(A, A') (B, B') comprise a polymer pad for cushioning effect. Each pair of jaws (27, 27') (77, 77')of forming and sealing assemblies (A, A') (B, B') of (270, 280) respectively opens and closes inperpendicular direction to the downwards movement of formed tube (T1, T2) and each pair of jaws(27, 27') (77, 77') also moves in a sequential and cyclic manner, in the downwards transfer directionof the formed tube (T1, T2) up to fixed length depending upon the desired pack height. Further, eachpair of forming and sealing assembly (A, A') (B, B') comprises a pair of volume flaps (not shown),which forms the initial shape of the pack based on volume. The integrated water panel (208) provideschilled water circulation for water spray before the cross sealing, through inductors for cross sealing,servo motor cooling and water ring vacuum pump.

[0077] Two pair of guide pillars (not shown) are mounted on the main body of the machine (100)and helps the cross sealing jaw unit (270, 280), to move in fixed path, while sealing the laminate (1,51) in a direction perpendicular to the downwards web transfer, to seal the formed tube (T1, T2) andsimultaneously cut in the middle of the cross sealed band on the formed and filled tube (T1, T2), toseparate each pack (P1, P2).

[0078] Further, the cyclic motion generated by the servo motor mounted on the main body of thepackaging machine (100), each cross sealing jaw unit (270, 280) is configured to move along withthe sealed laminate downwards in closed condition as shown in forming and cross sealing assemblies(A, B) of (270, 280) and then moving upward slightly as shown in forming and cross sealingassemblies (A', B') of (270, 280) to make the initial shape by volume flaps (provided in formingand cross sealing assemblies) and again come down in the direction of laminate. The operatingvelocities of the devices are accelerated, deaccelerated, and again accelerated by servo drivenmechanism to make the desired pack.

[0079] In preferable embodiment of the present invention, the integrated hydraulic power pack (222)is provided to operate cross sealing jaw units (270, 280) to perform cross sealing of laminate tubes(T1, T2) and actuate the cutting knife to separate the formed packs (P1, P2) along both or any oneof the transfer paths.The cross sealed tube (T1, T2) cut the middle of cross sealed band and movesalong the transfer path (200PP, 220PP) which further comprises a pair of final folder assembly (290,300) for vertical heads (200, 220) respectively. Each final folder (290, 300) comprises a final folderstation chain (28, 78) to shape the package (P1, P2). The package (P1, P2) moves to the final folderstation chain (28, 78) respectively, to fold fins and flaps on top and bottom of the packs (P1, P2) ofthe aseptic pack packaging machine (100). The final packs (P1, P2) can be withdrawn from thecommon outfeed (400) of the packaging machine (100) and conveyed further for sorting andpacking. Further, top and side squeezing of packages (P1, P2) is performed mechanically by pressuredevice and pull-down device. The final folder (290, 300) works in indexing mode.

[0080] According to an embodiment, the integrated pneumatic air panel (202) and the integratedwater panel (208) are provided in any one of the service units (201 or 221) and the integratedhydraulic power pack (222) is provided in the service unit (221 or 201) not having the integrated airpanel (202) and the integrated water panel (208), to operate the packaging machine (100).

[0081] According to the present invention, to make the packaging machine (100) compact in sizeand to reduce the energy consumption, the integrated pneumatic air panel (202) along with theintegrated water panel (208) may be configured in any one of the service units (201 or 221).Similarly, the integrated hydraulic power pack (222) may be configured in either service units (201or 221) of the aseptic pack packaging machine (100) of the present invention which does notcomprise the integrated pneumatic air panel (202) and the integrated water panel (208).

[0082] According to another embodiment of the present invention, the integrated hydraulic power pack (222) may be provided in the service unit (201) of the vertical head (200) or in the service unitwhich does not comprises the integrated pneumatic air panel (202) and the integrated water panel(208) to saves the space thereby reducing the overall size of the machine.

