Packaging machine for producing sealed packages from a web of packaging material

Abstract

A packaging machine (1) for producing sealed packages from a web of packaging material (4) fed along a conveying path (P) is described. The packaging machine includes: a tube forming and sealing unit (9) arranged along the conveying path (P) for folding the web of packaging material (4) from a planar shape into a tube (10) and for longitudinally sealing the tube (10); an isolation chamber (C) that separates an internal sterile / sterilized environment (IE) from an external environment (OE), wherein the tube forming and sealing unit (9) is at least partially arranged in the isolation chamber (C); and a control device (19) including a first sensor device (20) arranged upstream of the isolation chamber (C) along the conveying path (P) and configured to detect splices (S) on the web of packaging material (4); and a second sensor device (23) arranged in a region of the isolation chamber (C) along the conveying path (P) and configured to detect splices (S) of the packaging material.

Description

Technical Field

[0001] This invention relates to a packaging machine for producing sealed packages from packaging material webs. Background Technology

[0002] Many liquids or pourable foods, such as pasteurized or ultra-high temperature (UHT) milk, ketchup, wine, and juice, are known to be sold in packages made of aseptic packaging materials.

[0003] This type of packaging is typically produced using an automated packaging machine that feeds the web of packaging material through a sterilization unit via known guiding elements (such as rollers) to sterilize the web of packaging material by chemical sterilization in a sterilization bath (e.g., by applying a chemical sterilizing agent, such as a hydrogen peroxide solution) or alternatively by physical sterilization (e.g., by an electron beam).

[0004] The packaging machine also includes a folding unit, located downstream of the sterilization unit and extending substantially vertically, designed to fold the packaging material web to produce a continuous tube. Within the folding unit, the packaging material web is folded from a continuous planar shape into a continuous tubular shape with a vertical axis. The planar packaging material web is folded into a cylinder, which is then continuously subdivided into multiple pillow-shaped packages, which undergo a series of mechanical folding operations to obtain a sealed finished product package.

[0005] The folding unit is preferably arranged within a fixed structure, wherein the packaging material web is maintained in a sterile air environment. The folding unit also includes multiple folding devices placed sequentially (one after another); through interaction with the folding devices, opposing lateral portions (or edges) of the packaging material web are overlapped one on top of the other to form a tube and define an overlapping area. The packaging machine also includes a sealing unit for sealing the overlapping lateral portions of the packaging material web to ultimately achieve a fluid-impermeable longitudinal seal within the tube.

[0006] Finally, the packaging machine includes a control unit for monitoring the operation of different units within the machine and has at least one sensing element configured to detect splices of packaging material, i.e., where the ends of two packaging material webs are superimposed and joined to each other with a width substantially twice the width of a single packaging material web. When a splice is detected, the control unit is configured to regulate the operation of the tube forming and sealing equipment and / or the sterilization unit. While known sensing elements for detecting packaging material splices work well, there is a desire in the art to further improve and simplify the detection of packaging material splices. Summary of the Invention

[0007] The purpose of this invention is to provide a packaging machine for producing sealed packages from packaging material webs, which overcomes the shortcomings of the prior art, and is particularly simple and economical to manufacture.

[0008] According to the present invention, a packaging machine for producing sealed packages from packaging material webs is provided, as described in the appended claims. Attached Figure Description

[0009] Non-limiting embodiments of the invention will be described by way of example with reference to the accompanying drawings, wherein: - Figure 1 This is a perspective view of a packaging machine according to the invention for producing packaging from packaging materials, wherein some parts have been removed for clarity; - Figure 2 yes Figure 1 A schematic side view of the packaging machine; and - Figure 3 yes Figure 2 A schematic diagram of the sensor device. Detailed Implementation

[0010] Figure 1 and Figure 2 A packaging machine 1 for the continuous production of sealed packages containing pourable food products, such as pasteurized or ultra-high temperature (UHT) milk, ketchup, wine, and juice, is disclosed. The sealed packages are obtained from packaging material unwound from a reel 3 and fed along a conveyor path P. When unwound from the reel 3, the packaging material has the shape of a continuous planar packaging material web 4.

