Packaging machine for making capsules for viscous products

Abstract

A packaging machine for making capsules for viscous products comprises a feed station (2), a movement group (3) operatively arranged downstream of the feeding station (2) and comprising an orderly succession of receiving seats (7) movable along a movement direction (A), a dosing unit (4) comprising a plurality of dosing nozzles (10, 11) arranged along the movement direction (A) so that, in at least one filling position each dosing nozzle (10, 11) is facing a corresponding receiving seat (7), a closing station (5) operatively arranged downstream of the dosing unit (4), with reference to the movement direction (A) and configured to apply a closing film (F) to each capsule, and a control unit (6) associated with the feed station (2), the movement group (3) and the closing station (5) to operate them in a coordinated manner with a predetermined duty cycle.

Description

[0001] PACKAGING MACHINE FOR MAKING CAPSULES FOR VISCOUS PRODUCTS

[0002] The present invention relates to a packaging machine for making capsules for viscous products.

[0003] The main application of the present invention is in the food sector, more specifically in the technical field of making capsules for viscous products such as jams, honey, spreads and similar food products.

[0004] Over the last few decades, the technical field of packaging machines for disposable infusion products, such as capsules and pods, has undergone considerable acceleration, mainly due to the market's increasing focus on both the quality and recyclability of products.

[0005] It is no coincidence that many companies in the industry have developed various solutions which optimise and speed up both the filling and closing of such products.

[0006] However, similar developments have not occurred in the viscous food products sector, where the rate of innovation has been much lower in recent years.

[0007] It is no coincidence that to date the market does not provide capsule packaging machines for viscous products which combine the performance of packaging machines for granular infusion products with the dispensing and cleaning requirements which have always characterised viscous product machinery.

[0008] The Applicant has therefore invested intellectual and economic resources to solve such problems, studying which features were necessary to make a packaging machine for granular or infusion products suitable for treating viscous products.

[0009] Such studies revealed that the main critical issues were related to the difficulty of cleaning and testing and / or the inherent slowness of product dispensing. The aim of the present invention is therefore to provide a packaging machine for making capsules for viscous products which is capable of overcoming the drawbacks of the prior art mentioned above.

[0010] In particular, the aim of the present invention is to provide a packaging machine for making capsules for viscous products which is highly productive and easy to clean.

[0011] Further, the aim of the present invention is to make a packaging machine for making capsules for viscous products which is easy to set and highly versatile.

[0012] Said aims are achieved by a packaging machine for making capsules for viscous products having the features of one or more of the following claims.

[0013] In particular, the packaging machine comprises a feed station for a plurality of capsules, a movement group, a dosing unit, a closing station and a control unit.

[0014] Preferably, the feed station is configured to arrange said plurality of capsules in an orderly succession.

[0015] Preferably, the movement group is operatively arranged downstream of the feed station.

[0016] Preferably, the movement group comprises an orderly succession of movable receiving seats along a movement direction and each configured to receive therein a capsule of said plurality of capsules.

[0017] Preferably, the dosing unit comprises a plurality of dosing nozzles arranged along the movement direction so that, in at least one filling position, each dosing nozzle faces a corresponding receiving seat.

[0018] Preferably, the closing station is operatively arranged downstream of said dosing unit, with reference to the movement direction.

[0019] Preferably, the closing station has a feeding group of a closing firm up to an application section.

[0020] Preferably, in the application section, the portion of said closing film faces at least one of said receiving seats. Preferably, the closing station also has a welding group.

[0021] Preferably, the welding group is located at the application section of the feeding group.

[0022] Preferably, the welding group is configured to weld at least one portion of the closing film to a corresponding capsule housed in the respective receiving seat.

[0023] Preferably, the control unit is associated with the feed station, the movement group and the closing station in order to operate them in a coordinated manner at a predetermined duty cycle.

[0024] According to an aspect of the present invention, the dosing unit comprises a removable carriage.

[0025] Advantageously, it is thereby possible to remove the dosing unit, replacing it with an auxiliary one already prepared for dispensing the same or a new product, allowing the one in use to be taken out for a cleaning step.

[0026] Preferably, the removable carriage comprises a support frame of said dosing nozzles and at least one tank containing a viscous product.

[0027] The tank is preferably a receptacle or hopper which can be connected to a viscous product loading duct.

[0028] The removable carriage further comprises a (local) drive module of the dosing nozzles.

[0029] The drive module is preferably reversibly connected to the control unit and configured to communicate with said control unit during the execution of said work cycle.

[0030] Advantageously, the arrangement of an autonomous control unit makes the removable carriage a stand-alone component which can be used independently of the machine for set-up and testing steps.

[0031] Furthermore, any product variations which lead to changes in the filling time can be adjusted off-line during the calibration step, before connecting the carriage to the machine and significantly reducing setup times.

[0032] In at least one of the aforesaid aspects, the invention comprises one or more of the following preferred features, which are described below. Preferably, the machine comprises a main structure provided with a side compartment accessible transversally to said movement direction.