[0083] According to another embodiment of the present invention, the integrated pneumatic airpanel (202) and the integrated water panel (208) may be provided in the service unit (221) of thevertical head (220) or in the service unit which does not comprises the integrated hydraulic powerpack (222) to saves the space thereby reducing the overall size of the machine.

[0084] According to another embodiment of the present invention, if the machine (100) has morethan two vertical heads for example if the machine (100) has three vertical heads (200, 220, 230-notshown) for forming a plurality of sealed packages (P1, P2, P3) filled with a pourable product froma plurality of reels (R1, R2, R3) of packaging laminate, in this case, the integrated pneumatic airpanel (202), integrated water panel (208) and the integrated hydraulic power pack (222) can bearranged in any known combination in the service units of machine (100). Further, the service unitof the machine (100) can be divided based on the number of vertical heads, and the integratedpneumatic air panel (202), integrated water panel (208) and the integrated hydraulic power pack(222) can be modified to operate the various units of the machine (100) accordingly.

[0085] According to another embodiment, it may be contemplated that output feed (400) may beprovided separately for each vertical head (200 or 220), as per the requirement of products ofdifferent sizes.

[0086] In an exemplary embodiment, the preferred and optimum conditions to operate the asepticpack packaging machine (100) of the present invention are given below in Table-1. However, it isto be understood that other variations and modifications of the present invention may be madewithout departing from the scope thereof.TABLE -1

[0087] In an exemplary embodiment, the aseptic pack packaging machine (100) of the presentinvention can pack large quantity of the product. The main advantage of the present invention is toprovide a packaging machine (100) which is capable of producing approx. 20,000 packs / hour whileconsuming less power as against approx. 10,000 packs / hour by a conventional machine. Anotheradvantage according to another embodiment is to provide a packaging machine capable of producingapprox. 50,000 packs / hour. The present invention is capable of packaging different volume sizes,simultaneously, by each vertical head (200 or 220) individually, packaging same volume sizessimultaneously, by operating each vertical head (200 or 220) individually.

[0088] In a preferable embodiment of the invention, the strip applicator unit (9, 59) along eachtransfer path (200PP, 220PP) is provided for respective vertical head (200 or 220) for applying alongitudinal seal (LS) strip on the laminate (1, 51) by means of induction heat sealing.

[0089] According to the present invention, to operate either vertical head (200 or 220) individuallyor both the vertical heads (200, 220) of the machine (100) simultaneously, the pressure of thepneumatic air should be maintained at desired value of approx. 6 bar which can be further adjustedfor various circuits using plurality of pressure regulators (206).

[0090] In preferable embodiment of the present invention, the lubrication system is provided toensure proper lubrication of the moving parts of the machine (100).

[0091] In preferable embodiment of this invention, the integrated PLC (320) is provided to setupand control various functions of the aseptic pack packaging machine (100).

[0092] In preferable embodiment of the present invention, the HMI panel (500) is provided todigitally set up and control the operation of aseptic pack packaging machine (100) by an operator.

[0093] According to another embodiment, in order to increase the speed to more than 20,000 packsper hour, it is necessary to replace the transverse seal jaw unit (270, 280) with different transverseseal jaw units having a conveyor jaws system. Further, each forming and filling unit (250, 260) mayadapt two reels (R1, R1') of laminate (1, 1') and (R2, R2') of (51, 51') loaded at unwinders forforming the tube (T1, T2). However, one of the two reels (R1 or R1') is kept as a reserve. Similarly,one of the two reels (R2 or R2') is kept as a reserve. The spare web reel is kept to minimize themachine downtime due to reel changeover. The active web reel (R1, R2) of laminate (1, 51) isspliced to the spare web reel (R1', R2') by the automatic splicer mechanism as soon as the activeweb reel reaches near end. Further, each forming and filling unit (250, 260) comprises an inductionsealing arrangement to vertically seal the overlapping ends of laminate to form the respective tubes(T1, T2) along the transfer path (200PP, 220PP) instead of hot air sealing in the machine with speedof less than 20,000 packs per hour. Since the laminate moves at a very high speed, the laminate mayshift sideways. To eliminate this issue and to control the laminate alignment, a laminate edge guideis used before the tube formation in each forming and filling unit (250, 260).

