Container processing method and system

Abstract

A method and system for processing containers, particularly food containers, is provided for handling one or more containers, the method being performed by a system including a platen, an input conveyor, and a transfer mechanism, the platen and the input conveyor each including a movable container support surface. The method includes receiving one or more containers on the input conveyor, lowering the container support surfaces of the input conveyor and the platen so that each container is supported by the transfer mechanism above the input conveyor, transferring each container from on the input conveyor onto the platen using the transfer mechanism, raising the container support surfaces of the input conveyor and the platen so that each container is supported by the platen, and removing each container from the transfer mechanism.

Description

[Technical field]

[0001] The present invention relates to a container processing system and a method implemented using such a system. In this specification, the term "container" is understood to include containers having an upward opening that can be sealed, for example, using a lid or a film. These containers include those commonly referred to as "trays" or "pots".

[0002] In particular, the present invention allows containers, such as open trays, deep containers, etc., to be rapidly transported, processed, and sealed while reducing the risk of spilling their contents. Such systems and methods are particularly suited for use in the food packaging industry. [Background technology]

[0003] In the food industry, it is common to package foods such as fruits, vegetables, meats, and ready meals in hermetically sealed containers such as trays or tubs.

[0004] In some systems, open trays are filled with a food product (or products), usually fed in groups or batches, and sealed with a tray sealer equipped with a heat sealing tool. The heat sealing tool has a lower tool part on which the tray (or trays) to be sealed is placed, and an upper tool part which usually includes a heating element or plate that forms a contour. The lower and upper tool parts are brought together to sandwich a heat sealable film between the tray (or trays) and the upper tool part, and the upper tool part engages the heat sealable film with an edge of each tray. The upper tool part is then heated to bond the film to the edge (or edges) of the tray (or trays). The sealed tray (or trays) is then removed from the system. Although such systems may provide effective sealing, there are significant problems with this system and other existing systems.

[0005] Spilling is especially likely when containers with no lid are transported before they are sealed. Containers are typically dragged or pushed through gaps and interfaces between adjacent machines (e.g. conveyors and tray sealers). When a container passes through a gap between adjacent machines, significant forces are exerted on the container. These forces can cause damage to the container and its contents, or cause the contents to leak or spill from the container.

[0006] Spills occur especially when handling liquid foods such as soups, stocks, and yogurt, or foods that contain liquids or sauces such as curries and stews. Similarly, spills are more likely when handling relatively tall containers or containers made of flexible materials such as cardboard. Similarly, spills are more likely when handling containers with sharp vertical edges, i.e., edges between the faces of the container that are not smooth, rounded, or chamfered, and require more precise handling operations. Spills not only reduce the product in the container, but also increase the frequency of cleaning and maintenance of the machines that process the containers.

[0007] Spillage can be avoided or reduced by slowing down the conveying and movement of open containers, but slower speeds necessarily result in lower production output. Thus, an undesirable tradeoff exists between container throughput and risk of spillage.

[0008] It is therefore desirable, particularly in the food packaging industry, to provide an improved means for handling containers that overcomes at least some of the above-mentioned drawbacks, and in particular, methods and systems that result in increased production, improved product quality, and reduced maintenance and cleaning requirements. Summary of the Invention

[0009] The present invention solves the above-mentioned problems by providing a method and system for handling containers that reduces the forces applied to the containers and their contents. This is particularly important when handling open containers containing liquid-containing foods. For example, the present invention is particularly suited to handling deep containers of soup, yogurt, and other foods, which have a high center of gravity and tend to be less stable than many other packaged foods. Similarly, the present invention is also suited to handling fragile foods, such as baked goods, which may break or crumble under high forces.

[0010] When compared to existing methods and systems, the present invention allows for increased container throughput (i.e., system operating speed) while maintaining the same level of spillage and / or damage to the container contents. In other words, by reducing or avoiding forces on the container, higher speeds can be achieved in manufacturing and packaging systems without increasing cleaning and maintenance requirements.

[0011] According to one aspect of the invention, there is provided a method for processing one or more containers performed by a system including a platen, an input conveyor, and a transfer mechanism, the platen and the input conveyor each including a movable container support surface, the method including the steps of receiving one or more containers on the input conveyor, lowering the container support surfaces of the input conveyor and the platen so that each container is supported by the transfer mechanism above the input conveyor, transferring each container from on the input conveyor onto the platen using the transfer mechanism, raising the container support surfaces of the input conveyor and the platen so that each container is supported by the platen, and removing each container from the transfer mechanism.

[0012] In this method, one or more containers, such as trays or deep containers, are carried by a transfer mechanism across the interface between an input conveyor (sometimes called a spacing conveyor) and a platen. By lowering the container support surfaces of the input conveyor and platen relative to the transfer mechanism, each container can be moved laterally from the input conveyor to the platen without contacting either the input conveyor or the platen. This significantly reduces forces on the contents of the container compared to systems in which the containers are dragged or pushed between different machines.

[0013] Thus, the risk of liquid spilling from the container and damage to the container contents is significantly reduced. Similarly, the risk of the container tipping, tipping and being damaged is also reduced. This results in improved product quality and reduced cleaning and maintenance requirements. Furthermore, increased container processing speeds and production output can be achieved.

[0014] The term conveyor should be understood to refer to processing equipment configured to transport or convey containers (or other objects) placed thereon. Additionally, a container support surface is a surface of the input conveyor and platen that receives and supports containers. That is, a container support surface is typically an upwardly facing surface upon which containers are placed and moved. For example, if the input conveyor is a belt conveyor, the container support surface may be the upper surface of the conveyor belt of the input conveyor.

[0015] By "lowering" and "raising" it is to be understood that the container supporting surfaces of the input conveyor and platen move vertically (at least) downward and upward, respectively, i.e., from a raised position to a lowered position during lowering and from a lowered position to a raised position during raising.

[0016] Thus, the container support surface is lowered and raised relative to the transport mechanism, which preferably remains in approximately the same vertical position. Raising and lowering the container support surface may involve raising and lowering the entire platen and / or input conveyor. However, in other examples, only some of the components of the platen and input conveyor may be raised and lowered. For example, the container support surface may be raised and lowered while the remainder of the platen and input conveyor remain stationary.