[0033] The removable carriage of the dosing unit is shaped to be housed in said side compartment.

[0034] Preferably, the main structure comprises at least one abutment element responsible for abutting a positioning wall of the removable carriage.

[0035] In other words, the carriage is mobile with respect to the main structure between a non-operating position (or several positions) and an operating position, in which the positioning wall of the carriage abuts the abutment element.

[0036] In this regard, preferably the machine comprises a first and second dosing unit that can be alternately couplable with each other to the main structure so that an independently usable auxiliary or test dosing unit is always available.

[0037] Preferably, a position detection system associated with said removable carriage is provided.

[0038] Preferably, such a system is configured to determine the presence or absence of the dosing unit (along the movement direction).

[0039] Advantageously, this ensures that the machine cannot begin operation if the removable carriage is incorrectly positioned.

[0040] Preferably, the position detection system comprises a microcontroller with a magnetic presence sensor.

[0041] Preferably, moreover, the carriage of the dosing unit also comprises at least one electrical socket and / or at least one pneumatic socket reversibly connected to corresponding electrical and / or pneumatic connectors of the main structure.

[0042] Advantageously, the carriage is thus completely removable from the main structure and fully connectable and disconnectable thereto.

[0043] Preferably, the removable carriage of the dosing unit comprises a control panel associated with said drive module of the dosing nozzles and, more preferably, accessible to an operator. Preferably, the drive module is configured to activate, following a command imparted by the operator by means of said control panel, a test mode in which said dosing nozzles are activated even in the absence of connection to the main structure.

[0044] Advantageously, the removable carriage can also be set up and tested separately from the machine, which benefits the overall production efficiency of the plant.

[0045] Preferably, the machine is arranged to perform a filling / dosing procedure involving communication between the control unit and the drive module.

[0046] Preferably, the control unit is configured to send a start signal to the drive module of the dosing nozzles which is representative of a receiving seat having reached a filling position.

[0047] Preferably, the drive module of the dosing nozzles is configured to start, upon receiving said start signal, a pre-set dosing cycle.

[0048] Preferably, the drive module of the dosing nozzles is also configured to send an end-of-filling signal to said control unit at the end of said pre-set dosing cycle.

[0049] Preferably, the control unit, upon the receipt of said end-of-filling signal, is configured to impart a predefined advancement to the movement group along said movement direction.

[0050] Advantageously, no reprogramming of the control unit by the operator is thereby necessary when changing the product or if it is necessary to vary the filling time, as the drive module of the removable carriage autonomously manages such a step by communicating the start and end of the dosing to the control unit, which controls the movement group.

[0051] It should be noted that, preferably, the control unit is configured to detect the presence of the dosing unit before sending said start signal to the drive module of the dosing nozzles.

[0052] According to a further aspect of the invention, which is complementary or alternative to the previous ones, the receiving seats of the movement group are arranged in succession on a first and a second row parallel to each other and extending along said movement direction.

[0053] Thereby, each receiving seat of the first row is placed side by side to a corresponding receiving seat of the second row.

[0054] Preferably, moreover, the dosing unit comprises two first dosing nozzles and two second dosing nozzles associated with the first and the second row of the movement group, respectively.

[0055] In other words, there are two first dosing nozzles facing each other at respective receiving seats of the first row.

[0056] There are two second dosing nozzles facing each other at respective receiving seats of the second row.

[0057] Preferably, moreover, the first and second dosing nozzles are offset from each other along the movement direction.

[0058] Advantageously, it is thereby possible to flexibly manage the advancement pitch of the movement group according to production requirements.

[0059] Preferably, the receiving seats are each placed at a predetermined distance, or pitch, from the following and / or previous receiving seat.

[0060] More preferably, the first dosing nozzles are placed at a mutual first distance, measured along the movement direction, corresponding to said pitch or to a multiple of said pitch.

[0061] Preferably, moreover, the second nozzles are placed at a mutual second distance, measured along the movement direction, corresponding to said pitch or to a multiple of said pitch.

[0062] Preferably, the first distance is less than said second distance.

[0063] Preferably, the first distance corresponds to said pitch.

[0064] Preferably, the second distance corresponds to a multiple of said pitch, more preferably to three times said pitch.

[0065] Preferably, each first dosing nozzle is offset by a corresponding second nozzle, along the movement direction, by said pitch.

[0066] In this regard, preferably the control unit is configured to move the movement group alternatively at single pitch or double pitch.

[0067] The single-pitch movement involves advancing the receiving seats along the movement direction, for each dosing time, equal to said pitch.

[0068] The double-step movement involves advancing the receiving seats along the movement direction, for each dosing time, by twice said pitch.

[0069] According to a further aspect of the invention, complementary or alternative to the previous ones, the machine further comprises a sanitising device.

[0070] The sanitising device can be arranged along the movement direction between the feed station and the dosing unit and facing at least one of said plurality of receiving seats to sanitise the capsule contained therein. Alternatively, or jointly, the sanitising device is placed at a sanitising section of the feeding group of the closing station.