[0011] Typically, packaging materials have a multi-layered structure. More specifically, packaging materials may include at least one layer of fibrous material, such as a paper or cardboard layer, and at least two heat-sealed plastic material layers (e.g., polyethylene) interposed therebetween. One of these two heat-sealed plastic material layers may define the inner surface of the packaging that will ultimately come into contact with the pourable product.

[0012] According to some possible non-limiting embodiments, the packaging material may also include a gas barrier and light barrier material layer, such as aluminum foil or ethylene vinyl alcohol (EVOH) film, which is particularly disposed between one of the heat-sealing plastic material layers and the fiber material layer. Preferably, the packaging material may also include another heat-sealing plastic material layer interposed between the gas barrier and light barrier material layer and the fiber material layer.

[0013] Packaging material web 4 is guided by guiding element 6, particularly by multiple rollers 6 (one of which is in...) Figure 2 (As shown in the diagram) is fed into sterilization unit 5. Sterilization unit 5 may include a sterilization bath 7 in which a chemical sterilizing agent, such as a hydrogen peroxide solution, is applied to the packaging material web 4. The packaging material web 4 is fed through sterilization unit 5 by known guiding elements 8, such as rollers 8 or similar elements.

[0014] In addition, packaging machine 1 includes: - Tube forming and sealing equipment 9, configured to form tube 10 from a propelled packaging material web 4 and longitudinally seal tube 10; and - Filling device 17, which is used to fill tube 4 with pourable product.

[0015] More specifically, the packaging machine 1 includes an isolation chamber C, which preferably separates an internal environment IE from an external environment OE. Preferably, the internal environment IE is a sterile (sterilized) environment, preferably containing a controlled atmosphere. Preferably, the tube forming and sealing device 9 is at least partially arranged within the isolation chamber C, particularly within the internal environment IE, and is configured to fold and longitudinally seal the tube 10 within the isolation chamber C, particularly within the internal environment IE.

[0016] The tube forming and sealing device 9 is arranged downstream of the sterilization unit 5 along the conveyor path P. The tube forming and sealing device 9 extends substantially vertically along the conveyor path P for the production of continuous tubes 10. Specifically, within the tube forming and sealing device 9, packaging material webs 4 are folded from a continuous planar shape into a continuous tubular shape having a longitudinal axis Y. Specifically, the longitudinal axis Y is arranged in a vertical direction.

[0017] The tube forming and sealing device 9 is confined within the fixed structure 11. The tube forming and sealing device 9 also includes a plurality of forming / folding devices 12 placed continuously (one after another) along the conveying path P.

[0018] Advantageously, each of the folding devices 12 may include a ring shape, for example, at least partially surrounding the packaging material web 4. For example, the folding device 12 may include a formed ring 13 surrounding the packaging material web 4. The support device 12 may be configured to support a plurality of rollers 14 that cooperate to fold the packaging material web 4.

[0019] Specifically, the tube forming and sealing device 9 includes a (first) folding device 12A and a (second) folding device 12B, which are placed continuously (one after another) along the conveying path P carried by the fixed structure 11 and interact with the packaging material web 4 to gradually fold the packaging material web 4 into a tube (cylinder) and to superimpose the (first) lateral portion of the packaging material web 4 onto the (second) lateral portion of the packaging material web 4 opposite to the (first) lateral portion to form a continuous tube 10.

[0020] Folding device 12B is placed downstream of folding device 12A along the conveyor path P.

[0021] Specific reference Figure 1As shown in Figure 4, the first folding device 12A includes a first folding ring 13A supporting a plurality of first folding rollers 14A; the first folding rollers 14A have corresponding axes perpendicular to the Y-axis. The first folding rollers 14A have corresponding concave side surfaces (i.e., the diameter encountered by the packaging material web 4 at the end of the first folding roller 14A is larger than the diameter encountered at its center). The side surfaces of the first folding rollers 14A define a first forced channel for the folded packaging material web 4.