[0017] The transfer mechanism should be understood to transfer containers laterally from the input conveyor onto the platen. In a preferred embodiment, the transfer mechanism is preferably stationary vertically and moves in a generally horizontal plane. Thus, in a preferred embodiment, the input conveyor and the container support surfaces of the platen move generally vertically, while the transfer mechanism moves the containers generally horizontally.

[0018] After the platen and input conveyor container support surfaces are lowered, the weight of each container is transferred to the transfer mechanism, which supports or holds each container above the container support surfaces. In this manner, as these surfaces are lowered, a vertical space or gap is formed between the container and the input conveyor and platen. Each container may then be transferred or moved laterally by the transfer mechanism from a position on the input conveyor to a position on the platen without contacting the input conveyor or platen. After each container has been transferred laterally, the input conveyor and platen are raised, allowing each container to be supported by the platen again and safely removed by the transfer mechanism. In this manner, lateral forces on each container are minimized.

[0019] In a preferred example, the transfer mechanism comprises a transfer arm configured to support and transfer each container, and the method comprises closing the transfer arm around each container received on the input conveyor such that each container is supported by the transfer arm, such that at least one of the transfer arms can be moved relative to the other transfer arms to close and open in unison.

[0020] In a particularly preferred embodiment, the width of each container may increase from a bottom surface, where the container is normally received on the container support surface, towards an opposite free or top surface (e.g., the surface where the opening is formed). For example, each container may have a rim surrounding the opening, each container may have a tapered cross section, the side walls of the container may be formed with a draft angle, and / or a protrusion may extend laterally from the side walls of the container above the bottom surface (i.e., the container has a stepped cross section). In such an embodiment, the containers may be supported by closing the transfer arms around each container, with a spacing or distance between the transfer arms being greater than the width of each container at the height of the transfer arms, but less than the maximum width of the container. Thus, when the container support surface and the containers thereon are subsequently lowered, the containers will rest on and be supported by the surrounding transfer arms. In this way, the transfer arms support the containers above the underlying container support surface.

[0021] In this method, the transfer arms are positioned adjacent the periphery of the container before the container support surface and container are vertically lowered, which allows for a particularly gentle method of supporting the container above the underlying surface and prevents significant lateral forces on the container and its contents. Similarly, the container support surface above which one or more containers are supported can be raised to gently lift the container from the transfer arms on which it is held and supported, thereby removing the container from the transfer arms. In such a case, the transfer arms close around the container so that each transfer arm is positioned or positioned adjacent the container but does not apply significant lateral forces to the container, thereby preventing spillage or damage to the container and its contents. Furthermore, because the act of lowering the container support surface and the act of supporting the container using the transfer mechanism are performed simultaneously, the method can be performed very quickly, allowing for increased throughput.

[0022] However, the transfer arms may further close around the container to grip and secure the container between them. In this manner, the transfer arms may exert a lateral force on the container to limit movement of the container as the container support surface lowers. Gripping the container in this manner ensures that the container is held by the transfer mechanism. However, the lateral force may increase the risk of spillage or damage, especially when operating at high speeds.

[0023] In a preferred example, the step of lowering the container support surface of the input conveyor and / or platen includes two stages: a first stage of lowering the container support surface so that the weight of each container is supported by the transfer mechanism, and a second stage of further lowering the container support surface to form a gap between each container and the container support surface. After the first stage, the weight of each container is transferred from the container support surface to the transfer mechanism (e.g., the transfer arm described above). Thus, in the first stage, the container support surface is lowered so that the weight of each container is supported or supported by the transfer mechanism. Meanwhile, in the subsequent second stage, the container support surface is further lowered so that a vertical gap or gap is formed between the container support surface and the containers held in place by the transfer mechanism. This gap or gap allows each container to be moved laterally without contacting the underlying machine. Preferably, these stages are sequential and occur consecutively such that there is no pause in the movement of the container support surface. However, this is not required.

[0024] In a preferred example, removing each container from the transfer mechanism includes raising a container support surface of the platen. In this manner, the container support surface of the platen is raised to support the container, and the container is released without experiencing a significant vertical drop. As previously mentioned, in some cases, the container may be lifted from the transfer arm of the transfer mechanism by raising the container support surface of the platen. In that case, the transfer arm may be opened without applying significant lateral forces to the container. Alternatively, the container support surface of the platen may be raised until the container support surface of the platen contacts or engages the bottom surface of the container before the transfer arm of the transfer mechanism opens.

[0025] Optionally, each of the one or more containers received by the input conveyor includes an unsealed opening, such that each container is “open.” Each container received by the input conveyor may include an unsealed opening facing upward, away from the container support surface of the input conveyor and platen, during use.

[0026] Each of the one or more containers received by the input conveyor may contain a food product. As mentioned above, particular advantages are obtained where the containers contain food products that include liquids (such as curries and stews), liquid foods (such as soups, stocks, yogurts, etc.), and / or fragile foods (such as baked goods, etc.). The method may include dispensing the food product into the containers. This dispensing step of dispensing the food product into the containers is preferably performed upstream of the input conveyor and platen. Alternatively, the dispensing step may occur while the containers are on the input conveyor and / or platen.

[0027] In a particularly preferred embodiment, the method includes sealing one or more containers on the platen. A sealed (or "closed") container retains the contents and prevents spillage. Sealing the containers ensures product quality to the consumer and may reduce cleaning and maintenance requirements downstream of the system (i.e., subsequent container processing locations and systems).

[0028] Preferably, sealing the one or more containers comprises providing a film across the opening of each container. The film may be bonded around the container opening to seal and close the opening. For example, the film may be provided across an upwardly facing opening of a container such as a tray, deep container, etc. The film may be welded to the container and / or bonded to the container by an adhesive (e.g. an adhesive initially applied to the underside of the film or to the edge of the container). Alternatively, each container may be sealed in any other suitable manner. For example, a lid or cover may be provided over the opening of each container to close the container.

[0029] Preferably, each sealed container is airtight and / or waterproof. Thus, the ingress and egress of gases and liquids into and out of the container is restricted. For example, the seal may be an airtight seal that is impermeable to gases and liquids. Such a seal may prevent the contents of the container from leaking or spilling. In turn, these seals may protect the contents of the container. For example, airtight and waterproof seals are particularly beneficial in the food packaging industry, as they may prevent or delay food spoilage.