[0071] Advantageously, it is thereby possible to guarantee the sanitisation of both the capsules and the covering film, adapting the machine to applications for viscous products which, being neither intended for infusion nor for use at high temperatures, require in some cases a reduction in the bacterial load.

[0072] Preferably, the sanitising device comprises at least one UV lamp.

[0073] Preferably, such a UV lamp is arranged above a section of the movement group comprised between the feed station and the dosing unit.

[0074] Alternatively, or jointly, the UV lamp is facing a section of the closing film near the application section.

[0075] According to a further aspect of the invention, complementary or alternative to the previous ones, the welding group comprises one or more ultrasonic welding heads.

[0076] Preferably, the control unit is configured to perform a quality control procedure at the end of or during each weld.

[0077] Preferably, in such a quality control procedure, the control unit is configured to impart to the ultrasonic welding head the generation of an ultrasonic verification signal at a predefined frequency and at a welding zone between said closing film and a corresponding capsule housed in a housing seat. Furthermore, the control unit is configured to (directly or indirectly) detect a response of said welding zone to the generation of the ultrasonic verification signal.

[0078] Again, preferably the control unit is configured to compare said response with one or more predefined reference parameters.

[0079] Furthermore, the control unit is preferably configured to generate an alarm signal and / or initiate a rejection procedure if the result of said comparison is negative.

[0080] Advantageously, thanks to the presence of an ultrasonic welding station, it is the welding step itself (or one immediately following) which can be exploited to perform a quality check on the weld and thus on the seal of the closure, increasing the reliability and quality of the machine without negatively impacting either cost or size.

[0081] These and other features, together with their relative advantages, will become clearer by the following non-limiting example description of a preferred, and therefore non-exclusive, embodiment of a packaging machine for making capsules for viscous products as illustrated in the attached figures, wherein:

[0082] - figures 1 and 2 show front and rear overall perspective views of a packaging machine for making capsules for viscous products according to the present invention;

[0083] - figure 3 shows the machine of figure 2 in exploded view, in a nonoperating configuration of the dosing unit;

[0084] - figures 4-6 show perspective views of portions of the machine of figure 1 . With reference to the attached figures, the number 1 indicates a packaging machine for making capsules for viscous products according to the present invention.

[0085] The machine 1 therefore finds application in the production and manufacture of capsules for viscous products such as jams, creams, honey or other food products of similar type and density.

[0086] The machine 1 comprises a main structure 1 a to which are associated a feed station 2, a movement group 3, a dosing unit 4, a closing station 5 and a control unit 6, with the control unit 6 associated with the feed station 2, movement group 3 and closing station 5 to operate them in a coordinated manner with a predetermined duty cycle.

[0087] The feed station 2 is configured to feed a plurality of capsules and to arrange them in an orderly succession.

[0088] Preferably, the feed station 2 extends between an orientator (not shown) and the movement group 3.

[0089] Preferably, the feed station 2 comprises a positioner device 2a and a pickup device 2b.

[0090] The positioner device 2a is configured to receive the correctly orientated capsules from the orientator and arrange them in a predefined pick-up configuration.

[0091] In the preferred embodiment, said positioner device 2a is defined by a starwheel.

[0092] The pick-up member 2b is preferably configured to pick up the capsules in said pick-up configuration and transfer them to the movement group in said configuration.

[0093] In the preferred embodiment, said pick-up device 2b comprises a pick and place device provided with a gripping group movable between a pick-up position, at the positioner device 2a, and a release position, at the movement group 3.

[0094] In the preferred embodiment, the pick-up member 2b is configured to arrange the capsules in two parallel rows, preferably by transferring four capsules arranged two by two coupled in said rows from the positioner device 2a to the movement group 3.

[0095] The movement group 3 is operatively arranged downstream of feed station 2 and comprises an orderly succession of receiving seats 7 movable along a movement direction 'A'.

[0096] Each receiving seat 7 is configured (or shaped) to receive therein a capsule of said plurality of capsules. Such receiving seats 7 are each placed at a predetermined distance, or pitch 'P', from the following and / or previous receiving seat 7

[0097] Preferably, moreover, the receiving seats 7 of the movement group 3 are arranged in succession on a first F1 and a second F2 row parallel to each other and extending along the movement direction 'A'.

[0098] More preferably, each receiving seat 7 of the first row F1 is flanked by a corresponding receiving seat 7 of the second row F2.

[0099] Preferably, therefore, the movement group 3 comprises a modular transport member 8, wherein each module 8a has one or more receiving seats 7 and is movable in the movement direction 'A' along a movement path.

[0100] Said movement path comprises an operating section 3a and a return section 3b.

[0101] The operating section 3a extends between a receiving section, where the module 8a receives the capsules from the feed station 2, to a release section located operatively downstream of the closing station 5.

[0102] The return section 3b instead extends between the release section and the receiving section, preferably along an overturned (oriented downwards) portion of the modular transport member 8.

[0103] In the preferred embodiment, each module 8a of the modular transport member 8 comprises a block 9 provided with two receiving seats 7 placed side by side orthogonally to the movement direction; each receiving seat 7 is arranged on one of said first row F1 and second row F2.

