Packaging equipment and processes

Abstract

A packaging process and apparatus includes a film supply station (1) comprising a roller support (1a) configured to receive a feed roller (2) and rotate it about a corresponding unwinding axis (A) to unfold a continuous portion of a plastic film (3). A selected unfolded portion, with a width (W) significantly greater than its length (L), is positioned within the packaging station, wherein the width (W) is aligned along an alignment direction (D) of a row of product-loaded supports to be packaged. The packaging station heat-seals the selected unfolded portion to the lower row of product-loaded supports.

Description

Technical Field

[0001] This invention relates to an apparatus for manufacturing packaging intended to contain one or more products, which may have various properties, such as food products. The invention also relates to a process for manufacturing said packaging; the packaging includes a plastic support member supporting the product sealed by a plastic film. The invention can be applied to general packaging, vacuum packaging, or packaging under a controlled atmosphere. Background Technology

[0002] Several different devices and related methods / processes are known for packaging articles, such as food products, that are positioned on supports and then sealed by a sealing film.

[0003] Specifically, a packaging system is known in which a continuous plastic “bottom” film unfolds and is thermoformed along the machine’s working direction, thereby defining a continuous precursor body having multiple cavities. The cavities in the precursor body receive corresponding products and are sealed by a top plastic film fed parallel to and above the precursor body to form multiple packages; the bottom and top plastic films are then cut to form individual finished packages.

[0004] In an alternative solution, a cutting station located upstream of the thermoforming station cuts discrete portions from the plastic “bottom” film and moves the film to the thermoforming station; the thermoformed supports (which may be in the form of pallets or flat supports) obtained from the thermoforming station are then conveyed to a subsequent packaging station, where each pallet or support is sealed by a top plastic film.

[0005] In another alternative, the pre-formed pallet is moved on a conveyor to a packaging station. A film roller feeds a top plastic film, which moves parallel to and above the conveyor: the top plastic film is positioned in the packaging station, where it is sealed to the pallet below.

[0006] In the above solution, the packaging station can be designed to simultaneously handle multiple pallets or supports positioned in one or more rows to maximize productivity. Therefore, in each packaging cycle, a top plastic film needs to cover one or more rows of pallets / supports housed in the packaging station. This means that in each packaging cycle, a long sheet of top plastic film is pulled out and unwound from the supply rollers to cover and seal all pallets / supports present in the packaging station. Because multiple pallets / supports need to be sealed in each single cycle (e.g., the packaging machine may have a packaging station accommodating two or more rows of pallets / supports, with up to five or more pallets per row), the length of the film pulled and positioned above the pallets / supports in the packaging station can be quite long: for example, longer than 1 meter.

[0007] On the other hand, due to inherent inaccuracies in the current membrane manufacturing process, or due to other factors such as deformation applied during film winding / unwinding, internal stress in the membrane structure, the thin plastic film used as the top sealing film deviates from a perfectly straight construction. In fact, the plastic film used as the top sealing film can exhibit deviations from a straight construction of 30 mm or more per 10 linear meters, thus giving the plastic film an overall "serpentine" construction. This causes a problem when the relatively long film strip is pulled out from the feed rollers and moved to cover one or more rows of pallets / supports in the packaging station: in fact, if the pulled film strip has a "serpentine" construction, it may deviate from the perimeter of the support / pallet and therefore cannot perfectly seal all the pallets. On the other hand, the only known way to solve the above problem is to use a film that is much larger than the effective total width of the rows of pallets / supports to be covered, which obviously wastes material and requires then trimming any excess film that may be present on the sealed pallets / supports. Summary of the Invention

[0008] Purpose of the invention

[0009] The purpose of this invention is to overcome at least one of the shortcomings and / or limitations of the prior art.

[0010] The first objective of this invention is to provide a packaging device and process that addresses the described drawbacks while ensuring a high production yield.

[0011] Another object of the present invention is to provide a packaging device and process characterized by high production speed and reduced material waste.

[0012] Another object of the present invention is to provide an apparatus and process capable of processing multiple pallets / supports in the same cycle, ensuring a perfect seal for all pallets / supports.

[0013] Another objective is to provide a process and apparatus for packaging products that improves the positioning of the top sealing film on a pallet or support.

[0014] Furthermore, an auxiliary objective of the present invention is to provide a packaging apparatus and process suitable for forming hermetically sealed packaging or packaging under vacuum (i.e., vacuum skin packaging) or packaging under a controlled atmosphere.

[0015] Summary Section

[0016] One or more of the above-mentioned objectives are substantially achieved by a packaging process and / or packaging equipment according to one or more of the appended claims.

[0017] The aspects of the invention are described below.

[0018] The first aspect concerns the packaging process, which includes the following steps:

[0019] - Multiple supports (11) with corresponding products (P) are positioned inside the packaging station (8), which includes a lower tool (18) and an upper tool (19) that cooperates with the lower tool, wherein:

[0020] The support member (11) is positioned at the lower tool loading area (20) according to one or more parallel rows of support members (R).

[0021] Each support row (R) includes a plurality of support members (11) aligned along a predetermined alignment direction (D).

[0022] - The top sealing film (3) is unwound from the feed roller (2) of the film supply station (1) by allowing the feed roller (3) to rotate around the corresponding unwinding axis (A). The top sealing film has a width (W) measured parallel to the unwinding axis (A).

[0023] - A selected unfolded portion (7) of the top sealing film (3) is conveyed inside the packaging station (8), wherein the selected unfolded portion (7) is a strip that spans the top sealing film (3) and has the same width (W) as the top sealing film (3), and wherein the selected unfolded portion (7) is positioned above the lower tool loading area (20), wherein the width (W) of the selected unfolded portion (7) is aligned with the alignment direction (D) of the support row (R) present in the lower tool loading area (20).

[0024] - Secure the selected unfolded portion (7) of the top sealing film (3) to multiple supports present in the packaging station.

[0025] In the second aspect according to the first aspect, the selected unfolded portion (7) of the top sealing film (3) is secured to a plurality of supports present in the packaging station by heat-sealing the selected portion of the top sealing film to a plurality of supports present in the packaging station and specifically positioned at the lower tool loading area (20).

[0026] In the third aspect according to any of the foregoing aspects, the number of alignment supports (11) in each support row (R) is greater than the number of support rows (R) present in the lower tool loading area (20).

[0027] In the fourth aspect according to any of the foregoing aspects, the support loading area (20) extends further along the alignment direction (D) than perpendicular to the alignment direction (D).

[0028] In the fifth aspect according to any of the foregoing aspects, the support loading area (20) extends at least 1.5 times, preferably at least twice, along the alignment direction (D) compared to the direction perpendicular to the alignment direction (D).

[0029] In the sixth aspect according to any of the foregoing aspects, the support (7) is positioned at the lower tool loading area (20) corresponding to one or more rows of seats (R') including seats (21) aligned along the alignment direction (D).

[0030] In the seventh aspect according to the foregoing, each seat row (R') includes three or more seats (21), thus defining a corresponding support row (R) having three or more supports (11).

[0031] In the eighth aspect according to either of the two aspects mentioned above, each seat row (R') includes five or more seats (21), thus forming a corresponding support row (R) with five or more supports (11).

[0032] In the ninth aspect according to any one of the three aspects mentioned above, the lower tool (18) has a plurality of parallel seat rows (R') aligned along the alignment direction (D) at the lower tool loading area (20), and receives the support (11) positioned according to the support row (R).

[0033] In the tenth aspect according to any one of the four aspects mentioned above, the number of seats (21) on each seat row (R') is at least twice the number of seat rows (R') present in the lower tool loading area (20).

[0034] In aspect 11 according to any of the foregoing aspects, the selected unfolded portion (7) of the top sealing film conveyed inside the packaging station and above the lower tool loading area has a rectangular shape.

[0035] In aspect 12 according to any of the foregoing aspects, the selected unfolded portion (7) of the top sealing film conveyed inside the packaging station and above the lower tool loading area has:

[0036] - Width (W), sufficient to cover the extensions of all supports in the packaging station along the alignment direction (D), and

[0037] - A length (L) perpendicular to the width (W) that is sufficient to cover the extensions of all supports present in the packaging station that are perpendicular to the alignment direction (D).

[0038] In aspect 13 according to any of the foregoing aspects, each of the support members (11) is a tray having a bottom wall, side walls extending from the bottom wall, and a top flange defining a top opening of the tray and extending radially from the bottom wall.

[0039] In the 14th aspect according to the foregoing, the flange has a rectangular outer perimeter having two opposing first sides parallel to the alignment direction and two opposing second sides perpendicular to the alignment direction (D), wherein the width (W) of the selected unfolded portion conveyed inside the packaging station and above the support is at least equal to a measurement of one of the first sides multiplied by the number of support members present in each row, and wherein the length (L) of the selected unfolded portion conveyed inside the packaging station and above the support is at least equal to a measurement of one of the second sides multiplied by the number of rows of support members present in the packaging station.

[0040] In aspect 15 according to any one of aspects 1 to 12, each of the supports (11) is a flat support having a rectangular outer perimeter having two opposing first sides parallel to the alignment direction and two opposing second sides perpendicular to the alignment direction (D), wherein the width (W) of the selected unfolded portion conveyed inside the packaging station and above the support is at least equal to a measurement of one of the first sides multiplied by the number of supports present in each row, and wherein the length (L) of the selected unfolded portion conveyed inside the packaging station and above the support is at least equal to a measurement of one of the second sides multiplied by the number of rows of supports present in the packaging station.

[0041] In aspect 16 according to any of the foregoing aspects, a selected unfolded portion (7) of the top sealing film conveyed inside the packaging station and above the lower tool loading area is a transverse full-width slender strip of the top sealing film.

[0042] In aspect 17 according to any of the foregoing aspects, a selected unfolded portion (7) of the top sealing film conveyed inside the packaging station and above the lower tool loading area has a width (W) significantly greater than the corresponding length (L), which is measured perpendicular to the width (W).

[0043] In aspect 18 according to any of the foregoing aspects, a selected unfolded portion (7) of the top sealing film conveyed inside the packaging station and above the lower tool loading area has a width (W) at least twice the corresponding length (L), the corresponding length (L) being measured perpendicular to the width (W).

[0044] In aspect 19 according to any of the foregoing aspects, a selected unfolded portion (7) of the top sealing film conveyed inside the packaging station and above the lower tool loading area has a width (W) at least three times the corresponding length (L), which is measured perpendicular to the width (W).

[0045] In aspect 20 according to any of the foregoing aspects, a selected unfolded portion (7) of the top sealing film conveyed inside the packaging station and above the lower tool loading area has a width (W) of at least 5 times the corresponding length (L), which is measured perpendicular to the width (W).

[0046] In aspect 21 according to any of the foregoing aspects, a selected unfolded portion (7) of the top sealing film conveyed inside the packaging station and above the lower tool loading area has a width (W) of at least 10 times the corresponding length (L), which is measured perpendicular to the width (W).

[0047] In aspect 22 according to any of the foregoing aspects, the process includes repeating a packaging cycle at intervals, the packaging cycle including at least the following steps:

[0048] - The packaging station (8) is constructed as an open structure, wherein the upper tool and the lower tool are spaced apart from each other.

[0049] - In the case of an open construction at the packaging station

[0050] o Perform the step of positioning the support (11) on which at least one product is loaded in the packaging station (8),

[0051] Perform the step of transferring the unfolded portion (7) to the packaging station (8) and above the lower tool loading area (20).

[0052] - The packaging station (8) is constructed as a closed structure, wherein the upper tool and the lower tool are close to each other.