[0030] Each container may be formed of any suitable material, such as polymers, such as polypropylene (PP), amorphous polyester terephthalate (A-PET), crystallized polyester terephthalate (C-OPET), expanded polystyrene (EPS), polystyrene (PS), polyvinyl chloride (PVC), as well as metals and alloys, such as aluminum foil (including smooth wall aluminum foil), and corrugated cardboard. These materials are suitable for use with a variety of food products and are easily shaped and manufactured.

[0031] The film may be a single layer or a multi-layer film and may comprise any suitable material, including many polymers. In a preferred example, the film is a gas barrier film comprising layers of polyester (PS) or polypropylene (PP), ethylene vinyl alcohol (EVOH), and / or polyethylene (PE) or polypropylene (PP). Such multi-layer films may include an adhesive for adhering the layers. Additionally or alternatively, the film may include a metal foil (e.g., aluminum), or the film may include a cellulose-based paper film, and / or at least one paper layer.

[0032] In a particularly preferred embodiment, the system for carrying out the method comprises a tray sealer. In this way, the tray sealer can be used to quickly and efficiently seal containers on a platen. The tray sealer may comprise a heat sealing tool having a lower tool part on which the tray (or trays) to be sealed is placed, and an upper tool part including a heating element or plate that forms a contour. The lower and upper tool parts may be brought together by sandwiching a film between the container (or containers) and the upper tool part, which engages the film and the containers below it. The tool part may then be heated to bond the film to each container across the opening.

[0033] Preferably, the platen forms part of the lower tool part of a tray sealer, and the step of sealing one or more containers on the platen comprises the steps of providing a film between each container on the platen and the upper tool part, bringing the platen and the upper tool part into proximity so that the upper tool part engages the film and each container below it, and heating the tool part to bond the film to each container.

[0034] Preferably, the platen forms part of a lower tool part of a traysealer, and the step of sealing one or more containers on the platen comprises the steps of providing a film between each container on the platen and the upper tool part, bringing the platen and the upper tool part into proximity so that the upper tool part engages the film and each container below, and heating the tool part to bond the film to each container. Raising the platen (or a separate lower tool part) rather than moving the upper tool part has the advantage that the large, complex and heated upper tool part can remain fixed throughout the process.

[0035] Alternatively, each container may be sealed in any other suitable manner. For example, the containers may be laser sealed by placing a film across the opening of the container and irradiating the film or the container around the opening with a laser. The film may be welded to the container by the laser and / or may be bonded to the container by activating an adhesive between the film and the container (e.g., an adhesive that is initially provided on the underside of the film or on the edge of the container, such as a tray).

[0036] In a preferred example, the method may include filling the container with a purge gas before sealing the container. The purge gas may displace atmospheric gases, such as air, in the container. The purge gas may be inert or non-reactive with the contents of the container. For example, many food products can have their product life extended by removing oxygen from the container before sealing it. This may be achieved by carrying out the method in a controlled (e.g., oxygen-free) environment. Alternatively or additionally, a container processing system may be provided in a sealed environment filled with a purge gas maintained at atmospheric pressure or slightly above atmospheric pressure. As the container passes through such a system, the purge gas fills the interior volume of each tray and oxygen and / or other atmospheric gases are evacuated. This purge gas, sealed in the container by the film, is preferably inert and does not react with the packaged contents in the container.

[0037] Alternatively or additionally, each container on the platen may be processed in a manner other than sealing. For example, the container may be labeled or printed. Similarly, a product (such as a food product) may be dispensed or provided into the container. For example, a container received by the input conveyor may be partially filled and additional product may be inserted into the container at the platen. In some embodiments, multiple processing steps may be performed on each container on the platen, for example, the container may be filled and sealed. Thus, it can be seen that the method may comprise the step of processing each container transferred to the platen in any suitable manner.

[0038] In a preferred example, lowering the container support surface of the input conveyor and the platen includes lowering the container support surface of the input conveyor and / or the container support surface of the platen so that each container is supported by the transfer mechanism with a vertical gap between each container and its respective container support surface of at least 5 mm, preferably at least 8 mm, and more preferably at least 10 mm, such a gap being sufficient to transfer each container laterally from the input conveyor onto the platen without touching the input conveyor or platen.

[0039] For example, the lowering and raising steps may comprise lowering and raising the container support surface of the input conveyor and / or platen by at least 5 mm, preferably at least 10 mm, more preferably at least 15 mm. Additionally or alternatively, the lowering and raising steps may comprise lowering and raising the container support surface of the input conveyor and / or platen by 50 mm or less, preferably 30 mm or less, more preferably 25 mm or less. Thus, in a preferred embodiment, the container support surface of the input conveyor and / or platen is raised and lowered by a vertical distance in the range of 5 to 50 mm, more preferably 10 to 30 mm, even more preferably 15 to 25 mm, during each raising and lowering step.

[0040] These ranges of movement provide adequate clearance between each container supported by the transfer mechanism and the input conveyor and / or platen below, without the excessive energy and mechanical requirements associated with larger movements. However, larger gaps provide more flexibility by allowing containers to be safely transported despite variations in how a particular container is held or supported by the transfer mechanism. In preferred embodiments, the same or approximately the same vertical clearances are provided between the container and the container support surfaces of the platen and input conveyor, respectively. However, this is not required, and in further embodiments, the container support surfaces of the input conveyor and platen may be lowered by different amounts to provide different gaps.

[0041] In the above example, the process of lowering the container support surface is divided into two stages, and in each stage the container support surface may be lowered by about 10 mm (eg, 5 to 15 mm).

[0042] Preferably, each container is supported by the transfer mechanism at a location above the center of mass of the container and / or the center of mass of the container and its contents. For example, the transfer mechanism may engage or grip the container closer to the top of the container than the bottom of the container and / or may support each container by a protrusion such as a lip located above the center of mass of the container and / or the center of mass of the container and its contents. This reduces the risk of the container tipping or spilling as the transfer mechanism moves the container from the input conveyor onto the platen. As a result, the transfer speed can be increased. For example, in the above example where the width of the container increases between the bottom of the container and the top of the container, a protrusion or lip may be provided that allows the container to be supported by the transfer mechanism closer to the top of the container than the bottom.