[0094] For a very high-speed machine of approx. 50,000 packs per hour output, each forming andcross sealing assembly (A1) (B1) of cross-sealing jaw units (270, 280) may comprise a conveyorjaws system. The Forming and cross sealing assembly (A1) of cross-sealing jaw unit (270) maycomprises a conveyor system having two chain (C1, C1'), each having a number of first jaws (27)and second jaws (27'), each chain preferably has ten jaws i.e., five first jaw (27) and five second jaw(27') in total in one chain conveyor (C1, C1') defining an endless first lateral path (200LP, 200LP')along which said first and second jaws (27, 27') travel. Similarly the Forming and cross sealingassembly (B1) of cross-sealing jaw unit (280) may comprises a conveyor system having two chain(C2, C2') having a number of first jaws (77) and second jaws (77'), each chain (C2, C2') preferablyhas ten jaws i.e., five first jaw (77) and five second jaw (77') in total in one chain conveyor (C2,C2') preferably ten in numbers and defining an endless first lateral path (220LP, 220LP') alongwhich said first jaws (77) and second jaws (77'), travel.

[0095] The jaws (27) and (77) comprises the inductors for heating the laminate with aluminum foil.The other jaw (27', 77') comprises the polymer pad for cushioning effect are arranged such that jaws(27') and (77') always travel opposite to the jaws (27) and (77). The first and second jaws (27, 27')are mounted on the conveyor chains (C1, C1') and (77, 77') are mounted on the conveyor chains(C2, C2') in alternate fashion i.e. (27, 27', 27, 27'------) and (77, 77', 77, 77' ------). The jaws movingin two loops, pressing the tube (T1, T2) of laminate (1, 51). Further, it is not possible to provide theinduction energy through cables to each jaw (27, 77), so a system of non-contact transfer of inductionenergy to each jaw is provided. Whenever a jaw on the conveyor chain comes in proximity of aninductor source, the jaw with inductor transmits energy to the aluminum foil in the laminate, whichgets heated and melts the PE layer for cross sealing the two layers of laminate together between thejaws with inductor and opposite jaw with a polymer pad for cushioning effect, in order to balancethe loops (two chain (C1, C1') (C2, C2') of the conveyor system of cross sealing jaw unit (270,280)). The alternate jaws on both the chains may be energized by induction and the other jaws havinga polymer pad for cushioning effect, are mounted such that when two chains (C1, C1') move, thejaw on one side has induction heating means and the opposite jaw has a polymer pad for cushioningeffect face each other. Similarly, two chains (C2, C2') move.

[0096] The first and said second path (220LP, 220LP') comprising respective branches substantiallyfacing and parallel to each other, and between which the tube (T1, T2) of laminate (1) (51,) is fedso that the jaws (27, 27') on one chain (C1), cooperate with opposite jaws (27', 27) on the otherchain (C1') along said branches of the respective paths (200LP, 200LP'), to grip the tube (T1) at anumber of successive cross sections, and to seal the packs. Each jaw (27 or 77) on one conveyor (C1or C2) and the corresponding jaw (27' or 77') on the other conveyor (C1' or C2') define a formingand cross sealing assembly (A1 or B1) which interacts cyclically with the tube (T1, T2) of laminate(1, 51). The portion of the tube (T1, T2) gripped between each pair of jaws (27, 27') (77, 77') isnormally cross sealed by a contact less induction sealing carried by one of the jaws preferably (27and 77), and which melts the layers of heat-seal laminates gripped tightly between the jaws. As eachpair of jaws (27, 27') of chain (C1, C1') and similarly jaws (77, 77') of chain (C2, C2') completesthe cross-sealing operation. A cutter carried by one of the jaws, preferably jaw (27'and 77') withpolymer pad for cushioning effect, is activated and interacts with the tube of laminate to cut it in themiddle of the cross-sealing band just sealed, and so detach packages (P1, P2) from the bottom endof the tube (T1, T2) of laminates (1) (51). The bottom end being cross sealed, the relative jaws, onreaching the bottom position, can be opened to avoid interfering with the top portion of the tube (T1,T2). At the same time, the other pair of jaws (27, 27') (77, 77'), operated in exactly the same way,moves down from the top position, and repeats the above grip / form, seal and cut process. Packagecutting is performed by hydraulic pressure in machine for less than 20,000 packs / hour, however forhigh-speed operation, the speed of hydraulic movements cannot match the machine speed for cuttingthe packages, so mechanical cam and rollers mechanism is used for high-speed operation.