[0022] Similarly, the second folding device 12B includes a second folding ring 13B supporting a plurality of second folding rollers 14B; the second folding rollers 14B have corresponding axes perpendicular to axis Y. The second folding rollers 14B have corresponding concave side surfaces (i.e., the diameter encountered by the packaging material web 4 at the end of the second folding roller 14B is larger than the diameter encountered at its center). The side surfaces of the second folding rollers 14B define a second forced channel for the folded packaging material web 4.

[0023] The tube forming and sealing apparatus 9 includes a sealing unit 15 for sealing the overlapping lateral portions of the packaging material web 4 to obtain a fluid-impermeable longitudinal seal in the tube 10. The sealing unit 15 is arranged downstream of the first folding device 12A along the conveying path P. Advantageously, the sealing unit 15 is located between the two folding devices 12A and 12B.

[0024] The sealing unit 15 includes a heating element 16. According to a first embodiment, the heating element 16 may include an induction heating element 16 for inductively heating the inner surface of the lateral portion to overlap the facing surface of the second lateral portion. The inner surface of the lateral portion is the surface facing the second lateral portion.

[0025] As a possible alternative, the heating element 16 may include a hot air heating element 16 having a plurality of nozzles for directing hot air onto the inner surface of the lateral portion to overlap the facing surface of the second lateral portion. A sealing region corresponding to the sealing unit 15 is defined along the transport path P. More specifically, the sealing region is defined along the transport path P in the area between the two lateral portions of the packaging material web 4 where the heating element 16 is positioned.

[0026] The tube 10 is continuously filled with pourable food through a filling device 17, which includes a pouring conduit 18 that extends partially within the tube 10 and is part of the filling circuit. The tube 10 is then fed to a lateral forming and sealing unit (not shown), in which the tube 10 is clamped to laterally seal the tube and form a pillow-shaped package 2. Finally, the pillow-shaped package 2 is subjected to a series of mechanical folding operations to obtain a finished sealed package.

[0027] The packaging machine 1 includes a control device 19 having at least one electronic control unit (ECU) configured to monitor the operation of the packaging machine 1.

[0028] The control device 19 includes a (first) sensing element 20 connected to an electronic control unit (ECU) arranged along the conveying path P and configured to detect the splicing S of the packaging material. The splicing S of the packaging material is defined as the location where the ends of two packaging material webs 4 overlap and connect to each other. Therefore, in the area of ​​the splicing S, the width of the packaging material (e.g., 2 mm) is greater than the width of a single packaging material web 4 (e.g., 1 mm).

[0029] The control unit ECU can be configured to receive signals from the first sensing element 20 and / or the second sensing element 23 and determine whether a splice S exists. In particular, the control unit ECU can be configured to perform the steps of the method described herein, such as detecting the splice S by processing signals from the first sensing element 20 and / or the second sensing element 23.

[0030] The sensing element 20 is arranged upstream of the tube forming and sealing device 9 along the conveying path P. Advantageously, the sensing element 20 is arranged upstream of the isolation chamber C along the conveying path P. Even more advantageously, the sensing element 20 is arranged upstream of the sterilization unit 5 along the conveying path P. In other words, the sensing element 20 is arranged in an area of ​​the packaging machine 1 where contact with the packaging material web 4 is still permitted since it has not yet been sterilized.

[0031] The control device 19 may preferably include a (second) sensing element 23, which is connected to the electronic control unit (ECU) and arranged along the conveying path P, and is configured to detect the splicing S of the packaging material. Advantageously, the sensing element 23 may be arranged along the conveying path P in an area of ​​the isolation chamber C.

[0032] Advantageously, the presence of two sensing elements 20, 23 located before and at the isolation chamber C allows for improved control of the packaging machine 1. Specifically, between the first sensing element 20 and the second sensing element 23, the packaging material web 4 can form a so-called loop, i.e., a buffer zone for the packaging material web 4, to prevent damage to the packaging material web 4 from sudden pulling by the tube forming and sealing device 9. Therefore, the control device 19 with the (first) sensing element 20 can only roughly determine the position of the splice S at the forming and sealing device 9. Due to the presence of the (second) sensing element 23 positioned (immediately adjacent) upstream of the tube forming and sealing device 9, the precise position of the splice S can be calculated, thus improving the operation of the packaging machine 1.