[0043] As previously mentioned, the input conveyor (sometimes referred to as a spacing conveyor) rises and falls between a raised position and a lowered position. Preferably, the input conveyor is operable to transport articles received thereon in both the raised and lowered positions. Thus, the input conveyor can receive and transfer containers in both positions. This may enable the input conveyor to receive and prepare for transfer of containers (such as a new batch of containers) as one or more previous containers are transferred to the platen by the transfer mechanism. This may increase container throughput.

[0044] Preferably, the system includes an input conveyor drive mechanism configured to drive the input conveyor, the input conveyor drive mechanism being stationary as the container support surface of the input conveyor rises and falls. Thus, the input conveyor drive mechanism is stationary during the method and does not rise and fall with the container support surface. The drive mechanism of a conveyor system is typically heavy, fragile, and difficult and costly to maintain compared to other components of the conveyor system (such as the belt and rollers of a belt conveyor). Thus, energy and equipment requirements can be significantly reduced if the drive mechanism of the input conveyor remains stationary as the input conveyor itself rises and falls. However, this is not required, and in another example, the input conveyor drive mechanism may rise and fall together with the container support surface. For example, the input conveyor may rise and fall as a single unit.

[0045] The input conveyor may be any suitable conveyor configured to transport or convey each container, such as, but not limited to, a belt conveyor, a modular belt conveyor, a walking beam, a roller conveyor, a chain conveyor, a wire conveyor, a slat conveyor, etc.

[0046] In particularly preferred examples, the input conveyor is a belt conveyor comprising an input belt, and the container support surface is an outer surface of the input belt. Belt conveyors typically comprise a continuous or endless belt extending around two or more rollers. The rollers typically comprise drive rollers which are driven and rotated by the action of a drive mechanism which typically comprises a motor and gears. Friction between the drive rollers and the belt causes the belt to move around the rollers. Thus, in these examples, the container support surface and the input belt of the input conveyor can be raised and lowered by raising and lowering one or more rollers of the input conveyor.

[0047] Preferably, the tension of the input belt is substantially constant when the container support surface of the input conveyor rises and falls. Thus, the tension of the input belt is substantially constant when the container support surface is in the raised and lowered positions. Furthermore, in a preferred embodiment, the tension of the input belt is substantially constant when the input conveyor rises and falls. Because the tension of the input belt is maintained, the circumference of the belt, i.e. the length of the path that the belt will stretch or travel during use when attached to the conveyor, remains substantially constant in both the raised and lowered positions. As a result, the input belt can be manipulated to transport containers throughout the method with less chance of the belt slipping off the rollers of the input conveyor during vertical movement. In a preferred embodiment, the tension of the belt conveyor is about 400N (about 40kg), preferably 300-500N (about 30-50kg). Under this tension, the belt can stretch by about 0.5%, for example 0.25-0.75%. Therefore, the free length of a belt (the length of the belt when purchased and before it is installed on a conveyor) is slightly less than the circumference of the belt when it is installed on a conveyor and under tension.

[0048] If all of the rollers of the input conveyor rise and fall together as the container support surface rises and falls (e.g., if the entire input conveyor rises and falls as a single unit), tension in the belt will necessarily be maintained. However, if only a portion or portions of the input conveyor rise and fall with the container support surface, e.g., if the input conveyor drive mechanism and drive rollers are stationary as described above, tension in the belt may be more difficult to maintain. Even so, if the total length of the path traveled by the belt (the circumference of the belt) remains substantially constant, tension in the belt may be maintained even as the various rollers of the conveyor move relative to one another as the container support surface rises and falls.

[0049] For example, the tension of the input belt can be maintained substantially constant if the input conveyor includes a bias roller configured to maintain tension in the input belt. By "biased" it is understood that the tension roller is configured to contact the input belt and press against the input belt while maintaining the proper tension and belt circumference of the input belt as the container support surface of the input conveyor rises and falls. The tension roller may be biased against the input belt by a resilient member such as a spring. Alternatively, the proper tension of the input belt may be maintained if the rollers are positioned such that the belt circumference is constant when the container support surface is in the raised and lowered positions, respectively. For example, a constant belt circumference is maintained if a decrease in the distance between any first pair of rollers is compensated for by a corresponding increase in the distance between a different second pair of rollers.

[0050] Preferably, the system comprises an input conveyor drive mechanism configured to drive the input belt via a drive roller, where the contact length between the input belt and the drive roller is substantially the same when the container support surface of the input conveyor is raised and lowered. The contact length between the input belt and the drive roller is substantially the same when the container support surface of the input conveyor is in the raised and lowered positions. The contact length is understood to be the distance along the circumference of the drive roller where the input belt contacts the drive roller. This contact length defines how much torque the drive roller can transmit to the input belt without the input belt slipping. If the input conveyor is raised and lowered as a single unit, the positional relationship between the drive roller and the input belt will not change when the container support surface moves. However, if the drive mechanism and drive roller of the input conveyor remain stationary as the container support surface moves, the appropriate contact length can be maintained by carefully positioning the remaining rollers of the input conveyor. The change in position of each roller relative to the drive mechanism can be compensated for by a corresponding change in position of the other rollers of the input conveyor. For example, the contact arc length may be maintained at 60-140 mm, more preferably 80-120 mm, and even more preferably about 100 mm. These values ​​are suitable for a belt width of about 200 mm, but can be varied as necessary to maintain adequate drive force. In a preferred embodiment, the wrap angle at which the belt contacts the drive roller is between 90 degrees and 180 degrees, and more preferably between 120 degrees and 180 degrees.

[0051] Preferably, the platen and the input conveyor are mechanically coupled such that the container support surfaces of the platen and the input conveyor are raised and lowered simultaneously by a single lifting mechanism. For example, the platen and the input conveyor (and / or their respective container support surfaces) may be raised and lowered in unison by a single hydraulic or pneumatic ram or a single motor. In a preferred embodiment in which the input conveyor is a belt conveyor, the platen is mechanically coupled to one or more rollers of the input conveyor such that raising and lowering the platen also raises and lowers the container support surface defined by the rollers and the outer surface of the input belt that extends around those rollers. This simplifies handling of the platen and the input conveyor and reduces installation and maintenance costs. However, this is not required and the platen and the container support surface of the input conveyor may be provided with separate lifting mechanisms (such as separate hydraulic or pneumatic rams or motors).