[0097] A large number of packages cannot move by a chute to final folder (290, 300), so an infeedconveyor is used and the final folder (290, 300) folds in continuous mode instead of indexing modeof machine with less than 20,000 packs / hour output. The top and side squeezing of fins and flapsis done by squeezing belts for continuous operation.

[0098] According to another embodiment, since due to very high speed, print design registrationwith respect to forming the packages, is corrected by servo driven mechanism. To adjust the productvolume in high-speed operation of the machine servo driven mechanism is provided. However, formachines with less than 20,000 packs / hour, design correction is performed by pneumatic cylinderand volume correction is performed mechanically.

[0099] In preferable embodiment of the present invention, the forming and cross-sealing assembly(A, A') (B, B') are opening and closing with up-down movement, by actuating means. The actuatingmeans can be hydraulic, mechanical, electrical, pneumatic, rotary, or any other actuating mechanismknown in the art.

[00100] The present invention is used for packaging liquid products like juice, milk, oils and alcoholetc. In preferable embodiment of the present invention, the packaging machine is for asepticpackaging.

[00101] According to another embodiment, by changing a few components of the aseptic packpackaging machine (100), the present invention may be used to fill different volume sizes in thecapacity of 100 ml, 125 ml, 160 ml, and 200 ml.

[00102] According to the present embodiment the reel (R1, R2) of packaging laminate (1, 51) mayhave a multilayer structure, which includes at least one paperboard layer which on both sides thereofconfigures with at least one polymeric layer and at least one layer of metal foil.

[00103] The single or multilayer polymeric layer can be at least one or in combinations withPolyethylene (PE), Polyethylene Terephthalate (PET) web, Biaxially-Oriented Polypropylene(BOPP) web, Polyvinyl Chloride (PVC) web, Poly Carbonate (PC), Cast Polypropylene (CPP) web,Mylar, Nylon (PA), and Ethylene Vinyl Acetate or any other polymer or Biodegradable polymer.

[00104] Further, the laminate comprises at least a layer of fibrous material, such as e.g., a paper orcardboard layer.

[00105] The laminate shall have at least one barrier protection layer within the laminate structurecomprising Aluminum foil or vacuum metalized Aluminum layer, Aluminum Oxide, zinc Sulphide,Silicon Oxide, Silver, Gold, Copper, Chrome, Silicon monoxide, Silicon dioxide, Magnesiumfluoride, Titanium dioxide, Tin tungsten oxide and Indium tin oxide or any other suitable metalwhich provides resistance against water, oxygen and other gases permeation.

[00106] Further, typical laminate structures can be referred from Indian patent application Number202011023791.

[00107] It is to be understood that while the present invention is discussed in the context ofproducing aseptic packages, one skilled in the art could use the method and apparatus in other areasincluding, but not limited to, packages of different sizes, non-aseptic packages, or packages thatmust be kept refrigerated. Therefore, the foregoing and following description is to be viewed asillustrative and not in a limiting sense. By changing a few components and modifications, themachine of the present invention can be used for non- aseptic packaging also.