[0053] - When the packaging station (8) is in a closed structure, the top sealing film (3) is fixed to the support.

[0054] In aspect 23 according to any of the foregoing aspects, the process includes repeating a packaging cycle at intervals, the packaging cycle including at least the following steps:

[0055] - The packaging station (8) is constructed as an open structure, wherein the upper tool and the lower tool are spaced apart from each other.

[0056] - In the case of the packaging station (8) being in an open structure

[0057] o Perform the step of positioning the support (11) on which at least one product is loaded in the packaging station (8),

[0058] Perform the step of transferring the unfolded portion (7) to the packaging station (8) and above the lower tool loading area (20).

[0059] - The packaging station (8) is constructed as a closed structure, wherein the upper tool and the lower tool are close to each other.

[0060] - When the packaging station (8) is in a closed configuration, the selected portion (7) of the top sealing film (3) that has been transferred to the packaging station (8) and above the lower tool loading area (20) is heat-sealed to the support.

[0061] In aspect 24 according to any of the foregoing aspects, the process includes a cutting procedure performed at a cutting station (9) operably inserted between the supply station (1) and the conveying device (10), wherein the cutting station receives the top sealing film and separates the selected unfolded portion (7) from it before it is conveyed inside the packaging station (8).

[0062] In aspect 25 according to any of the foregoing aspects, the cutting procedure includes laterally separating the selected unfolded portion (7) from the top closing film (3) to form a separate unfolded portion that is separate from the remainder of the closing film from the feed roller, the separate unfolded portion being in the form of an integral strip having the same width (W) as the top closing film.

[0063] In aspect 26 according to any one of the foregoing aspects from 1 to 24, the cutting procedure includes laterally separating the selected unfolded portion (7) from the top sealing film (3) and longitudinally separating the sealing film at the selected unfolded portion to form a separated unfolded portion consisting of a plurality of longitudinally separated and laterally adjacent different films (7a).

[0064] In aspect 27 according to any of the three aspects mentioned above, the separated unfolded portion (7) is precisely sized to cover all the supports (11) of the same support row (R) present in the packaging station (8), and to cover all the row supports present in the packaging station (8).

[0065] In aspect 28 according to any of the four aspects mentioned above, once transferred to the sealing station, the separated unfolded portion (7) is engaged with the lower support (11) present in the lower tool loading area (20), such that each of the support (11) is heat-sealed to the corresponding portion of the separated unfolded portion (7) or the corresponding diaphragm (7a) of the different diaphragm.

[0066] In aspect 29 according to any of the foregoing aspects, the width of the top sealing film (3), measured parallel to the unwinding axis (A), and therefore the width (W) of each selected unfolding portion (7), is at least 450 mm.

[0067] In aspect 30 according to any of the foregoing aspects, the width of the top sealing film (3), measured parallel to the unwinding axis (A), and therefore the width (W) of each selected unfolding portion (7), is at least 600 mm.

[0068] In aspect 31 according to any of the foregoing aspects, the width of the top sealing film (3), measured parallel to the unwinding axis (A), and therefore the width (W) of each selected unfolding portion (7), is at least 1000 mm.

[0069] In aspect 32 according to any of the foregoing aspects, the width of the top sealing film (3), measured parallel to the unwinding axis (A), and therefore the width (W) of each selected unfolding portion (7), is at least 1200 mm.

[0070] In aspect 33 according to any of the foregoing aspects, the top sealing film (3) is a plastic film.

[0071] In aspect 34 according to any of the foregoing aspects, the top plastic film (3) is an extruded single-layer or multi-layer plastic film.

[0072] In aspect 35 according to any of the foregoing aspects, the top sealing membrane (3) has a thickness between 10 and 200 μm.

[0073] In aspect 36 according to any of the foregoing aspects, the transmission step includes:

[0074] - Position the selected unfolded portion (7) on the movable surface (40a) of the conveying body (40).

[0075] - In the case that the packaging station (8) is in an open structure,

[0076] The conveyor body (40) and the thus selected unfolded portion (7) are moved from the cutting station (9) to the packaging station (8) under the upper tool.

[0077] The selected unfolded portion (7) is released from the movable surface (40a) of the conveying body (40) and captured by the lower surface of the upper tool (19).

[0078] ο Return the main body (40) to the cutting station (9).

[0079] In aspect 37 of the foregoing, the active surface of the transmission body (40) is flat.

[0080] In aspect 38 according to either of the two aforementioned aspects, the movable surface of the conveying body (40) holds the selected unfolded portion in place by suction applied by air drawn in through a plurality of suction holes (41) present on the movable surface and connected to a vacuum source (42).

[0081] In aspect 39 according to any one of the three aspects mentioned above, wherein, under the action of suction applied by drawing air through a plurality of suction holes (41) present on the active surface and connected to the vacuum source (42), the active surface of the conveying body (40) maintains a selected unfolded portion (7) while the conveying body (40) is moved from the cutting station (9) to the packaging station (8) and until release.

[0082] In aspect 40 according to any of the foregoing aspects, the transfer includes grasping the leading edge (7b) of the selected unfolded portion (7) and moving the leading edge from the pick-up area outside the packing station to inside the packing station and above the lower tool loading area.

[0083] In aspect 41 according to any of the foregoing aspects, the selected unfolded portion (7) is transferred to the packaging station (8) without grasping the relative longitudinal side boundary of the selected unfolded portion.

[0084] In aspect 42 according to any of the foregoing aspects, the selected unfolded portion (7) is transferred from the cutting station to the packaging station without grasping the relative longitudinal side boundary of the selected unfolded portion.

[0085] In aspect 43 according to any of the foregoing aspects, the selected unfolded portion (7) is conveyed to the packaging station without using a conveying element such as a clamp that grips the longitudinal side boundary of the selected unfolded portion.

[0086] In aspect 44 according to any of the foregoing aspects, the selected unfolded portion (7) is transferred from the cutting station to the packaging station without using a conveying element such as a clamp that grips the longitudinal side boundary of the selected unfolded portion.

[0087] Aspect 45 relates to a packaging device (100) comprising:

[0088] A membrane supply station (1) for supplying the top sealing film (3), wherein the membrane supply station (1) is configured to engage at least one feed roller (2) to rotate about a corresponding unwinding axis (A) to allow the top sealing film (3) to unfold from the feed roller (2).

[0089] Packaging station (8), which has:

[0090] - A lower tool (18) presenting a lower tool loading area (20) configured to receive a plurality of supports (11) positioned according to one or more support rows (R), wherein each support row (R) includes a plurality of supports (11) aligned along a predetermined alignment direction (D).

[0091] - Upper tool (19), configured to cooperate with lower tool (18) for securing the top sealing film (3) to a plurality of supports (11) present in the packaging station (8);

[0092] The conveying device (10) is configured as follows:

[0093] - Acting on a selected unfolded portion (7) of the top sealing film, the selected unfolded portion having the same width (W) as the top sealing film (3) measured parallel to the unwinding axis (A), and

[0094] - The selected unfolded portion (7) is conveyed to the packaging station (8) and above the lower tool loading area (20), wherein the width (W) of each selected unfolded portion (7) is aligned with the alignment direction (D) of the support row (R) in the lower tool loading area.

[0095] In aspect 46 of the foregoing, the lower tool loading area is configured such that the number of supports (11) in each support row (R) is greater than the number of support rows (R) in the same lower tool loading area.

[0096] In aspect 47, which is based on either of the two aspects mentioned above, the support loading area (20) extends further along the alignment direction (D) than perpendicular to the alignment direction (D).

[0097] In aspect 48 according to any one of the three aspects mentioned above, the lower tool (18) has one or more seat rows (R') aligned along the alignment direction (D) at the lower tool loading area (20) and is configured to receive the support (11) positioned according to the one or more support rows (R).

[0098] In aspect 49 of the foregoing, each row of seats (R') comprises three or more aligned seats (21).

[0099] In aspect 49 of the foregoing, each row of seats (R') comprises five or more aligned seats (21).

[0100] In aspect 50, according to any one of the three aspects mentioned above, the lower tool (18) has a plurality of parallel rows of seats (R') aligned along the alignment direction (D) at the lower tool loading area (20), and is configured to receive the support (11) positioned according to the rows of support (R); and

[0101] The number of seats (21) on each seat row (R') is at least twice the number of seat rows (R') present in the lower tool loading area (20).

[0102] In aspect 51, which is based on any one of the aforementioned aspects from 45 to 50, the conveying device (10) is configured as follows:

[0103] - It acts on a selected unfolding section (7) located at the pick-up area (6) of the equipment positioned between the film supply station (1) and the packaging station (8), and

[0104] - The selected unfolded portion (7) of the top sealing membrane (3) having a width (W) greater than the corresponding length (L) is conveyed above the lower tool loading area (20).

[0105] In the 52nd aspect according to the foregoing, the conveying device (10) is configured to act on a selected unfolded portion (7) of the top sealing film (3) and convey the selected unfolded portion (7) of the top sealing film (3) over the lower tool loading area (20), the selected unfolded portion (7) having a width (W) at least twice the corresponding length (L).

[0106] In the 53rd aspect according to the foregoing, the conveying device (10) is configured to act on a selected unfolded portion (7) of the top sealing film (3) and convey the selected unfolded portion (7) of the top sealing film (3) over the lower tool loading area (20), the selected unfolded portion (7) having a width (W) at least three times the corresponding length (L).

[0107] In the 54th aspect according to the foregoing, the conveying device (10) is configured to act on a selected unfolded portion (7) of the top sealing film (3) and convey a selected unfolded portion (7) of the top sealing film (3) over the lower tool loading area (20), the selected unfolded portion (7) having a width (W) of at least five times the corresponding length (L).

[0108] In the 55th aspect according to the foregoing, the conveying device (10) is configured to act on a selected unfolded portion (7) of the top sealing film (3) and convey the selected unfolded portion (7) of the top sealing film (3) over the lower tool loading area (20), the selected unfolded portion (7) having a width (W) at least ten times the corresponding length (L).

[0109] In aspect 56, which is based on any one of the aforementioned aspects from 45 to 55, the conveying device (10) is configured as follows:

[0110] - It acts on a selected unfolding section (7), which is located in a pickup area (6) of the equipment positioned between the film supply station (1) and the packaging station (8), and

[0111] - The selected unfolded portion (7) of the top sealing membrane (3) is conveyed above the lower tool loading area (20).

[0112] The selected unfolded portion (7) of the top sealing membrane (3) has:

[0113] - Width (W) sufficient to cover the entire extension of the lower tool loading area (20) along the alignment direction (D), particularly covering all supports (11) of the same support row (R) present in the packaging station (8).

[0114] - Length (L) sufficient to cover the entire extension of the lower tool loading area (20) perpendicular to the alignment direction (D), in particular covering all the rows of supports (R) present in the packaging station (8).

[0115] In aspect 57, which is based on any one of the aforementioned aspects from 45 to 56, the conveying device (10) is configured as follows:

[0116] - It acts on a selected unfolding section (7), which is located in a pickup area (6) of the equipment positioned between the film supply station (1) and the packaging station (8), and

[0117] - The selected unfolded portion (7) of the top sealing membrane (3) is conveyed above the lower tool loading area (20).

[0118] The selected unfolded portion (7) of the top sealing film (3) has:

[0119] - Width (W) sufficient to cover the entire extension of the lower tool loading area (20) along the alignment direction (D), and to cover all supports (11) of the same support row (R) present in the packaging station (8).

[0120] - Length (L) sufficient to cover the entire extension of the lower tool loading area (20) perpendicular to the alignment direction (D) and to cover all the support rows (R) present in the packaging station (8).