[0033] Preferably, the sensing element 23 is arranged along the conveying path P at the isolation chamber C. More specifically, the sensing element 23 is arranged in the external environment OE. Advantageously, the sensing element 23 is arranged upstream of the tube forming and sealing device 9 along the conveying path P. In particular, the sensing element 23 is arranged downstream of the sterilization unit 5 along the conveying path P. In other words, the sensing element 23 is arranged in an area of ​​the packaging machine 1 where contact with the packaging material web 4 is not permitted since it has already been sterilized.

[0034] Therefore, sensing element 23 includes non-contact (optical) sensing element 23.

[0035] Preferably, sensing element 23 may include a ToF (Time-of-Flight) sensing element 23. Preferably, sensing element 23 includes a profilometer. Advantageously, sensing element 23 may include a CCD image sensor 23 or a CMOS image sensor 23. Figure 3 As shown in the non-limiting example, the non-contact sensing element 23 includes a beam emitter 24 and a receiver 25 that cooperate to detect a patch S. The beam emitter 24 is configured to emit (or emit) a (e.g., visible or invisible) beam LB focused on the web of packaging material 4 to detect the patch S. The receiver 25 is configured to detect a reflected beam RLB.

[0036] The beam LG travels from the beam emitter 24 to the packaging material web 4 and then bounces back from the packaging material web 4 to the receiver 25. In other words, the receiver 25 is configured to detect the beam reflected from the packaging material web 4 after the beam LB has illuminated it. Specifically, the beam emitter 24 is configured to emit (or emit) the beam LB focused on the packaging material web 4 to detect the stitching S.

[0037] The sensing element 23 can be positioned in the external environment OE; in particular, the sensing element 23 can be positioned between the internal environment IE and the external environment OE, separated by a light-transmitting barrier (e.g., a glass barrier).

[0038] Advantageously, the non-contact sensing element 23 allows for accurate measurements without direct contact with the packaging material web 4.

[0039] Sensing element 23 is configured to measure the distance between the beam emitter 24 and the packaging material web 4, and to detect the splice S based on the time difference between the beam emission and its return to the receiver 25 after being reflected by the packaging material web 4. In other words, sensing element 23 is configured to calculate the time required for the beam to travel to and from the packaging material web 4 to determine the distance between the beam emitter 24 and the packaging material web 4 and to detect the splice S.

[0040] More specifically, if the time difference between the beam emission and its return to receiver 25 falls within a predetermined range, the sensing element 23 is configured to generate a signal indicating the presence of a patch S of packaging material and transmit this signal to the electronic control unit (ECU). The ECU is configured to check the presence of the patch S of packaging material based on the received signal.

[0041] Advantageously, sensing element 23 is configured to determine the time difference between beam emission and its return receiver 25. Specifically, sensing element 23 is configured to determine the time difference between beam emission and its return receiver 25 multiple times. This signal indicates the presence of splicing S. In particular, the presence of splicing S is determined if the current (or actual) time difference between beam emission and its return receiver 25 is greater than the previous (or earlier) time difference between beam emission and its return receiver 25.

[0042] If splice S is detected, the control device 19 is configured to regulate the operation of the tube forming and sealing device 9. Furthermore, if splice S is detected, the control device 19 is configured to regulate the operation of the sterilization unit 5.

[0043] According to the first embodiment, the sensing element 20 includes a contact element 21 and a counter element 22 (particularly a counter roller 22); the contact element 21 is configured to contact a packaging material web 4 sliding on the counter element 22 and detect splices S.

[0044] According to another embodiment, sensing element 20 includes a non-contact (optical) sensing element.