[0052] More preferably, the system may include a single lift mechanism configured to lower the container support surface of the platen so that each grasped container is supported above the surface of the platen by the transfer mechanism, and to raise the container support surface of the platen so that each container placed thereon can be processed. For example, as described above, the single lift mechanism may be configured to raise the container support surface of the platen so that each container placed thereon can be engaged by an upper tool portion of a tray sealer (e.g., with a film placed therebetween to seal each container). Alternatively, each container thus elevated may be easier for an operator to inspect or fill. In particular, the single lift mechanism may be configured to raise the container support surface of the platen above (i.e., at a higher vertical position) the container support surface of the input conveyor so that each container placed on the platen can be processed while the input conveyor remains at a constant height. This allows the input conveyor to continue to operate to receive or accumulate additional containers while a batch of containers on the platen is being processed, thus increasing the processing speed. In other words, the single lifting mechanism may be configured to simultaneously lower the container support surfaces of the platen and input conveyor so that containers gripped above the platen and input conveyor container support surfaces are supported by the transfer mechanism, and the input conveyor container support surface may remain in a substantially constant (vertical) position while the platen container support surface is raised to allow processing of containers placed thereon. Thus, while the platen and input conveyor may be mechanically coupled to lower their respective container support surfaces in unison to allow safe transfer of containers, this mechanical coupling preferably also allows the input conveyor container support surface to be raised above the input conveyor during processing (e.g., sealing, inspection).

[0053] Providing a single lifting mechanism is particularly efficient since a single component can lower the container support surface of the platen while containers are being transferred and raise that surface while containers are being processed on the platen. Separate mechanisms for raising and lowering the platen are not required. This makes the system particularly efficient and requires less space and resources to manufacture and operate. Preferably, the platen may be driven vertically by a single hydraulic or pneumatic ram, a single motor, or other suitable lifting mechanism.

[0054] Preferably, each container received on the input conveyor is received from an upstream infeed conveyor (sometimes referred to as a take-off conveyor), which may form part of the system described above. Alternatively, each container may be received on the input conveyor from other suitable means, including manual transfer.

[0055] In a particularly preferred embodiment, the input conveyor includes a movable container support surface having a downstream end adjacent the input conveyor and an upstream end furthest from the input conveyor, and the method includes raising and lowering at least the downstream end of the container support surface of the input conveyor as the container support surface of the input conveyor is raised and lowered.

[0056] Thus, throughout the method, there is no significant height difference or vertical discontinuity between the container support surfaces of the infeed and input conveyors, and therefore, movement of the input conveyor container support surface does not exert significant forces on each container moving between the infeed and input conveyors, thereby reducing spillage or damage to the container contents and allowing for high throughput rates.

[0057] In a preferred embodiment, the upstream end of the container support surface of the input conveyor remains stationary as the downstream end is raised and lowered. Thus, the input conveyor container support surface rotates about the upstream end. Indeed, in a particularly preferred embodiment, the input conveyor upstream end includes a pivot fixed in place about which the input conveyor rotates or "nods" as the input conveyor is raised and lowered. This provides a smooth interface between the input conveyor and upstream equipment and machinery.

[0058] To further reduce the forces on the containers, preferably, as the loading conveyor container support surface and the input conveyor container support surface are raised and lowered, the upstream end of the loading conveyor container support surface remains stationary in a vertical position at a midpoint of the range of movement of the loading conveyor upstream end and / or the midpoint of the range of movement of the input conveyor container support surface. This minimizes the angle through which the loading conveyor container support surface rotates relative to the horizontal plane and avoids excessive changes in the vertical height of the loading conveyor as a whole. This thus reduces the height to which containers must be raised and lowered as they pass through the nodding loading conveyor, reducing the risk of spillage. In a preferred example, the container support surface of the input conveyor rotates within an angle range of +5 degrees to -5 degrees relative to the horizontal, more preferably within an angle range of +2 degrees to -2 degrees relative to the horizontal, even more preferably within an angle range of +1.5 degrees to -1.5 degrees relative to the horizontal, and even more preferably within an angle range of +1.28 degrees to -1.28 degrees, although this is not required and the upstream end of the input conveyor container support surface may be located at the same or approximately the same vertical height as the raised or lowered position of the downstream end (e.g., such that the container support surface rotates at an angle of 0 degrees to 4 degrees relative to the horizontal).

[0059] However, in further embodiments, the upstream and downstream ends of the container support surface of the input conveyor are raised and lowered in unison. In such an embodiment, the container support surface of the input conveyor remains horizontal as the downstream end of the input conveyor is raised and lowered.

[0060] In some examples, the downstream end of the input conveyor may be mechanically coupled to the input conveyor. In this manner, the platen, input conveyor and input conveyor are all mechanically coupled or articulated and may be moved by a single lift mechanism. However, in further examples, a stationary input conveyor may be provided that does not move with the input conveyor and / or platen.

[0061] The infeed conveyor may comprise any of the optional or preferred features described above with respect to the input conveyor, which features provide corresponding advantages. For example, the infeed conveyor may be any suitable conveyor, including, but not limited to, a belt conveyor, a roller conveyor, a chain conveyor, a slat conveyor, and the like. However, like the input conveyor, the infeed conveyor is preferably a belt conveyor, and may comprise an infeed belt, with the container support surface being an outer surface of the infeed belt. If the infeed conveyor is a belt conveyor, the tension in the infeed belt is preferably maintained substantially constant throughout the method by the techniques described above with respect to the input conveyor. Additionally or alternatively, the infeed conveyor may be driven by an infeed conveyor drive mechanism and / or drive rollers, which preferably remain stationary as the infeed conveyor moves. In such an example, the input conveyor may be configured such that the contact length between the input belt and the input conveyor drive rollers is substantially the same when the input conveyor container support surface is in each of the raised and lowered positions, or the input conveyor may move (e.g., raise and lower and / or rotate) as a single unit.