[0104] Preferably, each block 9 is hinged to the previous block and the following one, defining a link of a chain conveyor.

[0105] The dosing unit 4 is arranged along the movement direction 'A'.

[0106] Such a dosing unit comprises a plurality of dosing nozzles 10, 11 arranged along the movement direction 'A' so that, in at least one filling position, each dosing nozzle 10, 11 faces a corresponding receiving seat 7.

[0107] Preferably, each dosing nozzle 10, 11 comprises a respective outlet mouth from which the viscous product is dispensed. Preferably, at least two dosing nozzles 10, 11 are provided, arranged at the first F1 and second F2 row, so s to dispense the product in capsules housed in each row and increase productivity.

[0108] In the preferred embodiment, the dosing unit 4 comprises two first dosing nozzles 10 and two second dosing nozzles 11 associated with the first F1 and second F2 rows of receiving seats 7 of the movement group 3, respectively.

[0109] Preferably, a first 10 and a second dosing nozzle 11 are placed in connection with a first tank 12 containing the viscous product to be dispensed.

[0110] In accordance with this, the remaining first 10 and second dosing nozzle 11 are placed in connection with a second tank 13 containing the viscous product to be dispensed.

[0111] The first 12 and the second tank 13 are independent of each other, so as to allow an independent operation of the nozzles and an offset filling which allows to keep the machine 1 constantly operational, even at reduced speed, during any filling steps.

[0112] In certain embodiments, the tanks can be connected by means of special piping to storage recipients for the viscous product to be dispensed and fed by means of pumping systems, so as to limit machine downtimes.

[0113] It should be noted that, preferably, the first 10 and second dosing nozzles 11 are offset along the movement direction 'A'.

[0114] In other words, each first dosing nozzle 10 has a position along the movement direction 'A' which is different from that of the second dosing nozzles 11 and vice versa.

[0115] Preferably, the first dosing nozzles 10 are placed therebetween, along the movement direction 'A', at a mutual first distance 'D1 ' corresponding to a multiple of the pitch 'P', viz., ,a multiple of the distance between the centres of two successive receiving seats 7 of the same row F1 , F2.

[0116] Preferably, moreover, the second dosing nozzles 11 are placed therebetween, along the movement direction 'A', at a mutual second distance 'D2' corresponding to a multiple of said pitch 'P'.

[0117] The expression 'multiple' means that the second distance 'D2' corresponds to the pitch 'P' multiplied by an integer greater than or equal to 1 .

[0118] Preferably, the first distance 'D1 ' is less than said second distance 'D2'. Thus, the first dosing nozzles 10 are closer together with respect to the second dosing nozzles 11 .

[0119] Preferably, the arrangement of the first 10 and second nozzles 11 is symmetrical with respect to a horizontal centreline, orthogonal to the movement direction 'A' and equidistant from the two first dosing nozzles 10.

[0120] In the preferred embodiment, the first distance 'D1 ' corresponds to said pitch 'P'.

[0121] Preferably, moreover, the second distance 'D2' corresponds to a multiple of said pitch 'P'.

[0122] Preferably, moreover, each first dosing nozzle 10 is offset from a corresponding second dosing nozzle 11 , along the movement direction 'A', by a distance equal to the pitch 'P'.

[0123] Advantageously, the arrangement of multiple dosing nozzles offset along the movement direction 'A' allows for highly versatile management of product dispensing according to production logic and / or tank filling conditions.

[0124] For example, preferably the control unit 6 controlling the machine 1 is configured to move the movement group 3 alternatively at single pitch or double pitch.

[0125] Single-pitch movement involves advancing the receiving seats 7 along the movement direction 'A' at the pitch 'P', thus with each dispensing / dosing step performed following the advancement of the movement group 3 by a distance equal to the pitch 'P'.

[0126] Double-pitch movement handling involves advancing the receiving seats 7 along the movement direction 'A' by twice the pitch 'P', thus with each dispensing / dosing step performed following the advancement of the movement group 3 by a distance equal to twice the pitch 'P'.

[0127] In the single-pitch advancement mode, the dosing unit 4 is configured to activate only a first dosing nozzle 10 and a second dosing nozzle 11 , preferably connected to the same first 12 or second tank 13.

[0128] In the double-pitch advancement mode, the dosing unit 4 is preferably configured to activate all the dosing nozzles.

[0129] This clearly translates into a considerable advantage for staff, who can quickly and efficiently vary the production capacity of the plant according to the contingencies of the moment.

[0130] According to an aspect of the invention, the dosing unit 4 comprises a removable carriage 14, therefore movable between an engagement condition with the machine 1 and a disengagement condition.

[0131] In this regard, preferably, the main structure 1 a of the machine 1 is provided with a side compartment 'V accessible transversally to said movement direction 'A', in which the carriage 14 of the dosing unit 4 is shaped to house.

[0132] The carriage 14 is preferably provided with wheels or rolling elements placed at its base to facilitate the displacement thereof into and out of the side compartment 'V.