[0121] In aspect 58, according to any of the foregoing aspects from 45 to 57, the packaging equipment (100) includes a control unit (50) communicatively connected to the packaging station (8) and the conveying device (10).

[0122] In aspect 59 of the foregoing, the control unit is configured to perform the steps of any one of the processes in aspects 1 to 44.

[0123] In aspect 60 according to either of the two aforementioned aspects, the control unit (50) is configured to perform a packaging cycle comprising at least the following steps:

[0124] - The command packaging station (8) is positioned in an open structure, wherein the upper tool (19) and the lower tool (18) are spaced apart from each other to allow the support (11) to be positioned in the packaging station;

[0125] - With the packaging station (8) in an open configuration, the command conveying device (10) acts on one of the selected unfolded portions (7) of the top sealing film (3) and conveys the selected unfolded portion (7) to the packaging station (8) and above the lower tool loading area (20), wherein the width (W) of each selected unfolded portion (7) is aligned with the alignment direction (D) of the support row (R) in the lower tool loading area (20).

[0126] - The command packaging station (8) is positioned in a closed structure, wherein the upper tool (19) and the lower tool (18) are close to each other and cooperate to secure the top sealing film (3) to the support, and in particular heat-seal selected unfolded portions (7) of the top sealing film to the support.

[0127] In aspect 61, according to any of the foregoing aspects from 45 to 60, the membrane supply station (1) is configured to engage the at least one feed roller (2) for rotation about a corresponding unwinding axis (A) parallel to the predetermined alignment direction (D).

[0128] In aspect 62, which is according to any of the foregoing aspects from 45 to 61, the packaging equipment further includes a cutting station (9) operably inserted between the film supply station (1) and the conveying device (10).

[0129] In aspect 63 of the foregoing, the cutting station is communicatively connected to and controlled by the control unit.

[0130] In aspect 64 according to either of the two aforementioned aspects, the cutting station (9) is configured to laterally separate the selected unfolded portion (7) from the top sealing film (3) to form a separate unfolded portion that is separate from the rest of the sealing film from the feed roller, the separate unfolded portion being in the form of an integral strip having the same width (W) as the top sealing film (3).

[0131] In aspect 65 according to any one of aspects 62 or 63 above, the cutting station (9) is configured to laterally separate the selected unfolded portion (7) from the top sealing film (3) and longitudinally separate the sealing film (3) at the selected unfolded portion (7) to form a separated unfolded portion consisting of a plurality of longitudinally separated and laterally adjacent different films (7a).

[0132] In aspect 66 according to any of the foregoing aspects from 45 to 65, the membrane supply station (1) engages a feed roller (2) that provides a top-sealing membrane (3) of at least 450 mm in width (W) measured parallel to the unwinding axis (A).

[0133] In aspect 67 according to any one of the aforementioned aspects from 45 to 66, the membrane supply station (1) engages a feed roller (2) that provides a top-sealing membrane (3) of at least 600 mm in width (W) measured parallel to the unwinding axis (A).

[0134] In aspect 68 according to any of the foregoing aspects from 45 to 67, the membrane supply station (1) engages a feed roller (2) that provides a top-sealing membrane (3) of at least 1000 mm in width (W) measured parallel to the unwinding axis (A).

[0135] In aspect 69 according to any of the foregoing aspects from 45 to 68, the membrane supply station (1) engages a feed roller (2) that provides a top-sealing membrane (3) with a width (W) of more than 1200 mm parallel to the unwinding axis (A).

[0136] In aspect 70, according to any one of the aforementioned aspects from 45 to 69, the membrane supply station (1) engages a feed roller (2) that provides a top-sealing membrane (3), wherein the top-sealing membrane is a plastic film.

[0137] In aspect 71 of the foregoing, the top sealing membrane has a thickness between 10 and 200 μm.

[0138] In aspect 72, which is according to any of the foregoing aspects from 62 to 71, the conveying device (10) includes a conveying plate (40) optionally having a plurality of suction holes connected to a vacuum source, the conveying plate (40) being configured to move the separated unfolded portion or a plurality of different films (5) from the cutting station (9) to the packaging station (30).

[0139] In aspect 73 according to any one of the foregoing aspects from 62 to 72, the conveying device (10) includes a conveying plate (40) having a plurality of suction holes connected to a vacuum source, the conveying plate (40) being configured to move the separated unfolded portion or a plurality of different films (5) from the cutting station (9) to the packaging station (30).

[0140] In aspect 74, according to any of the foregoing aspects from 45 to 73, the conveying device (10) includes one or more clamps acting on the leading edge (7b) of a selected unfolding portion from the cutting station (9) to the packaging station (30).

[0141] In aspect 75, which is according to any of the foregoing aspects from 45 to 74, the device (100) does not have means for gripping the relative longitudinal side boundary of the selected unfolded portion, in particular there is no conveying element such as pliers gripping the longitudinal side boundary of the selected unfolded portion, and it operates to transfer the unfolded selected portion (7) from the cutting station to the packaging station.

[0142] In aspect 76, which is based on any one of aspects 1 to 44, the packaging process uses equipment based on any one of aspects 45 to 75.

[0143] In aspect 77, according to any one of aspects 45 to 75, the packaging equipment (100) is configured to perform a packaging process according to any one of aspects 1 to 44. Attached Figure Description

[0144] Embodiments and aspects of the invention are described below with reference to the accompanying drawings, which are provided for illustrative and non-limiting purposes, wherein:

[0145] Figure 1 This is a schematic perspective view illustrating an apparatus for performing a packaging process according to an aspect of the invention;

[0146] Figure 2 and Figure 3 This is a perspective view of a variation of the device according to the present invention;

[0147] Figure 4 This is a perspective view of an alternative device of the present invention;

[0148] Figure 5 A support member is shown in the form of a tray with sidewalls and peripheral flanges, which can be used in the process of the present invention and with the device of the present invention; the tray is closed by a top sealing film;

[0149] Figure 6 This is a schematic top view showing the lower tools of the packaging station, which houses eight supports or pallets positioned in two rows according to four pallets each; Figure 6 A conveyor is also schematically shown, carrying a selected unfolded portion of a top-sealed film composed of eight adjacent sheets that is about to be transported to a packaging station;

[0150] Figure 7 yes Figure 5 A schematic cross-section of a portion of a pallet, wherein the top closure film is heat-sealed to the flange to form a controlled atmosphere or natural atmosphere package; and

[0151] Figure 8 yes Figure 5 A schematic cross-section of a portion of the tray, wherein the top sealing film is heat-sealed to the flange to form a vacuum-sealed skin package. Detailed Implementation

[0152] Agreement

[0153] It should be noted that in this detailed description, corresponding parts shown in the various figures are denoted by the same reference numerals. The figures may be used to illustrate the purpose of the invention by means of non-proportional representation; therefore, the parts and components shown in the figures relating to the purpose of the invention are only schematic representations.

[0154] The terms upstream and downstream refer to the direction of travel of the packaging (or the support for manufacturing the packaging) along a predetermined path, which is defined by starting from the starting or forming station of the support for the packaging, passing through the packaging station, and then reaching the packaging unloading station.

[0155] definition

[0156] While some aspects of the invention can be applied to packaging products into packages made of only one or more plastic films, the following description will primarily relate to packaging products positioned on supports to which the plastic films are heat-sealed. Note that the product may or may not be a food product.

[0157] As used herein, a support refers to a substantially flat element on which a product is placed, or a container (alternatively referred to as a tray) having a bottom wall, side walls and a top edge extending radially from the side walls, which defines a volume in which the product is positioned.

[0158] The pallet or support may have a rectangular shape or any other suitable shape, such as round, square, oval, etc., and may be formed during the packaging process, such as at the thermoforming station of the packaging equipment, or they may be pre-manufactured and then supplied to the packaging equipment.

[0159] When used herein, "selected unfolded portion" refers to a portion of the top closure film unfolded from the top closure film feed roll, and that portion extends across the entire width of the top closure film. The selected unfolded portion has the same width as the top closure film (measured perpendicular to the flow direction of the top closure film and therefore parallel to the unwinding axis) and a length less than its width. Generally, the selected unfolded portion has the shape of a rectangular strip, with the longer side being the width and the shorter side being the length.

[0160] Pallets or supports

[0161] The tray or support may be made of a single layer or preferably multiple layers of polymer material. In the case of a single layer material, suitable polymers include, for example, polystyrene, polypropylene, polyester, high-density polyethylene, polylactic acid, PVC, etc. (foamed or solid).

[0162] In one option, the tray or support may have gas barrier properties. As used herein, such terms refer to films or sheets of material having an oxygen transport rate of less than 200 cm³ / m²-day-bar, less than 150 cm³ / m²-day-bar, or less than 100 cm³ / m²-day-bar, as measured according to ASTM D-3985 at 23°C and 0% relative humidity.

[0163] Suitable materials for gas barrier single-layer thermoplastic trays include polyester and polyamide.

[0164] When the pallet or support is made of multiple layers of material, suitable polymers include, for example, ethylene homopolymers and copolymers, propylene homopolymers and copolymers, polyamides, polystyrene, polyesters, polylactic acid, PVC, etc. Part of the multilayer material can be solid, and part can be foamed.

[0165] For example, a tray or support may include at least one layer of foamed polymer material selected from the group consisting of polystyrene, polypropylene, polyester, etc.

[0166] Multilayer materials can be produced by co-extruding all layers using co-extrusion technology, or by adhesive lamination or thermal lamination, such as rigid foam or solid substrate with a film (often referred to as a "liner"). The film can be laminated on the side of the pallet or support that contacts the product P, on the side opposite to the product P, or on both sides. In the latter case, the films laminated on both sides of the pallet can be the same or different. Optionally, an oxygen barrier material (e.g., ethylene-vinyl alcohol copolymer) may be present to increase the shelf life of the packaged product P.

[0167] Gas barrier polymers that can be used in gas barrier layers are PVDC, EVOH, polyamide, polyester, and blends thereof. The thickness of the gas barrier layer will be determined to provide the pallet with an oxygen transfer rate suitable for the specific packaged product.

[0168] The tray or support may also include a heat-sealable layer. Typically, the heat-sealable layer will be selected from polyolefins (such as ethylene homopolymers or copolymers, propylene homopolymers or copolymers, ethylene / vinyl acetate copolymers, ionomers) as well as homopolymers and copolyesters (e.g., PETG, ethylene glycol-modified polyethylene terephthalate).

[0169] Additional layers, such as adhesive layers, may be present in the gas barrier material used for the pallet to better adhere the gas barrier layer to adjacent layers, and are preferably present, in particular, depending on the specific resin used for the gas barrier layer.

[0170] In the case of multi-layered materials used to form a tray or support, a portion of the structure may be foamed and a portion may be unfoamed. For example, a tray may include (from the outermost to the innermost food contact layer): one or more structural layers, typically made of materials such as foamed polystyrene, foamed polyester, or foamed polypropylene, or cast sheets such as polypropylene, polystyrene, polyvinyl chloride, polyester, or cardboard; a gas barrier layer; and a heat-sealing layer.

[0171] The tray or support can be obtained from a sheet of foamed polymer material having a film comprising at least one oxygen barrier layer and at least one surface sealing layer, the at least one surface sealing layer being laminated to the side facing the packaged product such that the surface sealing layer of the film is the food contact layer of the tray. A second barrier or non-barrier film may be laminated onto the outer surface of the tray or support.