[0045] Preferably, the sensing element 20 may include a ToF (Time-of-Flight) sensing element 20. Preferably, the sensing element 20 includes a profilometer. Advantageously, the sensing element 20 may include a CCD image sensor 20 or a CMOS image sensor 20. Figure 3 As shown in the non-limiting example, the non-contact sensing element 20 includes a beam emitter 24 and a receiver 25 that cooperate to detect a patch S. The beam emitter 24 is configured to emit (or emit) a (e.g., visible or invisible) beam LB focused on the web of packaging material 4 to detect the patch S. The receiver 25 is configured to detect a reflected beam RLB.

[0046] The laser beam LG travels from the beam emitter 24 to the packaging material web 4 and then bounces back from the packaging material web 4 to the receiver 25. In other words, the receiver 25 is configured to detect the laser beam reflected from the packaging material web 4 after the laser beam LB has irradiated the packaging material web 4. Specifically, the beam emitter 24 is configured to emit (or emit) a laser beam LB focused on the packaging material web 4 to detect the stitching S.

[0047] Sensing element 20 is configured to measure the distance between beam emitter 24 and packaging material web 4, and to detect splice S based on the time difference between beam emission and its return to receiver 25 after being reflected by packaging material web 4. In other words, sensing element 20 is configured to calculate the time required for the beam to travel to and from packaging material web 4 to determine the distance between beam emitter 24 and packaging material web, and ultimately detect (or not detect) the presence of splice S.

[0048] More specifically, if the time difference between the beam emission and its return receiver 25 falls within a predetermined range, the sensing element 20 is configured to detect the presence of the splice S of the packaging material and send a signal to the electronic control unit ECU indicating that the splice S has been detected.

[0049] Advantageously, the sensing element 20 is configured to determine the time difference between the beam emission and its return receiver 25 multiple times. Specifically, the sensing element 20 is configured to determine the time difference between the beam emission and its return receiver 25 multiple times. If the current (or actual) time difference between the beam emission and its return receiver 25 is greater than the previous (or earlier) time difference between the beam emission and its return receiver 25, the sensing element 20 is configured to check for the presence of a splice S in the packaging material and send a signal to the electronic control unit (ECU) indicating that a splice S has been detected.

[0050] If splice S is detected, the control device 19 is configured to regulate the operation of the tube forming and sealing device 9. Furthermore, if splice S is detected, the control device 19 is configured to regulate the operation of the sterilization unit 5.

[0051] Advantageously, the aforementioned sensing elements 20 and 23 are configured to detect potential defects in the assembly S of the packaging material. More specifically, the aforementioned sensing elements 20 and 23 are configured to detect potential misalignments in the assembly S of the packaging material.

[0052] The control device 19, such as its control unit ECU, can be configured to perform the steps of the following method.

[0053] This specification describes a method for detecting splices S on a web of packaging material 4 fed along a conveying path P, wherein the method includes: -Emit a laser beam LB, preferably a laser beam, to the packaging material web 4; - Detect the beam RLB reflected by the packaging material web 4; and - The splicing S is detected based on the received beam RLB.

[0054] The method may include detecting splicing S based on the received beam RLB.

[0055] The method may include calculating the time interval between the transmission and reception of the beams LB and RLB; and detecting the splicing S based on the time interval.

[0056] The method may include sending a signal indicating that splicing S has been detected if the time interval falls within a predetermined range.

[0057] The method may include: - Multiple transmissions and receptions of beams LB and RLB; and - If the difference between the current time interval and the previous time interval is greater than a predetermined amount, a signal indicating that splicing S has been detected is sent.

[0058] The method may include adjusting the operation of the packaging machine 1 if splicing S is detected, preferably adjusting the operation of the tube forming and sealing unit 9.

[0059] This method may include detecting whether there are abnormalities, such as misalignment, in the splicing of packaging materials.