[0133] In this regard, preferably the presence of hooks, clamps or chains is envisaged, assigned to constrain the mutual position between the carriage 14 and main structure 1a once the carriage 14 is housed in the side compartment 'V, in a working position.

[0134] Preferably, the carriage 14 comprises a support frame 14a configured to support the dosing nozzles 10, 11 and at least one tank 12, 13 containing the viscous product.

[0135] More preferably, the support frame 14a is configured to support the first and the second tank 12, 13 and to which the first and second dosing nozzles 10, 11 are associated.

[0136] Preferably, the first and the second tank 12, 13 are constrained and supported by the carriage, while the dosing nozzles are placed in fluid connection with the tanks 12, 13 but are freely movable with respect to the carriage 14 to be able to be placed above the movement group 3, along the movement direction 'A'.

[0137] It should be noted that, preferably, the main structure 1a of the machine 1 comprises, at the side compartment 'V, at least one abutment element 16 designed to abut a positioning wall 14b of said carriage 14.

[0138] Therefore, the carriage 14 comprises the positioning wall 14b by means of which it is possible to unambiguously determine the correct positioning of the dosing unit 4 with respect to the remaining machine components 1 .

[0139] Advantageously, this thereby ensures a perfect alignment between dosing nozzles 10, 11 and receiving seats 7, therefore capsules.

[0140] Preferably, the carriage 14 comprises a drive module 15 configured to govern the dosing nozzles.

[0141] Said drive module 15 is reversibly connected to the control unit 6 of the machine and configured to communicate therewith while performing the duty cycle.

[0142] The drive module 15 is therefore an element independent of the control unit 6 and is configured to drive the dosing nozzles autonomously.

[0143] The control unit 6 is therefore preferably disconnected from the dosing nozzles 10, 11 , as it cannot govern the driving thereof except through the intervention of the drive module 15.

[0144] In this regard, preferably, the dosing unit 4 comprises a control panel 18 associated with said drive module 15.

[0145] The control (or interface) panel 18 is accessible to an operator to allow the operation of certain functions of the unit 4.

[0146] It should be noted that, preferably, the drive module 15 of the dosing unit 4 is configured to activate, following a command imparted by the operator by means of said control panel 18, a test mode in which said dosing nozzles 10, 11 are activated even in the absence of connection to the main structure 1 a.

[0147] Advantageously, the dosing unit 4 is thereby a stand-alone component capable of operating independently of the machine 1 and can be programmed autonomously.

[0148] This, together with the removability of the unit 4, greatly facilitates the setting of the most delicate packaging step, namely dosing and filling.

[0149] Any product / format change can be set and tested offline with the help of a second dosing unit 4, with a first dosing unit 4 acting as the machine 1 and located in the side compartment 'V.

[0150] Preferably, in this regard, the machine 1 preferably comprises a position detection system 17 associated with said carriage 14 and configured to determine the presence or absence of the dosing unit 4, viz., the carriage 14 within the side compartment 'V.

[0151] Preferably, the position detection system 17 comprises a microcontroller (not shown) with a magnetic presence sensor.

[0152] Preferably, the carriage 14 of the dosing unit 4 comprises at least one electrical socket and / or at least one pneumatic socket reversibly connected to corresponding electrical and pneumatic connectors of the main structure 1 a.

[0153] In certain other embodiments, there could also be a hydraulic socket reversibly connected to a corresponding hydraulic connector.

[0154] Advantageously, both the connection and disconnection of the dosing unit 4 from the main structure 1 a is thereby simple and immediate.

[0155] The expressions 'hydraulic socket', 'electrical socket' and 'pneumatic socket' are used in the present text to define connections which transfer electrical, hydraulic or pneumatic power from the main structure 1 a to the carriage 14.

[0156] In more detail, the carriage comprises an electrical socket for receiving electrical power capable of activating the drive module, control panel and / or dosing nozzles if electromagnetic.

[0157] The carriage further comprises a pneumatic socket which is connected to the pneumatic circuit of the main structure 1 a and is associated with a system for transferring the viscous product from the tanks 12, 13 to the dosing nozzles 10, 11.

[0158] Preferably, such a system comprises a plurality of dosing syringes 12a, 13a associated with the tanks and configured to transfer, with the aid of valves, the product from the tank to the nozzles first by suction and then by pumping.

[0159] The dosing syringes 12a, 13a are preferably associated with the dosing nozzles 10, 11 by means of flexible and removable conduits 12b, 13b.

[0160] The dosing nozzles 10, 11 , in turn, are constrained to the main structure 1a by means of a suitably shaped and removable bracket 24 (preferably fixed to the main structure 1 a by screws, clamps or quick couplings).

[0161] It should be noted that, in use, the machine 1 is configured to recursively start a dosing procedure with each work cycle.

[0162] Preferably, in this regard, the control unit 6 is configured to send a start signal to the drive module 15 which is representative of a receiving seat 7 (thus a block 9) having reached a filling position.