[0172] Specific formulations are used for food products that require heating in a conventional oven or microwave oven before consumption. The surfaces of the container that come into contact with the product (i.e., the surfaces involved in the formation of the seal with the sealing film) may comprise polyester resin. For example, the container may be made of polyester-coated cardboard, or it may be integrally made of polyester resin. Examples of suitable containers for the packaging of this invention are CPET, APET, or APET / CPET containers. Such containers may be foamed or non-foamed.

[0173] A film or film material applied to a pallet or support to form packaging

[0174] A film or film material (also referred to as a top film or top-sealing film) is applied to a pallet / support to form a cover (e.g., for MAP modified atmosphere packaging) or a skin associated with the pallet or support and conforming to the contours of the product.

[0175] The membrane for epidermal applications can be made of a flexible multilayer material comprising at least a first external heat-sealing layer, an optional gas barrier layer, and a second external heat-resistant layer. The external heat-sealing layer may comprise a polymer weldable to the inner surface of a support carrying the product to be packaged, such as, for example, ethylene homopolymers or copolymers (e.g., LDPE), ethylene / α-olefin copolymers, ethylene / acrylic acid copolymers, ethylene / methacrylic acid copolymers, and ethylene / vinyl acetate copolymers, ionomers, or copolyesters (e.g., PETG). The optional gas barrier layer preferably comprises an oxygen-impermeable resin, such as PVDC, EVOH, polyamide, and blends of EVOH and polyamide. The external heat-resistant layer may be made of ethylene homopolymers or copolymers, ethylene / cyclic olefin copolymers (such as ethylene / norbornene copolymers), propylene homopolymers or copolymers, ionomers, copolyesters, or copolyamides. The membrane may also include other layers, such as an adhesive layer or a host layer, to increase the membrane thickness and improve its abuse and deep-drawing properties. Particularly used host layers are ionomers, ethylene / vinyl acetate copolymers, polyamides, and polyesters. In all film layers, the polymer component may contain appropriate amounts of additives typically included in these compositions. Some of these additives are preferably included in the outer layer or one of the outer layers, while others are preferably added to the inner layer. These additives include lubricants and anti-restriction agents such as talc, wax, and silica; antioxidants; stabilizers; plasticizers; fillers; pigments and dyes; crosslinking inhibitors; crosslinking enhancers; UV absorbers; odor absorbers; oxygen scavengers; bactericides; antistatic agents, and other additives known to those skilled in the art of packaging films.

[0176] One or more layers of the membrane may be cross-linked to improve the membrane's strength and / or its heat resistance. Cross-linking can be achieved by using chemical additives or by subjecting the membrane layers to energetic radiation treatment. Films used for skin packaging are typically manufactured to exhibit low shrinkage when heated during packaging cycles. These films typically shrink less than 15% in both the longitudinal and transverse directions at 160°C, more commonly less than 10%, and even more commonly less than 8% (ASTM D2732). The film typically has a thickness between 20 and 200 micrometers, more commonly between 40 and 180 micrometers, and even more commonly between 50 and 150 micrometers.

[0177] On the other hand, when the membrane is used to form a cap on a tray / support, the membrane material can be obtained through a co-extrusion or lamination process. The capping membrane can have a symmetrical or asymmetrical structure and can be single-layered or multi-layered. Multilayered membranes have at least 2 layers, more commonly at least 5 layers, and even more commonly at least 7 layers. The total thickness of the membrane can commonly vary from 3 to 100 micrometers, particularly from 5 to 50 micrometers, and even more commonly from 10 to 30 micrometers.

[0178] The film may optionally be crosslinked. Crosslinking can be performed by high-energy electron irradiation at appropriate dose levels known in the art. The aforementioned cover film may be heat-shrinkable or heat-set. According to ASTM D2732, heat-shrinkable films typically exhibit free shrinkage values ​​at 120°C in both longitudinal and transverse directions ranging from 2% to 80%, more commonly from 5% to 60%, and even more commonly from 10% to 40%. Heat-set films typically have free shrinkage values ​​at 120°C in both longitudinal and transverse directions of less than 10%, preferably less than 5% (ASTM D2732). The cover film typically comprises at least a heat-sealing layer and an outer layer, the outer layer being substantially composed of a heat-resistant polymer or polyolefin. The sealing layer typically comprises a heat-sealing polyolefin, which in turn comprises a single polyolefin or a blend of two or more polyolefins, such as polyethylene or polypropylene or blends thereof. The sealing layer can also be provided with anti-fogging properties by incorporating one or more anti-fogging additives into the composition of the sealing layer, or by coating or spraying one or more anti-fogging additives onto the surface of the sealing layer using techniques known in the art. The sealing layer may also include one or more plasticizers. The surface layer may include polyester, polyamide, or polyolefin. In some configurations, blends of polyamide and polyester may be advantageously used as the surface layer. In some cases, the cover film includes a barrier layer. Barrier films typically have an OTR (evaluated according to ASTM D-3985 at 23°C and 0% relative humidity (RH)) of less than 100 cm³ / (m²·day·atm) and more commonly less than 80 cm³ / (m²·day·atm). The barrier layer is typically made of a thermoplastic resin selected from saponified or hydrolyzed products of ethylene-vinyl acetate copolymer (EVOH), amorphous polyamides, and vinylidene chloride and blends thereof. Some materials include an EVOH barrier layer sandwiched between two polyamide layers. The surface layer typically comprises polyester, polyamide, or polyolefin.

[0179] In some packaging applications, the cover film does not include any barrier layer. Such films typically comprise one or more polyolefins as defined herein.

[0180] Barrier-free membranes typically have an OTR (evaluated according to ASTM D-3985 at 23°C and 0% relative humidity) from 100 cm3 / (m2·day·atm) to 10,000 cm3 / (m2·day·atm), and more typically up to 6,000 cm3 / (m2·day·atm).

[0181] Special polyester-based compositions are used for tray lids in ready-to-eat food packaging. For these films, the polyester resin may comprise at least 50%, 60%, 70%, 80%, or 90% of the film's weight. These films are typically used in conjunction with polyester-based supports.

[0182] For example, the container may be made of cardboard coated with polyester, or it may be integrally made of polyester resin. Examples of suitable containers for packaging are CPET, APET, or APET / CPET containers (foamed or non-foamed).

[0183] Biaxially oriented PET is typically used as a cover film due to its high thermal stability at standard food heating / cooking temperatures. Biaxially oriented polyester films are usually heat-set, meaning they are not heat-shrinkable. To improve the heat-sealing performance of PET cover films on containers, a heat-sealable layer of low-melting-point material is typically provided on the film. This heat-sealable layer can be co-extruded with the PET base layer (as disclosed in EP-A-1,529,797 and WO2007 / 093495), or it can be solvent-coated or extruded onto the base film (as disclosed in US 2,762,720 and EP-A-1,252,008).

[0184] Especially in the case of packaging fresh red meat, it is advantageous to use a double-lid film consisting of an inner oxygen-permeable sealing film and an outer oxygen-impermeable sealing film. Even when the packaged meat extends upwards relative to the height of the pallet wall (which is the most critical case in barrier packaging of fresh meat), the combination of these two films significantly prevents meat discoloration.

[0185] These membranes are described, for example, in EP1848635 and EP0690012, the disclosures of which are incorporated herein by reference.

[0186] The cover film may be single-layered. Typical compositions of single-layer films include polyesters and blends thereof as defined herein, or polyolefins and blends thereof as defined herein.

[0187] In all the film layers described herein, the polymer component may contain appropriate amounts of additives typically included in such compositions. Some of these additives are preferably included in the outer layer or one of the outer layers, while others are preferably added to the inner layer. These additives include lubricants and anti-restriction agents such as talc, wax, silica, etc., antioxidants, stabilizers, plasticizers, fillers, pigments and dyes, crosslinking inhibitors, crosslinking enhancers, UV absorbers, odor absorbers, oxygen scavengers, bactericides, antistatic agents, antifogging agents, or compositions thereof, as well as additives known to those skilled in the art of packaging films.

[0188] Films suitable for sealing applications are advantageously perforated to allow the packaged food to breathe.

[0189] These membranes can be perforated using various techniques available in the art, such as lasers or mechanical means with rollers having several needles.

[0190] The number and size of perforations per unit area of ​​a membrane affect its air permeability.

[0191] Microperforated membranes are typically characterized by an OTR value (evaluated according to ASTM D-3985 at 23°C and 0% relative humidity) ranging from 2,500 cm³ / (m²·day·atm) to 1,000,000 cm³ / (m²·day·atm).

[0192] Large-perforation membranes are typically characterized by an OTR (evaluated according to ASTM D-3985 at 23°C and 0% relative humidity) of over 1,000,000 cm³ / (m²·day·atm).

[0193] Furthermore, the membranes described herein for capping applications can be formulated to provide a robust or peelable seal on a support. A method for measuring the force (referred to herein as “peel force”) of a peelable seal is described in ASTM F-88-00. Acceptable peel force values ​​are in the range of 100 g / 25 mm to 850 g / 25 mm, 150 g / 25 mm to 800 g / 25 mm, and 200 g / 25 mm to 700 g / 25 mm.

[0194] The desired seal strength is achieved through specially designed tray and lid formulations.

[0195] Generally, one or more layers of film can be printed on the packaging to provide consumers with useful information, visually appealing images, and / or trademarks or other advertising messages to increase the retail sales of packaged products.

[0196] The film can be printed by any suitable method, such as rotary screen printing, gravure printing or flexographic printing techniques known in the art.

[0197] Definitions and conventions regarding materials

[0198] PVDC is any copolymer of vinylidene chloride, wherein the majority of the copolymer comprises vinylidene chloride, and a minority of the copolymer comprises one or more unsaturated monomers capable of copolymerizing therewith, typically vinyl chloride, and alkyl acrylates or methacrylates (e.g., methyl acrylate or methacrylate) and blends thereof in different proportions. Typically, the PVDC barrier layer will contain plasticizers and / or stabilizers known in the art.

[0199] As used herein, the term EVOH includes saponified or hydrolyzed ethylene-vinyl acetate copolymers and refers to ethylene / vinyl alcohol copolymers, wherein the ethylene comonomer content preferably includes ethylene from about 28 mol% to about 48 mol%, more preferably from about 32 mol% to about 44 mol%, and even more preferably at least 85%, preferably at least 90%, of the degree of saponification.

[0200] As used herein, the term "polyamide" is intended to refer to homopolymers and copolymers or tripolymers. Specifically, this term includes: aliphatic polyamides or copolymers, such as polyamide 6, polyamide 11, polyamide 12, polyamide 66, polyamide 69, polyamide 610, polyamide 612, copolymer 6 / 9, copolymer 6 / 10, copolymer 6 / 12, copolymer 6 / 66, and copolymer 6 / 69; aromatic and partially aromatic polyamides or copolymers, such as polyamide 6I, polyamide 6I / 6T, polyamide MXD6, and polyamide MXD6 / MXDI; and blends thereof.

[0201] As used herein, the term "copolymer" refers to a polymer derived from two or more types of monomers, and includes terpolymers. Ethylene homopolymers include high-density polyethylene (HDPE) and low-density polyethylene (LDPE). Ethylene copolymers include ethylene / α-olefin copolymers and ethylene / unsaturated ester copolymers. Ethylene / α-olefin copolymers generally comprise copolymers of ethylene and one or more comonomers selected from α-olefins having 3 to 20 carbon atoms, such as 1-butene, 1-pentene, 1-hexene, 1-octene, 4-methyl-1-pentene, etc.