[00108] According to another embodiment, by changing a few components of the aseptic packpackaging machine (100) can be used for non-aseptic packaging for products which are selfsterilizable like alcoholic beverages etc. When used as non-aseptic, the forming and filling unit (250,260) of the machine (100), excludes sterilization bath unit (12, 62), cover for sterilization (13, 63)and air knife (15, 65) for vertical heads (200, 220) along the respective transfer paths (200PP,220PP). Further, sterilization of the laminate (1, 51) by hydrogen peroxide and system sterilizationby sterile air and hydrogen peroxide spray are also not required. Alkali tank and Nitric acid (HNO3)tank for cleaning purposes are also not required in the non-aseptic packaging condition. Further, themain water ring compressor is also excluded when non-aseptic arrangement is required.

[00109] The foregoing descriptions of specific embodiments of the present disclosure have beenpresented for purposes of illustration and description. They are not intended to be exhaustive or tolimit the present disclosure to the precise forms disclosed and obviously many modifications andvariations are possible in light of the above teaching. The embodiments were chosen and describedin order to best explain the principles of the present disclosure. Further, the present inventioncomprises various electronics components but for the sake of brevity, conventional components ofthe systems and units may not be described in detail herein. It is also understood that variousomission and substitutions of equivalents are contemplated as circumstance may suggest or renderexpedient, but such are intended to cover the application or implementation without departing fromthe spirit or scope of the present disclosure.LIST OF REFERENCE NUMERALS100 Aseptic Pack Packaging Machine110, 120 Machine frames200, 220 Vertical heads of the Machine (100)201, 221 Service Units202 Integrated Pneumatic Air Panel203 Air Filter, Regulator & Lubricator Unit or FRL204 Solenoid Valves of Pneumatic Air Panel205 Flow Meters of Pneumatic air Panel206 Pressure Regulators of Pneumatic Air Panel207 Pressure Gauges of Pneumatic Air Panel208 Integrated Water Panel209 Solenoid valves of Water Panel210 Flow Meters of Water Panel211 Ball Valves212 Strainer213 Water Filter214 Pressure Regulators of Water Panel215 Pressure Gauges for vertical heads in Water panel222 Integrated Hydraulic Power Pack250, 260 Forming and Filling Units270, 280 Cross Sealing Jaw Units290, 300 Final Folders320 Integrated PLC400 Output Feed500 HMI PanelR1, R2 Reels of Packaging Laminate1, 51 Packaging laminate of Reel (R1, R2)2, 52 Paper Guide Rollers3, 53 Power Feed Rollers4, 54 Dancer Rollers5, 55 First Pair of Bending Rollers6, 56 Marking Units7, 57 LS (longitudinal seal) Strip Reels8, 58 Splicing Units for Ls Strip9, 59 Strip Applicators Units10, 60 Bending Rollers11, 61 Bending Rollers12, 62 Sterilization Bath Units for vertical heads (200, 220)13, 63 Cover of Sterilization Bath14, 64 Calender Rollers15, 65 Air Knives16, 66 Bending Rollers (Driven)17, 67 Bending Rollers18, 68 Upper Forming Ring19, 69 Crease Rollers20, 70 Movable Forming Rings21, 71 Filler Tubes for vertical heads (200, 220)22, 72 Divided Forming Rings23, 73 LS Nozzles24, 74 LS Short Stop Nozzles25, 75 Lower Forming Rings26, 76 Tube Support RollersT1, T2 Tube at (200PP, 220PP)(A, A') and (B, B') Pair of Forming and Cross Sealing assembly of (270) and (280)(27', 27) and(77', 77)Front and Rear Cross-sealing jaws of (A, A') of (270) andFront and Rear Cross-sealing jaws of (B, B') of (280)(28, 78) Final Folder Station Chain of Folders (290, 300)P1, P2 Formed packages at vertical heads (200, 220) of machine (100)(200 PP) Transfer Path for vertical heads (200)(220 PP) Transfer Path for vertical heads (220)(200LP, 200LP') Lateral path of Chain C1 & C1' of conveyor of forming andcross sealing assembly (A1) of (270)(220LP, 220LP') Lateral path of Chain C2 & C2' of conveyor of forming andcross sealing assembly (B1) of (280)(27 and 77) Jaws with Inductor(27' and 77') Jaws with Polymer pad..