[0163] More preferably, the control unit 6 is configured to detect the presence of the dosing unit 4 (viz., correct positioning of the carriage 14 in the side compartment 'V') before sending said start signal to the drive module 15 of the dosing nozzles 10, 11.

[0164] In the filling position, the receiving seat 7 designed to be subjected to filling has a centre which is substantially aligned with the outlet mouth of a dosing nozzle 10, 11.

[0165] In more detail, in the filling position, all the receiving seats 7 designed to be subjected to filling have a centre which is substantially aligned with a corresponding outlet mouth of a dosing nozzle 10, 11.

[0166] At this point, preferably the drive module 15 of the dosing nozzles 10, 11 is configured for:

[0167] - starting, upon the receipt of said start signal, a pre-set dosing cycle;

[0168] - sending an end-of-filling signal to said control unit 6 at the end of said pre-set dosing cycle. Therefore, upon receiving said end-of-filling signal, the control unit 6 is configured to impart a predefined advancement (single or multi-pitch) to the movement group 3 along said movement direction 'A'.

[0169] Advantageously, therefore, the control unit 6 does not directly control the dosing nozzles, merely limiting itself to sending and receiving start and stop dosing signals from the dosing unit.

[0170] This makes the dosing unit an independent element from the rest of the machine, which can be programmed independently and set autonomously. Preferably, moreover, the drive module 15 is also configured to detect the filling level of the tank (viz., of the tanks 12, 13) by means of special sensors.

[0171] If a tank close to emptying is detected, the control module 15 is configured to deactivate the dosing nozzles 10, 11 associated with such a tank, simultaneously transferring a deactivation signal representative of such a deactivation to the control unit 6.

[0172] The control unit 6 is therefore configured to receive said signal, process it and adapt the advancement pitch of the movement group 3 to such a condition.

[0173] For example, in the embodiments in which the machine 1 operates at the double pitch, upon the receipt of the deactivation signal, the control unit 6 is configured to give impart an advancement change to the movement group 3, bringing the advancement mode to single pitch.

[0174] The closing station 5 is operatively arranged downstream of said dosing unit 4, with reference to the movement direction 'A'.

[0175] Such a closing station 5 is configured to apply a closing film 'F' to each capsule filled with the viscous product, so as to obtain a packaged and finished product.

[0176] In this regard, preferably the closing station 5 comprises a feeding group 19 of the closing film 'F' and a welding group 20. The feeding group 19 is configured to advance said closing film 'F' up to an application section in which a portion of said closing film 'F' faces at least one of said receiving seats 7 (thus the respective capsule).

[0177] The feeding group 19 preferably comprises a spool (not illustrated), on which the closing film 'F' is wound onto a reel, and an advancement system comprising motorised rollers and idlers.

[0178] The welding group 20 is located at said application section of the feeding group 19.

[0179] Such a welding unit 20 is configured to weld at least one (annular) portion of the closing film 'F' to a corresponding capsule housed in the respective receiving seat 7, in particular to an upper edge of the capsule.

[0180] Such a welding group 20 comprises a plurality of welding heads 21 , 22 configured to move towards and away from the closing film 'F' between a distanced position, in which the feeding group 19 can move the film, and a welding position, in which the welding heads 21 , 22 press on a surface of the film, external in use, to weld it to the edge of the capsule.

[0181] It should be noted that, similarly to the dosing unit 4, the welding group 20 also comprises at least two welding heads 21 , 22 each arranged at a respective first F1 or second row F2.

[0182] In the preferred embodiment, however, the welding group 20 comprises at least four welding heads 21 , 22 coupled two by two.

[0183] Two first welding heads 21 are placed at the first row F1 .

[0184] Two second welding heads 22 are placed at the second row F2.

[0185] Preferably, the first and second welding heads 21 , 22 are also offset along the movement direction 'A'.

[0186] In particular, in the preferred embodiment, the first welding heads 21 are adjacent to each other and arranged, with reference to the movement direction 'A', immediately downstream of the second welding heads 22, which are also adjacent to each other.

[0187] Advantageously, it is thereby possible to manage the variability of the single or double-pitch advancement. It should be noted that, in contrast to the dosing unit 4, the welding heads are more compact and it is therefore easier to place them along the advancement direction in close proximity.

[0188] In certain embodiments, the welding heads are of the hot welding type. Preferably, however, said welding heads 21 , 22 are of the ultrasonic type. In this regard, preferably the control unit 6 is configured to perform a quality control procedure at the end of or during each weld.

[0189] Advantageously, the adoption of ultrasonic welding allows to verify in real time and for all products the quality of the weld and the seal of the closure, a fundamental quality parameter for viscous products such as those for which the machine in accordance with the present invention is designed. During such a procedure, the control unit 6 is configured to impart to each welding head 21 , 22 the generation of an ultrasonic verification signal at a predetermined frequency at a welding zone between said closing film 'F' and the corresponding situated in the housing seat 7.

[0190] Preferably, the ultrasound verification signal has a frequency comprised between 20 and 30 kHz, more preferably selected according to the capsule diameter.