[0202] Ethylene / α-olefin copolymers generally have densities ranging from about 0.86 to about 0.94 g / cm³. The term linear low-density polyethylene (LLDPE) is generally understood to include the group of ethylene / α-olefin copolymers falling within the density range of about 0.915 to about 0.94 g / cm³, and particularly about 0.915 to about 0.925 g / cm³. Sometimes, linear polyethylene in the density range of about 0.926 to about 0.94 g / cm³ is referred to as linear medium-density polyethylene (LMDPE). Low-density ethylene / α-olefin copolymers may be referred to as very low-density polyethylene (VLDPE) and ultra-low-density polyethylene (ULDPE). Ethylene / α-olefin copolymers can be obtained through heterogeneous or homogeneous polymerization processes.

[0203] Another useful ethylene copolymer is an ethylene / unsaturated ester copolymer, which is a copolymer of ethylene and one or more unsaturated ester monomers. Useful unsaturated esters include: vinyl esters of aliphatic carboxylic acids, wherein the ester has from 4 to 12 carbon atoms, such as vinyl acetate; and alkyl esters of acrylic acid or methacrylic acid, wherein the ester has from 4 to 12 carbon atoms.

[0204] Ionomers are copolymers of ethylene and unsaturated monocarboxylic acids, having the carboxylic acid neutralized by metal ions such as zinc or preferably sodium.

[0205] Useful propylene copolymers include propylene / ethylene copolymers and propylene / ethylene / butene terpolymers. Propylene / ethylene copolymers are copolymers of propylene and ethylene, in which propylene accounts for the majority by weight percentage. Propylene / ethylene / butene terpolymers are copolymers of propylene, ethylene, and 1-butene.

[0206] As used herein, the term "polyolefin" refers to any polymeric olefin, which may be linear, branched, cyclic, aliphatic, aromatic, substituted, or unsubstituted. More specifically, the term polyolefin includes homopolymers of olefins, copolymers of olefins, copolymers of olefins and non-olefin comonomers (such as vinyl monomers) capable of copolymerizing with olefins, modified polymers thereof, etc. Specific examples include polyethylene homopolymers, polypropylene homopolymers, polybutene homopolymers, ethylene-α-olefin copolymers, propylene-α-olefin copolymers, butene-α-olefin copolymers, ethylene-unsaturated ester copolymers, ethylene-unsaturated acid copolymers (e.g., ethylene-ethyl acrylate copolymers, ethylene-butyl acrylate copolymers, ethylene-methyl acrylate copolymers, ethylene-acrylic acid copolymers, and ethylene-methacrylic acid copolymers), ethylene-vinyl acetate copolymers, ionomer resins, polymethylpentene, etc.

[0207] The term "polyester" is used herein to refer to both homopolymers and copolymers, wherein a homopolymer is defined as a polymer obtained from the condensation of a dicarboxylic acid and a diol, and a copolymer is defined as a polymer obtained from the condensation of one or more dicarboxylic acids and one or more diols. Suitable polyester resins are, for example, polyesters of ethylene glycol and terephthalic acid, namely polyethylene terephthalate (PET). Preferred are polyesters containing ethylene units and comprising at least 90 mol% and more preferably at least 95 mol% terephthalic acid units based on the dicarboxylic acid ester units. The remaining monomer units are selected from other dicarboxylic acids or diols. Suitable other aromatic dicarboxylic acids are preferably isophthalic acid, phthalic acid, 2,5-naphthalenedicarboxylic acid, 2,6-naphthalenedicarboxylic acid, or 2,7-naphthalenedicarboxylic acid. Among alicyclic dicarboxylic acids, cyclohexanedicarboxylic acid (especially cyclohexane-1,4-dicarboxylic acid) should be mentioned. Among aliphatic dicarboxylic acids, (C3-Ci9) alkyl bisaccharides are particularly suitable, especially succinic acid, sebacic acid, adipic acid, azelaic acid, octanoic acid, or pimelic acid. Suitable diols are, for example: aliphatic diols such as ethylene glycol, diethylene glycol, triethylene glycol, propylene glycol, 1,3-butanediol, 1,4-butanediol, 1,5-pentanediol, 2,2-dimethyl-1,3-propanediol, neopentanediol, and 1,6-hexanediol; and alicyclic diols such as 1,4-cyclohexanediol and 1,4-cyclohexanediol, and optionally heteroatom-containing diols having one or more rings.

[0208] Copolyester resins derived from one or more dicarboxylic acids or their lower alkyl (up to 14 carbon atoms) diesters with one or more diols (especially aliphatic or alicyclic diols) can also be used as polyester resins for base films. Suitable dicarboxylic acids include: aromatic dicarboxylic acids, such as terephthalic acid, isophthalic acid, phthalic acid, or 2,5-naphthalenedicarboxylic acid, 2,6-naphthalenedicarboxylic acid, or 2,7-naphthalenedicarboxylic acid; and aliphatic dicarboxylic acids, such as succinic acid, sebacic acid, adipic acid, azelaic acid, octanoic acid, or pimelic acid. Suitable diols include: aliphatic diols such as ethylene glycol, diethylene glycol, triethylene glycol, propylene glycol, 1,3-butanediol, 1,4-butanediol, 1,5-pentanediol, 2,2-dimethyl-1,3-propanediol, neopentanediol, and 1,6-hexanediol; and alicyclic diols such as 1,4-cyclohexanediol and 1,4-cyclohexanediol. Examples of such copolyesters are (i) a copolyester of azelaic acid and terephthalic acid with aliphatic ethylene glycol (preferably ethylene glycol); (ii) a copolyester of adipic acid and terephthalic acid with aliphatic ethylene glycol (preferably ethylene glycol); and (iii) a copolyester of sebacic acid and terephthalic acid with aliphatic ethylene glycol (preferably butanediol); and (iv) a copolyester of ethylene glycol, terephthalic acid, and isophthalic acid. Suitable amorphous copolyesters are those derived from aliphatic and alicyclic diols with one or more dicarboxylic acids (preferably aromatic dicarboxylic acids). Typical amorphous copolyesters include copolyesters of terephthalic acid with aliphatic and alicyclic diols (especially ethylene glycol and 1,4-cyclohexanediol).

[0209] product

[0210] The term "product" P refers to any kind of article or complex of articles. For example, a product can be of food type and can be in a solid, liquid, or gel state, that is, in two or more of the aforementioned aggregate states.

[0211] In the food industry, products may include: meat, fish, cheese, processed meat, and various prepared and frozen foods.

[0212] Control Unit

[0213] The packaging equipment described and claimed herein may include one or more control units designed to control operations performed by the equipment. Depending on design choices and operational requirements, the control unit may obviously be a single control unit or comprise multiple different control units.

[0214] The term "control unit" refers to an electronic component that may include at least one of the following: a digital processor (e.g., including at least one selected from the group consisting of a CPU, GPU, GPGPU), memory (multiple memories), analog circuitry, or a combination of one or more digital processing units and one or more analog circuitry. A control unit may be "configured" or "programmed" to perform certain steps: this can be done virtually by any means that allows you to configure or program the control unit. For example, in the case where the control unit includes one or more CPUs and one or more memories, one or more programs may be stored in a suitable memory set connected to the CPU or multiple CPUs; the one or more programs contain instructions that, when executed by the one or more CPUs, program or configure the control unit to perform the operations described with respect to the control unit. Alternatively, if the control unit is or includes analog circuitry, the control unit circuitry may be designed to include configured circuitry for processing electrical signals in order to perform steps associated with the control unit. A control unit may include one or more digital units of, for example, microprocessor type, or one or more analog units, or a suitable combination of digital and analog units; the control unit may be configured to coordinate all actions required to execute instructions and instruction sets.

[0215] actuator

[0216] The term actuator refers to any device capable of inducing movement on the body, such as one located behind a control unit (where the actuator receives commands from the control unit). Actuators can be electric, pneumatic, mechanical (e.g., with a spring), or of another type.

[0217] Detailed description

[0218] Referring to the accompanying drawings, a packaging apparatus 100 is described, which includes a film supply station 1 having a feed roller 2 configured to rotate about a corresponding unwinding axis A to unfold a continuous portion of a top sealing film 3.

[0219] According to one aspect, the width W of the top sealing membrane 3, measured parallel to the unwinding axis A, is at least 450 mm, optionally at least 600 mm, more optionally at least 1000 mm, or even more optionally greater than 1200 mm.

[0220] In terms of materials, the top sealing film is a plastic film, particularly an extruded single-layer or multi-layer plastic film as disclosed in the above-described special section, and may have a thickness including between 10 and 200 μm.

[0221] According to a preferred configuration, the rotation axis A of the feed roller 2 is arranged horizontally, particularly parallel to the ground. The supply station 1 may have an electric motor 4 connected to the feed roller 2 and configured to initiate rotation of the feed roller 2 about the unwinding axis A, so as to unfold subsequent portions of the plastic film 3 in a controlled manner. The electric motor 4 may be connected to the feed roller 2 via a gear train to reduce the angular velocity of the motor 4 and increase the applied torque. Of course, it is not excluded that the feed roller 2 may also be non-motorized and, for example, freely rotatable or braked, for example, by a friction brake. The top-sealing film 3 unfolds gradually and preferably moves around a plurality of rollers 5, the task of which is to give the film 3 a predetermined path and maintain appropriate film tension. The unfolded portion of the top-sealing film is driven, for example, via a conventional device such as a motorized roller or pliers, to the film pickup area 6, where, in each packaging cycle, a selected unfolded portion 7 of the top-sealing film 3 is picked up and conveyed into the packaging station 8 of the device 100. At the pickup area 6, according to, for example, in Figure 1 , Figure 2 and Figure 6 In some embodiments shown, the cutting station 9 is operable. In other words, the unfolded portion of the sealing film 3 is either cut off by the cutting station 9 located downstream of the film supply station 1, or fed directly to the packaging station 8, as will be described in further detail below.

[0222] Generally, the equipment includes a conveying device 10 (including a single conveying device or multiple cooperating conveying devices), which is responsible for conveying from the cutting station (see...). Figure 1 and Figure 2 (Example) or pick-up area 6 accessible directly from the selected expanded portion 7 (see example) Figure 3 The selected unfolded portion 7 of the top sealing film is picked up. The conveying device 10 acts on the selected unfolded portion 7 of the top sealing film and carries it into the packaging station 8. As can be seen from the figures, each of the selected unfolded portions 7 has the same width W measured parallel to the unwinding axis A as the top sealing film 3. In other words, each selected unfolded portion 7 is preferably a rectangular strip extending across the entire width of the top sealing film 3, which is therefore transported by the conveying device 10 inside the packaging station 8 for subsequent sealing of multiple product-loaded supports 11 positioned within the same packaging station.