[0062] In a preferred example, the method may include varying the operating speed of the input and / or infeed conveyors as the container support surfaces of the infeed and input conveyors move (i.e., rise and fall and / or rotate). This minimizes variations in the speed at which the conveyors transport containers and avoids unnecessary forces on the containers and their contents, thereby preventing spillage or damage to the containers and their contents. For example, if the input and infeed conveyors are belt conveyors, the input power to the motors and drive rollers may be varied as the respective container support surfaces move to allow the belt of each conveyor (and each container supported thereon) to maintain a substantially constant speed. The varying operating speed may accommodate changes in the forces on the conveyor belt as the position of the belt and non-driven rollers of the conveyors move relative to the motors and drive rollers. This may take the form of software corrections to the motor speeds made by a controller for the system.

[0063] Preferably, the method includes subsequent steps including lowering the container support surface of the platen such that each container is supported above the platen by a transfer mechanism, transferring each container from above the platen to an output conveyor using the transfer mechanism, and removing each container from the transfer mechanism. Each container received and / or processed on the platen is thus transferred or ejected from the platen by the transfer mechanism using substantially the same process as described above. These steps may include any of the optional or preferred features described hereinbefore.

[0064] The method thus comprises the step of ejecting each container from the platen using an output conveyor (although in further examples each container may be ejected and transported using a container handling component or machine, including manual handling). These steps may be performed after the container has been processed on the platen, for example after the container has been filled, sealed, labeled and / or printed. The output conveyor may comprise any of the optional or preferred features discussed above with reference to the input and infeed conveyors. The output conveyor may be any suitable conveyor, including, but not limited to, a belt conveyor, a roller conveyor, a chain conveyor, a slat conveyor, etc.

[0065] The method may then further comprise transporting each container off the platen using an output conveyor, after which each container may be processed in other manner, such as labeling, printing, boxing, shipping, selling, etc.

[0066] In a particularly preferred embodiment, the output conveyor and / or the container support surface of the output conveyor remain substantially stationary in the vertical direction throughout the method. For example, a transfer mechanism may drag each container from the platen to the stationary output conveyor or open each container on the output conveyor. This is particularly suitable for methods and systems in which the containers are sealed on the platen (for example, using a tray sealer as described above). In these embodiments, the containers may be subjected to high forces as they are transferred to the stationary output conveyor, but the contents of the sealed container are prevented or made less likely to spill by the seal opening. This allows the design and construction of the system to be simplified without increasing the risk of spillage. For example, the container support surface of the output conveyor may be positioned to be at the same height as the platen in the lowered position and / or to be substantially parallel to the platen. In a preferred embodiment, the container support surface of the output conveyor is positioned at the height of the container support surfaces of the platen and / or input conveyor in their respective lowered positions.

[0067] However, in a further example, the output conveyor and / or the container support surface of the output conveyor may be movable and the method may include lowering the container support surface of the platen and output conveyor before each container is transferred from the platen to the output conveyor. This method is preferred if the container contains a fragile product or is not sealed, as it reduces the forces on the container. The output conveyor and the platen may be mechanically coupled such that the platen and the output conveyor are raised and lowered by a single lifting mechanism (e.g., a motor or hydraulic ram). The output conveyor may include a stationary output conveyor drive mechanism that does not move as the container support surface is raised and lowered. If the output conveyor is a belt conveyor with an output belt, the tension in the output belt and the contact length between the output belt and the drive roller of the output conveyor may be maintained at a substantially constant level. Similarly, in a further example, the output conveyor may be configured to rotate in a manner similar to the input conveyor, with the upstream end of the container support surface of the output conveyor furthest from the platen remaining substantially stationary and the downstream end of the product support surface of the output conveyor rising and falling with the platen.

[0068] Whether the output conveyor is stationary or movable, the platen may optionally be lowered once or after the container on the platen is supported by the transfer mechanism (i.e., once or after the weight of the container is handed over to the transfer mechanism) and before the container is transferred from the platen to the output conveyor. For example, both the platen and the input conveyor may be lowered before the container is transferred to the output conveyor. This is particularly suitable when processing a batch of multiple consecutive containers (as described further below), in which case each container supported by the transfer mechanism is lifted off the platen and supported above the platen before being conveyed to the output conveyor for ejection. The manner in which the containers on the platen are held or gripped by the transfer mechanism may involve similar steps as for containers received on the input conveyor. These steps may occur substantially simultaneously with the steps performed in connection with each container received on the input conveyor.

[0069] Preferably, the method includes repeating the above steps (including any of the steps described as optional or preferred steps) as the system processes a subsequent container or batch of containers. The containers transferred to the platen may be removed manually or using the output conveyor as described above. To allow for repeated processing, the transfer mechanism reciprocates and returns to a starting position after the product has been transferred to the platen and / or output conveyor so that the transfer mechanism can receive and support a subsequent container received on the input conveyor and the method may be resumed.

[0070] According to a further aspect of the invention there is provided a method for processing two successive batches of containers, each batch comprising one or more containers, the two successive batches of containers comprising a downstream batch followed by an upstream batch, the containers of each batch being processed according to the method of any of the preceding claims, the method comprising using a transfer mechanism to transfer the containers of the downstream batch from the platen to the output conveyor while simultaneously transferring the containers of the upstream batch from on the input conveyor onto the platen. It will be appreciated that this method allows further improved throughput by simultaneously transferring successive batches of containers to and from the platen. The first downstream batch is discharged from the platen onto the output conveyor as the subsequent upstream batch is received onto the platen from the input conveyor.

[0071] More specifically, containers of a first downstream batch may be transferred to the platen as described above and processed on the platen. For example, the containers of the downstream batch may be filled, sealed, labeled and / or printed on the platen. Preferably, as the containers of the first downstream batch are processed, containers of a subsequent upstream batch are received on the input conveyor. Thus, the processed downstream batch can be discharged from the platen while simultaneously transferring containers of a new upstream batch to the platen for processing. This is particularly efficient.

[0072] Preferably, the downstream batch of containers on the platen and the new upstream batch of containers on the input conveyor are supported by the transfer mechanism substantially simultaneously. For example, the transfer mechanism may have two laterally spaced supports, a first support configured to support or hold the downstream batch of containers and a second gripper configured to support or hold the subsequent upstream batch of containers. The upstream and downstream supports may form laterally spaced portions of the same transfer arm. In such a method, the container support surfaces of the input conveyor and the platen may be lowered, again preferably substantially simultaneously, to transfer the weight of the upstream and downstream batch of containers to the transfer mechanism before the transfer mechanism is actuated to laterally move both batches of containers in unison. In such an example, the transfer mechanism transfers the downstream batch of containers from the platen to the output conveyor while simultaneously transferring the upstream batch of containers from the input conveyor onto the platen. The container support surfaces of the input conveyor and platen may then be raised (again, preferably simultaneously) and containers of both batches may be removed (again, preferably simultaneously) by the transfer mechanism. Thus, as containers of an upstream batch are processed on the platen, previously processed containers of a downstream batch can be transferred off the platen by the output conveyor.