[0191] Furthermore, control unit 6 is configured to detect a response of said welding zone to the generation of the ultrasonic verification signal.

[0192] In particular, the control unit 6 detects, by means of special sensors situated in the welding head 21 , 22, a 'return vibration' generated by the material in response to the generation of the ultrasonic signal.

[0193] Said response, thus the return vibration, is compared with one or more predefined reference parameters; knowing the features of the injected ultrasonic signal and those of the material (capsule+film), in the absence of defects in the weld, the system should detect a return vibration at the same predefined frequency and speed / amplitude.

[0194] On the contrary, in the presence of defects, the return signal is more complex, going to identify a criticality.

[0195] The analysis of the return signal can also allow to understand the nature and position of the defect, which is particularly useful in the event of repeated defects over time,

[0196] The control unit 6 is further configured to generate an alarm signal and / or to initiate a rejection procedure if the result of said comparison is negative, thereby increasing the quality of the products obtained.

[0197] A further aspect of interest in the packaging of viscous products is that of sanitisation and control of the bacterial load, which must be reduced below certain legal limits.

[0198] In this regard, preferably the machine 1 comprises at least one sanitising device 23.

[0199] Such a sanitising device 23 can be arranged along the movement direction 'A' between the feed station 2 and the dosing unit 4 and facing at least one of said plurality of receiving seats 7 to sanitise the capsule contained therein.

[0200] In such a case, the sanitising device 23 is preferably arranged along the operating section 3a of the movement group 3 so as to sanitise the capsules in the immediate vicinity of the dosing unit 4.

[0201] Alternatively, or jointly, the sanitising device 23 is placed at a sanitising section of the supply feeding group 19 of the closing station 5.

[0202] In the preferred embodiment, wherever it is located, the sanitising device 23 preferably comprises at least one UV lamp 23a, 23b.

[0203] In the illustrated embodiment, there is preferably a first UV lamp 23a arranged above the operating section 3a of the movement group 3, in a zone comprised between the feed station 2 and the dosing unit 4.

[0204] Furthermore, it is preferable to have a second UV lamp 23b facing a section of the closing film 'F' near the application section.

[0205] It should be noted that the nomenclature first and second used herein has been chosen for purely illustrative purposes and in no way implies that the presence of elements indicated as 'second' necessitates the presence of the corresponding elements indicated as 'first' and vice versa. The invention achieves its intended purposes and obtains important advantages.

[0206] In fact, the presence of a removable dosing unit allows to change the product very quickly or replace the filling hoppers without a long interruption in production, being able to wash, sanitise and re-set the carriage independently of production (possibly by arranging a second similar carriage to be used alternately).

[0207] Moreover, the adoption of a stand-alone carriage greatly facilitates the management of product or format changes, guaranteeing operators can set dosing times offline.

[0208] Further, the presence of a dosing unit with alternating and offset distribution of the dosing nozzles allows maximum versatility in the management of cycle time and advancement speed, allowing operators or the machine to independently manage advancement rates according to production requirements.

[0209] Furthermore, the adoption of sanitising devices along the line allows to cope with the more stringent constraints in terms of bacterial load reduction required by the use of viscous products instead of the classic infusion products normally dispensed in capsules.

[0210] Finally, the arrangement of an ultrasonic welding station allows the control unit to initiate in-line quality control procedures, which benefits product quality and does not have a negative impact on overall dimensions.

Claims

CLAIMS1. Packaging machine for making capsules for viscous products, comprising:- a feed station (2) configured to feed a plurality of capsules and to arrange said plurality of capsules in an orderly succession;- a movement group (3) operatively arranged downstream of the feed station (2) and comprising an orderly succession of receiving seats (7) movable along a movement direction (A); each receiving seat (7) being configured to receive therein a capsule of said plurality of capsules;- a dosing unit (4) comprising a plurality of dosing nozzles (10, 11 ) arranged along the movement direction (A) so that, in at least one filling position, each dosing nozzle (10, 11 ) faces a corresponding receiving seat (7);- a closing station (5) operatively arranged downstream of said dosing unit (4), relative to the movement direction (A) and configured to apply a closing film (F) to each capsule;- a control unit (6) associated with the feed station (2), the movement unit (3) and the closing station (5) to operate them in a coordinated manner with a predetermined duty cycle; characterised in that said dosing unit (4) comprises a removable carriage (14) comprising:- a support frame (14a) configured to support at least one tank (12, 13) containing a viscous product and associated with said dosing nozzles (10, 11 );- a drive module (15) configured to govern the dosing nozzles (10, 11 ), reversibly connected to the control unit (6) and configured to communicate therewith while performing the duty cycle, wherein: said control unit (6) is configured to send a start signal (SS) to the drive module (15) representative of a receiving seat (7) having reached a filling position;- said drive module (15) is configured for: o starting, upon the receipt of said start signal (SS), a pre-set dosing cycle, o sending an end-of-filling signal (EOF) to said control unit (6) at the end of said pre-set dosing cycle; o said control unit (6), upon the receipt of said end-of-filling signal (EOF), is configured to impart a predefined advancement to the movement group (3) along said movement direction (A).