[0223] In this respect, the device 100 includes a support feeding station 12, where empty supports 11 are loaded onto a first conveyor 13. For example, the supports 11 may be located on a conveyor belt, or a conveyor with a sliding surface for receiving the supports and a cross section for pushing the supports, or a conveyor with a top side having a seat of a suitable shape for receiving the supports, or another type of conveyor. The support feeding station 12 may include a support distributor that automatically stores the supports in their proper positions on the first conveyor, or it may simply include one or more columns where an operator manually loads the supports 11. Downstream of the support feeding station 12, a product loading station 15 operates, where one or more operators assist in loading product P into the corresponding supports 11 positioned on the first conveyor, or where one or more automatic product dispensing devices deliver one or more products or product doses P into or above each of the supports traveling on the first conveyor 13. The first conveyor 13 may be designed to transport product-loaded supports 11 inside the packaging station 8. Alternatively, a suitable conveying mechanism 17 may operate between the downstream end 13a of the first conveyor 13 and the packaging station 8 to pick up one or more arriving product-loaded supports 11 from the first conveyor 13 and move them to a suitable position inside the packaging station 8, where the product-loaded supports will receive a top sealing film 3 and form a closed package. The conveying mechanism 17 may, for example, include two side rods operating on opposite sides of a row of supports. The opposite rods may present forming cavities facing the supports to receive the sides of the supports: the rods may be actuated back and forth from the downstream end of the conveyor to the interior of the packaging station and from the interior of the packaging station to the downstream end of the conveyor to properly load the packaging station with a sufficient number of supports in each packaging cycle. Alternatively, the conveying mechanism may include a robotic arm that picks up the supports and moves them to a suitable position inside the packaging station. However, other conveying systems are contemplated without departing from the scope of this disclosure. As shown in the accompanying drawings, packaging station 8 includes a lower tool 18 and an upper tool 19 cooperating with the lower tool. Supports 11 are positioned at a lower tool loading area 20, which is designed to receive supports 11 provided by a first conveyor 13 or a conveying mechanism 17. According to one aspect, the supports 11 are positioned in the lower tool loading area 20 according to one or more parallel rows of supports (each row of supports is indicated by R in the drawings): each row R of supports includes a plurality of supports aligned along a predetermined alignment direction D, and the number of aligned supports 11 in each row R is greater than the number of rows R of supports in the lower tool loading area 20. For example, the lower tool loading area 20 may be designed to receive a row of three supports, or a row having four or more supports (see [reference]). Figures 1 to 3 ) or two rows, each with three or more supports (see Figure 4In one possible example, the product-loaded support 11 corresponds to one or more rows R' of seat 21 positioned in the lower tool loading area; the rows R' of seat 21 are aligned along the alignment direction D: each row R includes three or more seats, thus defining a corresponding support row R with three or more supports. For example, each row R' may include five or more seats, thus forming a corresponding support row R with five or more supports. It should be noted that, according to one aspect, the lower tool loading area 20 may be very elongated in the alignment direction D, and thus include one or two (more rarely three or more) rows R' of seats (and therefore rows R of supports), which include up to seven, eight or more aligned seats 21 or supports 11. The number of seats 21 on each seat row may be at least twice the number of seat rows R' present in the lower tool loading area. Therefore, the number of supports in each support row may correspondingly be at least twice the number of rows. As will be further explained, this does not impair the ability of the device and process of the present invention to perfectly position the top sealing film 3 and all the supports 11 in the sealing packaging station 8, due to the special manner in which the present invention feeds the top sealing film into the packaging station.

[0224] Referring again to the accompanying drawings, and as already mentioned, the lower tool loading area 20 has a plurality of parallel rows R' of seats 21 aligned along the alignment direction D: each of the supports 11 is positioned in a corresponding seat 21, thus forming multiple rows of aligned supports; the seat 21 may be, for example, a dedicated area on the top side of the lower tool, or a recess in the top side of the lower tool, the shape of which is opposite to the periphery of the support to be received by each seat. The top sealing film unfolds from the feed roller 2 and moves to the pick-up area 6, where a selected unfolded portion 7 arrives and is picked up by the conveyor 10, which acts on the selected unfolded portion 7 of the top sealing film and carries it into the packaging station 8. Essentially, in each packaging cycle, each selected unfolded portion 7 is thus transported by the conveyor 10 inside the packaging station 8 so as to subsequently close multiple product-loaded supports positioned inside the same packaging station. Selected unfolded portions 7 of the top sealing film are conveyed inside the packaging station 8 and positioned above the lower tool loading area 20, wherein the width W of each unfolded portion is aligned with the alignment direction D of rows R and R' (support and seat, respectively) in the lower tool loading area 20.

[0225] In fact, the selected unfolded portion 7 of the top sealing film conveyed inside the packaging station 8 and above the lower tool loading area 20 is a rectangular plastic strip with a width W sufficient to cover the extension along the alignment direction D of all the supports 11 present in the packaging station: in other words, the selected unfolded portion 7 is a strip of the top sealing film 3 extending in the width direction, which is longer in width than in length and moves onto one or more rows of supports 11 with its width W aligned with the alignment direction D of the (multiple) rows of supports / seats.

[0226] The length L of each selected unfolded portion 7 transported inside the packaging station 8 (note that the length L is measured perpendicular to the width W of the same selected unfolded portion) is sufficient to cover the lower tool loading area 20 and thus the extensions of all supports present in the packaging station perpendicular to the alignment direction D. In the illustrated embodiment, it should also be noted that the film supply station 1 rotatably engages the feed roller 2 about a corresponding unwinding axis A parallel to the predetermined alignment direction D.

[0227] In one embodiment, each of the supports 11 can be presented as a tray (see [link]). Figure 5 , Figure 7 , Figure 8 The tray has the form of a bottom wall 22, side walls 23 extending from the bottom wall 22, and a top opening 24' defining the tray and a top flange 24 extending radially from the side walls (see...). Figure 5 For example, flange 24 may have a rectangular outer perimeter 25 having two opposing first sides 25a and two opposing second sides 25b that meet the first sides at a corner region 26 of the flange: Figure 6 In this case, the support (in the form of a pallet) is positioned in the packaging station 8, with two opposing first sides 25a pointing parallel to the alignment direction D, and two opposing second sides 25b pointing perpendicular to the alignment direction D, as shown. Figures 1 to 4 and Figure 6 As shown. The width W of the selected unfolded portion 7 conveyed inside the packaging station 8 and above the support 11 is at least equal to the measurement of one first side 25a (of the outer perimeter 25 of the flange) multiplied by the number of supports 11 present in each row R, so as to cover the extensions of the flange 25 (in direction D) of all supports or trays positioned in the lower tool loading area 20 (see, for example). Figure 6 The length L of the selected unfolded portion 7 conveyed inside the packaging station 8 and above the support 11 (as already mentioned, it is shorter than the width) is at least equal to the measurement of a second side 25b (of the outer periphery 25 of the flange) multiplied by the number of rows R of the support 11 present in the packaging station, so as to cover the extension of the flange in the direction perpendicular to D.

[0228] Although the accompanying drawings show a support 11 in the form of a tray with transverse walls and flanges, the support 11 may alternatively be flat. In the case of a flat support, each support 11 may have a rectangular outer perimeter (similar to the outer perimeter of the flanges described above), which has two opposing first sides and two opposing second sides meeting the first sides at the corner areas of the flat support: in this case, the support is positioned in the packaging station, wherein the two opposing first sides point parallel to the alignment direction D, and the two opposing second sides point perpendicular to the alignment direction D. The width W of the selected unfolded portion conveyed inside the packaging station and above the support is at least equal to the measurement of one of the first sides (of the outer perimeter of the support) multiplied by the number of supports present in each row, so as to cover the extension of the support positioned in the lower tool loading area (see, for example, [reference needed]). Figure 6 The length L of the selected unfolded portion conveyed inside the packaging station and above the supports (as mentioned, shorter than the width) is at least equal to a measurement of a second side (outer perimeter of the supports) multiplied by the number of rows of supports present in the packaging station.

[0229] One aspect of the invention specifies that a selected unfolded portion 7 of the top sealing film 3 conveyed inside the packaging station and above the lower tool loading area 20 is a transversely full-width elongated strip of the top sealing film. Specifically, the width W of the selected unfolded portion 7 of the top sealing film 3 conveyed inside the packaging station 8 is significantly greater than the corresponding length L (measured perpendicular to said width W). For example, the width W of each selected unfolded portion of the top sealing film conveyed inside the packaging station can be at least two or three times, or at least five or at least ten times, the corresponding length L. In practice, by using a relatively wide feed roller 2 and therefore a relatively wide top sealing film 3, the entire longitudinal extension (along direction D) (or the extension of (a plurality of) rows of supports) of the lower tool loading area 20 can be covered with the width W of each selected portion 7, thus enabling the use of a relatively short length of top sealing film in each packaging cycle, thereby overcoming all the disadvantages of the prior art in a simple manner.

[0230] More specifically, the apparatus and process according to an aspect of the invention provide a packaging cycle for repeating at intervals including at least the following steps. In this regard, the apparatus has a control unit 50 configured to perform the packaging cycle and connected for this purpose to a packaging station 8, a conveying device 10, and the other components described above. The packaging cycle includes configuring the packaging station 8 in an open configuration, wherein an upper tool 19 and a lower tool 18 are spaced apart from each other, and positioning a support 11 loaded with at least one product within the packaging station while the packaging station is in the open configuration. Similarly, with the packaging station in the open configuration, an unfolded portion 7 is conveyed into the packaging station 8 and above the lower tool loading area 20. As discussed above, these steps can be performed under the control of the control unit 50, which can suitably coordinate one or more actuators 30 acting on the packaging station to put it in the open configuration, coordinate the first conveyor 13 and / or the conveying mechanism 17 to move the product-loaded support 11 to a position in the lower tool loading area 20, and coordinate the aforementioned conveying device 10 to move the selected unfolded portion 7 to a desired position above the product-loaded support.

[0231] The packaging cycle then provides a method for configuring the packaging station 8 into a closed configuration, with the upper tool 19 and the lower tool 18 close to each other. With the packaging station in the closed configuration, the top sealing film 3 is secured to a support, and a selected unfolded portion 7 of the top sealing film is heat-sealed to the support 11. As discussed above, these steps can be performed under the control of a control unit 50, which may appropriately command a heater 31, present inside the packaging station (typically on the upper tool), to heat at least one outer band of the selected unfolded portion and bring it against the lower support 11 to achieve a heat seal between them.

[0232] According to a possible variation of the invention, the apparatus and process can provide a cutting procedure for execution at cutting station 9 (see, for example, [link to relevant documentation]). Figure 1 , Figure 2 and Figure 6 The cutting station 9 is operatively inserted between the film supply station 1 and the conveying device 10. In practice, the cutting station 9 receives the top-sealing film 3 and separates the selected unfolded portion 7 from it before the selected unfolded portion is conveyed into the packaging station.

[0233] The cutting station 9, also connected and controlled by the control unit 50 in coordination with other parts of the aforementioned equipment, can laterally separate the selected unfolded portion 7 from the top sealing film to form a single, integrally separated unfolded portion, which is separate from the remainder of the sealing film 3 extending upstream of the separated unfolded portion and originating from the feed roller 2. The separated unfolded portion 7 is in the form of an integral strip having the same width W as the top sealing film and a length L significantly smaller than its width W. Alternatively, the cutting station 9 can be configured to both laterally separate the selected unfolded portion 7 from the top sealing film and longitudinally separate the sealing film 3 correspondingly to the same selected unfolded portion 7. In this way, the separated unfolded portion 7 is separated from the remainder of the top sealing film 3 (which remains connected to the feed roller 2) and consists of a plurality of longitudinally separated and laterally adjacent different films 7a (see...). Figure 1 and Figure 6 ).Notice, Figure 1 As shown, one or more first blades 28a firstly intervene to form parallel cuts in the direction of movement of the top sealing film 3, and then one or more second blades 28b intervene to transversely cut selected unfolded portions 7, thereby forming a plurality of adjacent, separate films 7a that collectively define the selected unfolded portions. However, the cutting order can be reversed, or longitudinal and transverse cuts can be performed simultaneously, for example, using a cutter or die-cutting machine of appropriate shape.