[0073] It will be further understood that this method may be further repeated as the system processes additional batches of containers. For example, a third batch of containers may arrive on the input conveyor while the aforementioned upstream batch is on the platen (e.g., as the upstream batch is being processed). This third batch of containers may be processed and transferred to the platen in the same manner as described above with respect to the upstream batch, while the upstream batch may be discharged and transferred off the platen in the same manner as described above with respect to the downstream batch.

[0074] It will be appreciated that in these examples, two batches of containers can be processed simultaneously by the transfer mechanism. As previously discussed, the transfer mechanism may comprise a first support configured to support one or more containers (e.g., a downstream batch) on the platen and a second support configured to support one or more containers (e.g., an upstream batch) on the input platen. Thus, the first support is disposed downstream of the second support. The transfer mechanism moves such that each container held by the first support is transferred from the platen to the output conveyor while each container held by the second support is transferred from the input conveyor onto the platen. The transfer mechanism may then remove both batches of containers and return to the starting position to receive a further batch of containers to complete the reciprocating motion.

[0075] This method of processing multiple batches of containers may include and combine any of the optional or preferred features of the methods and systems described above, providing corresponding advantages.

[0076] According to a further aspect of the invention, a container processing system is provided, comprising a platen and an input conveyor, each of the platen and the input conveyor having a movable container support surface configured to move between an elevated position and a lowered position, and a reciprocating transfer mechanism configured to support one or more containers previously received on the input conveyor as the container support surface of the input conveyor descends from the elevated position to the lowered position, such that the one or more containers are supported by the transfer mechanism above the input conveyor, and to transfer the one or more containers from on the input conveyor onto the platen when the input conveyor and the platen are in their respective lowered positions. In this manner, the transfer mechanism holds each container above the input conveyor when its container support surface moves to its lowered position. A vertical gap may be formed between each container and the container support surfaces of the input conveyor and the platen, allowing each container to be moved laterally from on the input conveyor onto the platen without significant lateral forces.

[0077] The system according to this aspect of the invention therefore offers similar advantages to the methods described above, in particular reducing the risk of spillage or damage to the contents of the container, reducing cleaning and maintenance requirements and improving product quality and throughput.

[0078] Preferably, the vessel processing system is adapted to carry out a method including any of the methods according to the preceding aspects of the invention, and thus may be configured to carry out any or preferred steps as described above and may include any of the components and features described above with reference to the preceding aspects of the invention.

[0079] For example, the transfer mechanism of the container processing system may include a transfer arm configured to support and transfer each container, and the method may include closing the transfer arm around each container received on the input conveyor such that each container is supported by the transfer arm. Similarly, the system may be configured to lower each container support surface of the input conveyor and / or platen in two stages, including a first stage lowering the container support surface so that the weight of each container is supported by the transfer mechanism, and a second stage further lowering the container support surface to form a gap between each container and the container support surface.

[0080] Similarly, in a preferred example, the container processing system may include a sealing unit, such as a tray sealer, configured to seal one or more containers on the platen. The sealing unit may be configured to provide a film across an opening of each container. The sealing unit may be configured to seal an upwardly facing opening of each of the one or more containers with the film to close the opening and prevent contents of the container from leaking out of the container. Preferably, the sealing unit is adapted to form an airtight and / or watertight seal across the opening of the container.

[0081] If the container processing system includes a tray sealer, the platen may form a lower tool part of the tray sealer. The platen may be configured to mate with an upper tool part of the tray sealer, with the upper tool part configured to engage a container on the platen and a film disposed between the container and the upper tool part. For example, the system may be configured to raise a container support surface of the platen relative to the input conveyor. The tray sealer may be configured to heat the upper tool part such that when the container engages the upper tool part with the film disposed between the container and the upper tool part, the film is bonded to the container to seal the opening of the container. Additionally or alternatively, the system may include an alternative processing unit (or multiple units), such as a label maker to apply a label to the container on the platen, a printer to print on the container on the platen, or a product dispensing unit to dispense a product (e.g., food) into the container.

[0082] The distance between the respective raised and lowered positions of the container support surface of the input conveyor and / or the platen is at least 5 mm, more preferably at least 10 mm, even more preferably at least 15 mm. Similarly, the respective raised and lowered positions of the input conveyor and / or the platen are at most 50 mm, preferably at most 30 mm, even more preferably at most 25 mm. Thus, the range of movement of the respective container support surface of the input conveyor and the platen during use may be in the range of 5-50 mm, more preferably 10-30 mm, even more preferably 15-25 mm. In a particularly preferred embodiment, the distance between the respective raised and lowered positions of the input conveyor and the platen is 20 mm.

[0083] Preferably, the transfer mechanism supports each container at a location above the centre of mass of the container and / or the centre of mass of the container and its contents.

[0084] Preferably, the system includes an input conveyor drive mechanism configured to drive the input conveyor, and the input conveyor is positioned such that the input conveyor drive mechanism remains stationary as the container support surface of the input conveyor rises and falls.

[0085] Preferably, the input conveyor is a belt conveyor comprising an input belt, and the container support surface is an outer surface of the input belt. Other suitable forms of conveyor may be used. Preferably, the system is configured such that the tension in the input belt is substantially the same when the container support surface of the input conveyor is in the raised and lowered positions. Preferably, the system comprises an input conveyor drive mechanism configured to drive the input belt via a drive roller, and the contact length between the input belt and the drive roller is substantially the same when the container support surface of the input conveyor is in the raised and lowered positions. Preferably, the platen and the input conveyor are mechanically coupled such that the container support surfaces of the platen and the input conveyor are raised and lowered simultaneously by a single lifting mechanism.