2. The machine according to claim 1 , comprising a main structure (1 a) provided with a side compartment (V) accessible transversally to said movement direction (A), wherein said carriage (14) of the dosing unit (4) is shaped to be housed in said side compartment (V).

3. The machine according to any one of the preceding claims, comprising a position detection system (17) associated with said carriage (14), configured to determine the presence or absence of the dosing unit (4).

4. The machine according to claim 3, wherein said position detection system (17) comprises a micro-controller with a magnetic presence sensor.

5. The machine according to any one of claims 2 to 4, wherein said carriage (14) of the dosing unit (4) comprises at least one pneumatic socket and at least one electrical socket reversibly connected to corresponding pneumatic and electrical connectors of the main structure (1 a).

6. The machine according to any one of the preceding claims, wherein said carriage (14) of the dosing unit (4) comprises a control panel (18)associated with said drive module (15) and accessible to an operator; said drive module (15) being configured to activate, following a command imparted by the operator by means of said control panel (18), a test mode wherein said dosing nozzles (10, 11 ) are activated even in the absence of connection to the main structure (1a).

7. The machine according to claim 1 , wherein said control unit (6) is configured to detect the presence of the dosing unit (4) before sending said start signal (SS) to the drive module (15).

8. The machine according to any one of the preceding claims, wherein said receiving seats (7) of the movement group (3) are arranged in succession on a first row (F1 ) and a second row (F2) parallel to each other and extending along said movement direction (A), so that each receiving seat (7) of the first row (F1 ) is placed side by side to a corresponding receiving seat (7) of the second row (F2).

9. The machine according to claim 8, wherein said dosing unit (4) comprises two first dosing nozzles (10) and two second dosing nozzles (11 ) associated with the first (F1 ) and second (F2) row of the movement group (3), respectively.

10. The machine according to claim 9, wherein said first dosing nozzles (10) and said second dosing nozzles (11 ) are offset from each other along the movement direction (A).

11. The machine according to claim 9 or 10, wherein said receiving seats (7) are each placed at a predetermined distance, or pitch (P), from the following and / or previous receiving seat (7) and wherein:- said first dosing nozzles (10) are placed at a mutual first distance (D1 ), measured along the movement direction (A), corresponding to a multipleof said pitch (P);- said second dosing nozzles (11 ) are placed at a mutual second distance (D2), measured along the movement direction (A), corresponding to a multiple of said pitch (P).

12. The machine according to claim 11 , wherein said first distance (D1 ) is less than said second distance (D2).

13. The machine according to claim 11 or 12, wherein said first distance (D1 ) corresponds to said pitch (P).

14. The machine according to any one of claims 11 to 13, wherein said second distance (D2) corresponds to a multiple of said pitch (P), preferably three times said pitch (P).

15. The machine according to any one of claims 11 to 14, wherein each first dosing nozzle (10) is offset by a corresponding second dosing nozzle (11 ), along the movement direction (A), by a distance corresponding to said pitch (P).

16. The machine according to any one of claims 8 to 15, wherein said control unit (6) is configured to move said movement group (3) alternatively at:- a single pitch, with advancement of the receiving seats (7) along the movement direction (A) equal to said pitch (P);- a double pitch, with advancement of the receiving seats (7) along the movement direction (A) equal to twice said pitch (P).

17. The machine according to any one of the preceding claims, comprising a sanitising device (23) arranged:- along the movement direction (A) between the feed station (2) and thedosing unit (4) and facing at least one of said plurality of receiving seats (7) to sanitise the capsule contained therein and / or- at a sanitising section of a feed unit (19) of a closing film (F) of the closing station (5).

18. The machine according to claim 17, wherein said sanitising device (23) comprises at least:- a first UV lamp (23a) arranged above a section of the movement group (3) between the feed station (2) and the dosing unit (3) and / or- a second UV lamp (23b) facing a section of the closing film (F) near an application section, wherein a portion of said closing film (F) faces at least one of said receiving seats (7).

19. The machine according to any one of the preceding claims, wherein the closing station (5) comprises:- a feeding group (19) for feeding a closing film (F) up to an application section (AS) wherein a portion of said closing film (F) faces at least one of said receiving seats (7);- a welding group (20) placed at said application section (AS) of the feeding group (19) and configured to weld at least a portion of the closing film to a corresponding capsule housed in the respective receiving seat (7).

20. The machine according to claim 19, wherein said welding group (20) comprises one or more ultrasonic welding heads (21 , 22).

21. The machine according to claim 20, wherein the control unit (6) is configured to perform a quality control procedure at the end of or during each weld, wherein it:- imparts to each welding head (21 , 22) the generation of an ultrasonic verification signal at a predetermined frequency at a welding zonebetween said closing film (F) and a corresponding capsule housed in a housing seat (7);- detects a response of said welding zone to the generation of the ultrasonic verification signal; - compares said response with one or more pre-defined reference parameters;- generates an alarm signal and / or initiates a rejection procedure if the result of said comparison is negative.

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