[0234] Separated expanded section 7 (see Figure 6 The dimensions are precisely determined to cover all supports 11 in the same row R present in the packaging station, and to cover (in the direction perpendicular to the alignment direction D) all support rows R present in the packaging station. Figure 6 In the example, the lower tool 18 of the packaging station accommodates eight seats and thus supports or trays positioned in two rows according to four seats / trays each; the conveying device 10 loads selected unfolded portions 7 of the top-sealing film formed by eight adjacent pieces 7a into the packaging station, such that each piece 7a is perfectly fitted to the dimensions of the corresponding tray flange 24 and is therefore closureable, in particular, hermetically closureable of the corresponding one of the lower supports / trays 11. More generally, once the separate unfolded portions 7 are conveyed to the packaging station, they engage with the lower supports 11 present in the lower tool loading area 20, such that each of the supports 11 is heat-sealed to the corresponding portion of the separate unfolded portion 7 or the corresponding film (part of the same unfolded portion) in the different films 7a. Figure 5 An example of a support 11 in the form of a tray with sidewalls and peripheral flanges is shown for use in the process of the invention and with the device of the invention: the tray 11 is closed by a corresponding diaphragm 7a of a diaphragm that is transported to an unfolded portion of a packaging assembly.

[0235] Figure 7This illustrates a case where the top sealing film 7a is heat-sealed to the flange 24 to form a controlled atmosphere or natural atmosphere package, while Figure 8 This illustrates a case where the top sealing film 7a is heat-sealed to the top surface of the flange 24 and the tray not occupied by the product to form a vacuum-sealed skin package.

[0236] Returning to the transfer of the selected unfolded portion 7 to the packaging station, it should be noted that the transfer device 10 for transferring the selected film portion 7 from the pick-up area 6 to the packaging station 8 may include a transfer body 40 capable of traveling back and forth between the cutting station and the packaging station, which may be, for example, in the form of a plate, or in any case, in the form of a body of relatively small thickness. After the selected unfolded portion 7 is separated from the remainder of the top-sealed film by the cutting station 9, the step of transferring the selected unfolded portion 7 provides for positioning the selected unfolded portion on a continuous movable surface 40a of the transfer body: in the example shown, the movable surface 40a is the top surface of the transfer body 40, which may be flat, slightly convex, or slightly concave, and it holds the selected unfolded portion 7 in place under the constant action of suction applied by air drawn in through a plurality of suction holes 41 present on the same movable surface 40a and connected to a vacuum source 42 controlled by the aforementioned control unit 50. Then, with the packaging station 8 in an open configuration, the transfer step of the process provides for moving the transfer body 40 and thus the selected unfolded portion 7 (which has just been cut from the remainder of the top sealing film 3) from the cutting station 9 to the packaging station 8, below the upper tool 19, and for releasing the selected unfolded portion from the active surface of the transfer body once the transfer body is just below and near the upper tool. This release can be controlled by a control unit 50 configured to command the vacuum source 42 to stop drawing air from the suction port 41, or it can vent the suction port 41 to the atmosphere through the action of a suitable valve system 43. The unfolded portion released by the transfer body 40 is then captured by the lower surface 19a of the upper tool 19 under the control of the control unit. The lower surface 19a of the upper tool 19 may also be provided with a corresponding number of suction ports 19b connected to a vacuum source (which may be the same vacuum source 42 or another vacuum source 45). At this point, the transfer body 10 can be controlled to return to the cutting station 9. The movement of the described conveyor body is controlled by a control unit, which commands one or more actuators 46 that are controllably connected to the conveyor body 10. The control unit 10 is configured to synchronize the operation of the cutting unit, the intervention of the vacuum source, the opening / closing of the packaging station, the movement of the conveyor body, the movement of the first conveyor, and the movement of the conveying mechanism, such as the device 100 performing the described steps in the appropriate described sequence without interference between the various moving parts.

[0237] According to the alternative solution, the selected unfolded portion 7 is not laterally cut and separated from the remainder of the top sealing film 3 before being conveyed into the packaging station 8. In this case, there is no cutting unit between the film supply assembly 1 and the packaging station 8. Of course, the conveyance of the selected unfolded portion can be carried out as described above. On the other hand, according to, for example, in Figure 3 and Figure 4 The alternative shown involves transferring the selected unfolded portion 7 by grasping the leading edge 7b of the selected unfolded portion 7 (i.e., the end free boundary extending in the width direction of the top closure film) and moving the selected unfolded portion 7 from the pick-up area 6 outside the packaging station to inside the packaging station and above the lower tool loading area 20. To do this, one or more clamps 46 are operable to grasp the leading edge 7b of the selected unfolded portion; the clamps 46 may, for example, engage with another part of the upper tool or equipment 100 and are configured to travel back and forth to properly position the selected unfolded portion within the packaging station in each cycle. For example, the traveling clamps 46 may pick up the selected unfolded portion 7 of the top closure film in area 6 of the equipment near the packaging station 8 and pull the top closure film 3 in the direction of and towards the packaging station to position the selected unfolded portion 7 below the upper tool and above the lower tool loading area. Then, once the packaging station has completed securing the selected unfolded portion to the lower support within the packaging station, the traveling clamps 46 can move back to their initial positions and pick up the new selected unfolded portion 7 to begin a new packaging cycle. One or more traveling clamps 46 acting on the leading edge 7b can cooperate with one or more fixed clamps 47 mounted on the upper tool or on the fixed frame of the equipment carrying the packaging station: the fixed clamps 47 can hold the top sealing film 3 in place as the traveling clamps 46 move back to their initial positions at the end of each packaging cycle.

[0238] In a supplementary but particularly advantageous aspect, the step of conveying the selected unfolded portion to the packaging station 8 is achieved without gripping the relative longitudinal side boundaries of the selected unfolded portion: in other words, the selected unfolded portion is conveyed using the conveyor body 40 or using the aforementioned traveling clamps 46. This means that no conveying element such as clamps, rollers, or other devices contacts or grips the longitudinal side boundaries of the selected unfolded portion. This not only avoids damage to the side boundaries of the top sealing film but also saves a relatively large amount of top sealing film material, since any device that intervenes at the side boundaries must occupy a strip on each side of the top sealing film, which cannot then be used to close the support.

[0239] Once the packaging cycle is complete and the support 11 has been closed by the selected unfolded portion of the sealing film 3, the packaging station 8 moves to the open configuration, and another conveyor 48 can extract the packaged products PP and move them onto a second conveyor 49, which may be opposite to the first conveyor 13 (as shown in the figure) or may travel orthogonally to the first conveyor. If necessary, a packaging cutting station 51, including one or more blades 52, can operate downstream of the packaging station 8 to separate the packaged products one by one.

Claims

1. A packaging process, the process comprising the following steps: - A plurality of supports (11) with corresponding products (P) are positioned inside a packaging station (8), the packaging station including a lower tool (18) and an upper tool (19) cooperating with the lower tool, wherein: The support member (11) is positioned at the lower tool loading area (20) according to one or more parallel support rows (R). Each support row (R) includes a plurality of support members (11) aligned along a predetermined alignment direction (D). The number of alignment supports (11) in each support row (R) is greater than the number of support rows (R) in the lower tool loading area (20), or the lower tool loading area (20) extends further along the alignment direction (D) than perpendicular to the alignment direction (D). - The top sealing film (3) is unwound from the film supply station (1) by allowing the feed roller (2) to rotate around the corresponding unwinding axis (A), the top sealing film having a width (W) measured parallel to the unwinding axis (A). - A selected unfolded portion (7) of the top sealing film (3) is conveyed inside the packaging station (8), wherein the selected unfolded portion (7) is a strip that spans the top sealing film (3) and has the same width (W) as the top sealing film (3), and wherein the selected unfolded portion (7) is positioned above the lower tool loading area (20), wherein the width (W) of the selected unfolded portion (7) is aligned with the alignment direction (D) of the support row (R) present in the lower tool loading area (20). - Secure the selected unfolded portion (7) of the top sealing film (3) to the plurality of supports present in the packaging station; The selected unfolded portion (7) of the top sealing film, which is conveyed inside the packaging station (8) and above the lower tool loading area (20), has: - Width (W) sufficient to cover the extensions of all supports in the packaging station along the alignment direction (D), and - A length (L) perpendicular to the width (W) that is sufficient to cover the extensions of all supports present in the packaging station that are perpendicular to the alignment direction (D).

2. The process of claim 1, wherein, The fixing step is achieved by heat-sealing the selected unfolded portion (7) of the top sealing film (3) to the plurality of supports present in the packaging station.

3. The process of claim 1, wherein, The support (11) corresponds to one or more seat rows (R') aligned along the alignment direction (D) and positioned at the lower tool loading area (20), wherein each seat row (R') includes three or more seats (21), thus defining a corresponding support row (R) having three or more support members (11).

4. The process of claim 3, wherein, Each seat row (R') includes five or more seats (21), thus forming a corresponding support row (R) with five or more supports (11).

5. The process according to claim 1, wherein, The selected unfolded portion (7) of the top sealing film, which is conveyed inside the packaging station (8) and above the lower tool loading area (20), has a rectangular shape.

6. The process according to claim 3, wherein, The lower tool (18) has a plurality of parallel seat rows (R') aligned along the alignment direction (D) at the lower tool loading area (20), and receives the support (11) positioned according to the support row (R).

7. The process according to claim 3, wherein, The number of seats (21) on each seat row (R') is at least twice the number of seat rows (R') present in the lower tool loading area (20).

8. The process according to claim 3, wherein, Each of the supports (11) is a tray having a bottom wall (22), a side wall (23) extending from the bottom wall, and a top flange (24) defining a top opening (24') of the tray and extending radially from the side wall, wherein the top flange (24) has an outer periphery (25) having two opposing first sides (25a) parallel to the alignment direction and two opposing second sides (25b) perpendicular to the alignment direction (D), wherein the width (W) of the selected unfolded portion (7) conveyed inside the packaging station and above the supports is at least equal to a measurement of one of the first sides multiplied by the number of supports present in each row, and wherein the length (L) of the selected unfolded portion conveyed inside the packaging station and above the supports is at least equal to a measurement of one of the second sides multiplied by the number of rows of supports present in the packaging station.

9. The process according to claim 3, wherein, Each of the supports (11) is a flat support having an outer periphery having two opposing first sides parallel to the alignment direction and two opposing second sides perpendicular to the alignment direction (D), wherein the width (W) of the selected unfolded portion conveyed inside the packaging station and above the support is at least equal to a measurement of one of the first sides multiplied by the number of supports present in each row, and wherein the length (L) of the selected unfolded portion conveyed inside the packaging station and above the support is at least equal to a measurement of one of the second sides multiplied by the number of rows of supports present in the packaging station.

10. The process according to any one of the preceding claims, wherein, The selected unfolded portion (7) of the top sealing film conveyed inside the packaging station (8) and above the lower tool loading area (20) is a transverse full-width elongated strip of the top sealing film, wherein the width (W) of the selected unfolded portion (7) of the top sealing film conveyed inside the packaging station is significantly greater than the corresponding length (L) measured perpendicular to the width (W).

11. The process according to claim 10, wherein, The selected unfolded portion (7) of the top sealing film, which is conveyed inside the packaging station (8) and above the lower tool loading area (20), has a width (W) that is at least two or at least three times, or at least five or at least ten times the corresponding length (L).

12. The process according to any one of claims 1-9, wherein, The process includes repeating a packaging cycle at intervals, the packaging cycle including at least the following steps: - The packaging station (8) is configured as an open structure, wherein the upper tool and the lower tool are spaced apart from each other. - In the case that the packaging station (8) is in the open structure o Perform the step of positioning the support (11) on which at least one product is loaded into the packaging station (8), The step of transferring the unfolded portion (7) to the packaging station (8) and above the lower tool loading area (20) is performed. - The packaging station (8) is constructed as a closed structure, wherein the upper tool and the lower tool are close to each other. - When the packaging station (8) is in a closed configuration, the top sealing film (3) is fixed to the support, and the selected unfolded portion (7) of the top sealing film (3) that has been transferred to the packaging station (8) and above the lower tool loading area (20) is fixed to the support.