[0060] List of reference numerals 1 Packaging machine 2 pillow-shaped bags 3 scrolls 4 Packaging materials 5 sterilization units 6 guiding elements 7 Sterilization Bath 8 guiding elements 9-tube forming and sealing equipment 10 tubes 11 Structure 12, 12A, 12B forming / folding equipment 13, 13A, 13B forming rings Rollers 14, 14A, and 14B 15 sealing units 16 heating elements 17 Filling Equipment 18 Pouring Tubes 19 Control Devices 20 sensing elements 21 Contact Elements 22 relative components 23 sensing elements 24-beam emitter 25 receivers P teleportation path Y-axis C Isolation Room IE internal environment OE external environment S-joint LB beam RLB reflected beam ECU (Electronic Control Unit)

Claims

1. A packaging machine (1) for producing sealed packages from a web (4) of packaging material fed along a conveying path (P), the packaging machine (1) comprising: - A tube forming and sealing unit (9), which is arranged along the conveying path (P), for folding the packaging material web (4) from a planar shape into a tube (10) and for longitudinally sealing the tube (10); - An isolation chamber (C) that separates an internal sterile / sterilized environment (IE) from an external environment (OE), wherein the tube forming and sealing unit (9) is at least partially arranged in the isolation chamber (C); as well as - Control device (19) including a first sensor device (20) arranged upstream of the isolation chamber (C) along the conveying path (P) and configured to detect splices (S) on the packaging material web (4); The packaging machine (1) is characterized in that the control device (19) includes a second sensor device (23) which is arranged along the conveying path (P) in the area of ​​the isolation chamber (C) and configured to detect the splicing (S).

2. The packaging machine (1) according to claim 1, wherein the second sensor device (23) is arranged in the external environment (OE).

3. The packaging machine (1) according to claim 1 or 2, comprising a sterilization unit (5) for the packaging material, the sterilization unit (5) being arranged upstream of the tube forming and sealing unit (9) relative to the packaging material web (4) along the advancing direction of the conveying path (P); the first sensor device (20) and the second sensor device (23) being respectively arranged upstream and downstream of the sterilization unit (5) relative to the advancing direction of the packaging material web (4).

4. The packaging machine (1) according to any of the preceding claims, wherein the first sensor device (20) and / or the second sensor device (23) comprises a non-contact sensor element (23).

5. The packaging machine (1) according to any of the preceding claims, wherein the first sensor device (20) and / or the second sensor device (23) includes an optical sensor element (23).

6. The packaging machine (1) according to any one of the preceding claims, wherein the first sensor device (20) and / or the second sensor device (23) includes a beam emitter (24) for emitting a beam (LB), preferably a laser beam, toward the packaging material web (4), and a receiver (25) for detecting a beam (RLB) reflected by the packaging material web (4).

7. The packaging machine (1) according to claim 6, wherein the control device (19) is configured to detect the splicing (S) based on the received light beam (RLB).

8. The packaging machine (1) according to claim 6 or claim 7, wherein the control device (19) is configured to calculate the time interval elapsed between the emission and reception of the light beam (LB, RLB); and detect the splicing (S) based on the time interval.

9. The packaging machine (1) according to claim 8, wherein if the time interval falls within a predetermined range, the control device (19) is configured to send a signal indicating that the splicing (S) has been detected.

10. The packaging machine (1) according to any one of claims 6 to 9, wherein the control device (19) is configured to: - Multiple transmit and receive beams (LB, RLB); and - If the difference between the current time interval and the previous time interval is greater than a predetermined amount, a signal indicating that the splicing (S) has been detected is sent.

11. The packaging machine (1) according to any of the preceding claims, wherein if splicing (S) is detected, the control device (19) is configured to adjust the operation of the packaging machine (1), preferably the tube forming and sealing unit (9).

12. The packaging machine (1) according to any of the preceding claims, wherein the control device (19) is configured to detect whether there is an abnormality, such as misalignment, in the splicing (S) of the packaging material.

13. A method for detecting splicing (S) on a web of packaging material (4) fed along a conveying path (P), the method comprising: -Emit a beam (LB), preferably a laser beam, to the web (4) of the packaging material; - Detect the light beam (RLB) reflected from the web of the packaging material (4); and - The stitching (S) is detected based on the received beam (RLB).

14. The method of claim 13, further comprising adjusting the operation of a packaging machine (1) for producing sealed packages from the web of the packaging material (4) if a splice (S) is detected.

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