Claims

1. An aseptic pack packaging machine (100) comprising: a. a plurality of transfer paths (200PP, 220PP); b. a plurality of strip applicator units (9, 59); c. a plurality of vertical heads (200, 220); d. a plurality of final folder assembly (290, 300); e. an output feed (400); f. a plurality of service units (201, 221); g. an integrated PLC (320); and h. an HMI panel (500) for setting and controlling the various units of the aseptic pack packaging machine (100).

2. The aseptic pack packaging machine (100) as claimed in claim 1, wherein an integrated pneumatic air panel (202) and an integrated water panel (208) are provided in any one of the service units (201 or 221) of the aseptic pack packaging machine (100).

3. The aseptic pack packaging machine (100) as claimed in claim 1 and claim 2, wherein an integrated hydraulic power pack (222) is provided in the service unit (221 or 201) not having the integrated air panel (202) and the integrated water panel (208) of the aseptic pack packaging machine (100).

4. The aseptic pack packaging machine (100) as claimed in claim 1, wherein each strip applicator unit (9, 59) is provided for uninterrupted supply and sealing of longitudinal seal (LS) strip (7, 57) on the packaging laminate (1, 51) by means of induction sealing.

5. The aseptic pack packaging machine (100) as claimed in claim 1, wherein each vertical head (200, 220) comprises a forming and filling unit (250, 260); and a cross sealing jaw unit (270, 280) for forming packages (P1, P2) in an independent transfer path (200PP, 220PP).

6. The aseptic pack packaging machine (100) as claimed in claim 1 and claim 5, wherein each forming and filling unit (250, 260) comprises a vertical sealing system with sealing either by hot air and pressing or induction sealing and pressing, in the vertical direction, along the transfer path (200PP, 220PP).

7. The aseptic pack packaging machine (100) as claimed in claim 1, wherein each cross-sealing jaw unit (270, 280) comprises a pair of Forming and cross sealing assemblies (A, A') and (B, B') respectively for the forming and cross-sealing of the tube (T1, T2) using an induction sealing.

8. The aseptic pack packaging machine (100) as claimed in claim 1, wherein each final folder (290, 300) comprises a final folder station chain (28, 78) to fold fins and flaps on top and bottom of the packages (P1, P2) of the aseptic pack packaging machine (100).

9. The aseptic pack packaging machine (100) as claimed in claim 1, wherein the output feed (400) may be provided separately for each vertical head (200 or 220) of the aseptic pack packaging machine (100).

10. The aseptic pack packaging machine (100) as claimed in claim 1, wherein the machine (100) is capable of packaging different volume sizes, simultaneously, by each vertical head (200 or 220) individually.

11. The aseptic pack packaging machine (100) as claimed in claim 1, wherein the machine (100) is capable of packaging same volume sizes simultaneously, by operating each vertical head (200 or 220) individually.

12. The aseptic pack packaging machine (100) as claimed in claim 1, wherein the machine (100) comprises two transfer paths (200PP, 220PP) for forming packages (P1, P2).

13. The aseptic pack packaging machine (100) as claimed in claim 1, wherein the machine (100) is used for non-aseptic packaging for products which are self-sterilizable like alcoholic beverages etc., by excluding a sterilization bath unit (12, 62), a cover for sterilization (13, 63) and an air knife (15, 65) from the forming and filling unit (250, 260) of the vertical heads (200, 220) of the machine (100).