13. The process according to any one of claims 1-9, comprising a cutting procedure performed at a cutting station (9) operably inserted between the membrane supply station (1) and the conveying device (10) of the selected unfolding portion (7), wherein, The cutting station receives the top sealing film and separates the selected unfolded portion (7) from the top sealing film (3) before the top sealing film (3) is conveyed inside the packaging station (8); and The cutting process includes: - The selected unfolded portion (7) is laterally separated from the top sealing film (3) to form a separate unfolded portion that is separate from the rest of the top sealing film from the feed roller, the separate unfolded portion being in the form of an integral strip having the same width (W) as the top sealing film; - Alternatively, the selected unfolded portion (7) can be separated laterally from the top sealing film (3), and the top sealing film can be separated longitudinally at the selected unfolded portion to form a separated unfolded portion consisting of multiple longitudinally separated and laterally adjacent different films (7a).

14. The process according to claim 13, further wherein, The separate unfolding portion (7) is precisely sized to cover all the supports (11) of the same support row (R) present in the packaging station (8) and to cover all one or more rows of supports present in the packaging station (8), and wherein, once conveyed to the packaging station, the separate unfolding portion (7) engages with the lower support (11) present in the lower tool loading area (20), such that each of the supports (11) is fixed to a corresponding portion of the separate unfolding portion (7) or a corresponding diaphragm in the different diaphragms (7a).

15. The process according to any one of claims 1-9, wherein, The width of the top sealing film (3), measured parallel to the unwinding axis (A), and therefore the width (W) of each selected unfolded portion (7), is at least 450 mm; and wherein the top sealing film (3) is a plastic film having a thickness between 10 and 200 μm; and / or The width of the top sealing film (3), measured parallel to the unwinding axis (A), and therefore the width (W) of each selected unfolded portion (7) is at least 600 mm; and the top sealing film (3) is an extruded single-layer or multi-layer plastic film.

16. The process according to claim 12, wherein, The transmission includes: - Position the selected unfolded portion (7) on the movable surface (40a) of the conveying body (40). - When the packaging station (8) is in the open configuration, The conveying body (40) and therefore the selected unfolding portion (7) are moved from the cutting station (9) to the packaging station (8) below the upper tool. The selected unfolded portion (7) is released from the movable surface (40a) of the conveying body (40) and captured by the lower surface of the upper tool (19). The conveying body (40) is returned to the cutting station (9).

17. The process according to claim 16, wherein, The movable surface (40a) of the conveying body (40) is flat, and the selected unfolding portion is held in place by suction applied by drawing air in through a plurality of suction holes (41) present on the movable surface and connected to a vacuum source (42).

18. The process according to any one of claims 1-9, wherein, The transmission includes: - Grasp the leading edge (7b) of the selected unfolded portion (7) and move the selected unfolded portion (7) from the pick-up area outside the packaging station to the packaging station and above the lower tool loading area.

19. The process according to claim 16, wherein, The selected unfolded portion (7) is transferred to the packaging station (8) without gripping the relative longitudinal side boundaries of the selected unfolded portion.

20. A packaging device (100), comprising: A membrane supply station (1) for supplying a top-sealing film (3), wherein the membrane supply station (1) is configured to engage at least one feed roller (2) to rotate about a corresponding unwinding axis (A) to allow the top-sealing film (3) to unfold from the feed roller (2). Packaging station (8), which has: - A lower tool (18) having a lower tool loading area (20) configured to receive a plurality of supports (11) positioned according to one or more support rows (R), wherein Each support row (R) includes a plurality of support members (11) aligned along a predetermined alignment direction (D). The number of supports (11) in each support row (R) is greater than the number of support rows (R) in the lower tool loading area, or the lower tool loading area (20) extends further along the alignment direction (D) than perpendicular to the alignment direction (D). - An upper tool (19) configured to cooperate with the lower tool (18) for securing the top sealing film (3) to the plurality of supports (11) present in the packaging station (8); The conveying device (10) is configured as follows: - Acting on a selected unfolded portion (7) of the top sealing film, the selected unfolded portion having the same width (W) as the top sealing film (3) measured parallel to the unwinding axis (A), and - The selected unfolded portion (7) is conveyed to the packaging station (8) and above the lower tool loading area (20), wherein the width (W) of each selected unfolded portion (7) is aligned with the alignment direction (D) of the support row (R) in the lower tool loading area (20); The membrane supply station (1) is configured to engage the at least one feed roller (2) to rotate about a corresponding unwinding axis (A) parallel to the predetermined alignment direction (D); and The conveying device (10) is configured as follows: - It acts on a selected unfolding section (7), which is located in the pick-up area (6) of the device positioned between the film supply station (1) and the packaging station (8), and - The selected unfolded portion (7) of the top sealing membrane (3) is conveyed above the lower tool loading area (20). The selected unfolded portion (7) of the top sealing membrane (3) has: - Width (W) sufficient to cover the entire extension of the lower tool loading area (20) along the alignment direction (D), and to cover all supports (11) of the same support row (R) present in the packaging station (8). - Length (L) sufficient to cover the entire extension of the lower tool loading area (20) perpendicular to the alignment direction (D), and to cover all support rows (R) present in the packaging station (8).

21. The packaging equipment according to claim 20, wherein, The lower tool (18) has one or more rows of seats (R') aligned along the alignment direction (D) at the lower tool loading area (20) and is configured to receive the support (11) positioned according to the one or more rows of support (R), wherein each row of seats (R') includes three or more aligned seats (21).

22. The packaging equipment according to claim 20, wherein, The conveying device (10) is configured as follows: - It acts on a selected unfolding section (7) located at the pick-up area (6) of the device positioned between the film supply station (1) and the packaging station (8), and - The selected unfolded portion (7) of the top sealing membrane (3) having a width (W) greater than the corresponding length (L) is conveyed above the lower tool loading area (20).

23. The packaging equipment according to claim 22, wherein, The conveying device (10) is configured to act on a selected unfolded portion (7) of the top sealing membrane (3) and convey the selected unfolded portion (7) above the lower tool loading area (20), wherein the width (W) of the selected unfolded portion (7) is at least two or at least three, or at least five or at least ten times the corresponding length (L).

24. The packaging equipment according to claim 20, wherein, The lower tool (18) has a plurality of parallel seat rows (R') at the lower tool loading area (20), the plurality of parallel seat rows (R') being aligned along the alignment direction (D) and configured to receive the support (11) positioned according to the support row (R); and The number of seats (21) on each seat row (R') is at least twice the number of seat rows (R') present in the lower tool loading area (20).

25. The packaging equipment according to claim 20, comprising a control unit (50) communicatively connected to the packaging station (8) and the conveying device (10), in, The control unit (50) is configured to perform a packaging cycle including at least the following steps: - The packaging station (8) is positioned in an open structure, wherein the upper tool (19) and the lower tool (18) are spaced apart from each other to allow the support (11) to be positioned in the packaging station; - With the packaging station (8) in the open configuration, the conveying device (10) is commanded to act on one of the selected unfolded portions (7) of the top sealing film (3) and convey the selected unfolded portion (7) to the packaging station (8) and above the lower tool loading area (20), wherein the width (W) of each selected unfolded portion (7) is aligned with the alignment direction (D) of the support row (R) in the lower tool loading area (20). - The packaging station (8) is positioned in a closed structure, wherein the upper tool (19) and the lower tool (18) are close to each other and cooperate to secure the top sealing film (3) to the support.

26. The packaging equipment according to claim 25, in the step of commanding the packaging station (8) to be positioned in the closed structure, wherein the upper tool (19) and the lower tool (18) are brought close to each other and cooperate to secure the top sealing film (3) to the support by heat-sealing the selected unfolded portion (7) of the top sealing film to the support.

27. The packaging equipment according to any one of claims 20-26 further comprises a cutting station (9), said cutting station (9) being operably inserted between the film supply station (1) and the conveying device (10), wherein: - The cutting station (9) is configured to laterally separate the selected unfolded portion (7) from the top sealing film (3) to form a separate unfolded portion that is separate from the rest of the top sealing film from the feed roller, the separate unfolded portion being in the form of an integral strip having the same width (W) as the top sealing film (3). - Alternatively, the cutting station (9) is configured to laterally separate the selected unfolded portion (7) from the top sealing film (3) and longitudinally separate the top sealing film (3) at the selected unfolded portion (7) to form a separated unfolded portion consisting of a plurality of longitudinally separated and laterally adjacent different films (7a).

28. The packaging equipment according to any one of claims 20-26, wherein, The membrane supply station (1) engages a feed roller (2) that provides the top sealing membrane (3) with a width (W) of at least 450 mm parallel to the unwinding axis (A); and The top sealing film is a plastic film with a thickness between 10 and 200 μm.

29. The packaging equipment according to any one of claims 20-26, wherein, The membrane supply station (1) engages a feed roller (2) that provides the top sealing membrane (3) with a width (W) of at least 600 mm parallel to the unwinding axis (A).

30. The packaging equipment according to claim 27, wherein, The conveying device (10) includes a conveying plate (40) having a plurality of suction holes connected to a vacuum source, the conveying plate (40) being configured to move the separated unfolded portion (7) or the different films (7a) from the cutting station (9) to the packaging station (30).

31. The packaging equipment according to claim 27, wherein, The conveying device (10) includes one or more clamps that act on the leading edge (7b) of the selected unfolded portion from the cutting station (9) to the packaging station (30).

32. The packaging equipment according to claim 30, wherein, No means is provided to act on the longitudinal side boundary of the separated unfolded portion to move the separated unfolded portion (7) or the different film (7a) from the cutting station (9) to the packaging station (30).

33. The packaging equipment according to claim 27, comprising a control unit (50) communicatively connected to the packaging station (8) and the conveying device (10), in, The control unit (50) is configured to perform a packaging cycle including at least the following steps: - The packaging station (8) is positioned in an open structure, wherein the upper tool (19) and the lower tool (18) are spaced apart from each other to allow the support (11) to be positioned in the packaging station; - With the packaging station (8) in the open configuration, the conveying device (10) is commanded to act on one of the selected unfolded portions (7) of the top sealing film (3) and convey the selected unfolded portion (7) to the packaging station (8) and above the lower tool loading area (20), wherein the width (W) of each selected unfolded portion (7) is aligned with the alignment direction (D) of the support row (R) in the lower tool loading area (20). - The packaging station (8) is positioned in a closed structure, wherein the upper tool (19) and the lower tool (18) are close to each other and cooperate to secure the top sealing film (3) to the support; The control unit is further connected to the cutting station (9), and the packaging cycle configured to be executed by the control unit further includes commanding the cutting station (9) to perform a cutting procedure, the cutting procedure including: - The selected unfolded portion (7) is laterally separated from the top sealing film (3) to form a separate unfolded portion that is separate from the rest of the sealing film from the feed roller. The separate unfolded portion is in the form of an integral strip with the same width (W) as the top sealing film (3). - Alternatively, the selected unfolded portion (7) can be separated laterally from the top sealing film (3) and the sealing film (3) can be separated longitudinally at the selected unfolded portion (7) to form a separated unfolded portion consisting of multiple longitudinally separated and laterally adjacent different films (7a).

34. The packaging equipment according to claim 33, wherein, The control unit is configured to execute the cutting procedure before commanding the conveying device (10) to convey the selected unfolded portion (7) to the packaging station (8).

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