[0086] Preferably, the system further comprises an upstream input conveyor, the input conveyor adapted to receive the containers from the input conveyor. Preferably, the input conveyor comprises a movable container support surface having a downstream end adjacent the input conveyor and an upstream end furthest from the input conveyor, the input conveyor adapted to have the downstream end rise and fall with the container support surface of the input conveyor while the upstream end remains stationary.

[0087] Preferably, the system includes an output conveyor configured to eject or transfer the containers from the platen. Preferably, the transfer mechanism is further configured to removably support one or more containers on the platen so as to transfer the one or more containers from (or on) the platen to the output conveyor. Preferably, the output conveyor and / or the container support surface of the output conveyor remain stationary as the input conveyor and the container support surfaces of the platen rise and fall.

[0088] Preferably, the system is configured to simultaneously process two successive batches of containers, each batch containing one or more containers. In a particularly preferred embodiment, the transfer mechanism transfers containers of a downstream batch from the platen to the output conveyor while simultaneously transferring containers of a subsequent upstream batch from the input conveyor onto the platen. This is a particularly efficient method of container transfer, which allows high throughput to be achieved without risk of spilling or damaging the contents of the containers.

[0089] In the above-described aspects of the invention, a gap is created between each container supported or held by the transfer mechanism and the underlying input conveyor and platen by relative movement of the container support surfaces of the input conveyor and platen. The input conveyor and platen are lowered to create a vertical gap or space between the container support surfaces and each container. This gap allows lateral movement of the supported container without contact between the container and the platen or input conveyor.

[0090] Alternatively, the inventors have recognized that a similar gap or spacing between the container and the conveyor or platen below can be achieved by gripping each container with a transfer mechanism and lifting the gripped container with the transfer mechanism. In other words, relative vertical movement between a gripped container and the input conveyor and / or platen can be achieved by raising the transfer mechanism and / or container instead of lowering the input conveyor and platen (as described above).

[0091] However, this potential alternative approach has significant drawbacks, especially as processing speeds and capabilities increase. In contrast to the transfer mechanism of the present invention, which only needs to grip and transfer the container, these potential alternative transfer mechanisms need to quickly grip, lift, transfer, and remove the container. It is difficult to design a single mechanism that can perform the additional operations. Furthermore, this potential alternative transfer mechanism will necessarily be larger than the examples of the present invention described herein, since it needs to perform the additional operations.

[0092] The increased size, weight and complexity of the transfer mechanism becomes problematic as processing speeds increase because the transfer mechanism must be highly dynamic. Larger moving mechanisms require more support due to added inertia and forces, and the energy and power requirements are also significantly greater. These problems are exacerbated when the transfer mechanism is configured to transport containers over longer distances.

[0093] Thus, the system of the present invention for lowering container support surfaces of a conveyor and / or platen is easier to design and requires fewer resources to manufacture and operate than alternative options that may raise containers above these support surfaces.

[0094] Potential alternative transfer mechanisms to lift the containers would need to rapidly shuttle the container both vertically to raise or lower it, and laterally from above the input conveyor to above the platen to transfer the container, while simultaneously rapidly gripping and releasing the container. Combining these dynamic motions into a single transfer mechanism would increase the overall system complexity and energy requirements. [Brief description of the drawings]

[0095] [Figure 1] FIG. 1a is a schematic side view of a container processing system according to an embodiment of the present invention, and FIGS. 1b to 1j are schematic views showing successive steps of a container processing method according to an embodiment of the present invention, which is carried out by the container processing system of FIG. 1a. [Diagram 2] FIG. 2a is a perspective view of a vessel processing system according to one embodiment of the present invention, and FIGS. 2a and 2b are side views of components of the vessel processing system. [Diagram 3] 3a and 3b are cross-sectional views of components of a vessel processing system according to one embodiment of the invention, and FIG. 3c is a side view of further components of the vessel processing system. [Figure 4] 4a to 4d are schematic diagrams showing successive steps of a method for treating a container according to the present invention. [Diagram 5] 5a to 5d are schematic diagrams showing successive steps of a method for treating a container according to the present invention. [Figure 6] 6a to 6d are schematic diagrams showing successive steps of a method for treating a container according to the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0096] 1a-1j each show a schematic diagram of a container handling system 10 including a platen 11, an input conveyor 12, an output conveyor 13 and a transfer mechanism 14. The system 10 further comprises a tray sealer formed by the platen 11 acting as the lower tool part of the tray sealer and a heated upper tool part 15 (although in other examples the system may comprise additional or alternative container processing units such as dispensers, labellers and / or printers). FIGS. 1b-1e show schematic diagrams of successive steps and processes of a method carried out using this system. This method avoids the application of significant forces to the containers when they are transferred between the input conveyor 12 and the platen 11 and when they pass through the gap G shown in FIG. 1a. FIGS. 1f and 1g-1j show (optional) continuations of the method.

[0097] Both the input conveyor 12 and the output conveyor 13 are belt conveyors (although this is not required) adapted to transport and move each container in a direction parallel to the x-axis shown in Figure 1a. The input conveyor 12 is configured to transport the containers towards the platen 11, and the output conveyor 13 is adapted to transport the containers away from the platen 11.

[0098] Platen 11, input conveyor 12, and output conveyor 13 each have a container support surface 11a, 12a, and 13a, respectively, capable of supporting a container. Container support surface 11a of platen 11 is one surface of the platen, while container support surfaces 12a, 13b of input conveyor 12 and output conveyor 13 are defined by the moving outer surfaces of the respective conveyor belts.

[0099] The platen 11 and the input conveyor 12 are movable such that they can be raised and lowered as a whole. Thus, the platen 11 and the input conveyor 12 can each be moved at least in a vertical direction (the y-axis shown in FIG. 1a). As a result, the upwardly facing container support surfaces 11a, 12a of the platen 11 and the input conveyor 12 are also configured to be raised and lowered vertically and move vertically between their respective raised positions and their respective lowered positions.

[0100] In the example described below, the output conveyor 13 and its upwardly facing container support surface 13a remain in place and vertically stationary during the method illustrated in Figures 1b-1j. Specifically, the container support surface 13a of the output conveyor 13 is substantially coplanar with the container support surfaces 11a, 12a of the platen 11 and input conveyor 12 when these surfaces are in their respective lowered positions. However, these features are not required. For example, in another example, the output conveyor 13 may be movable, such that it can be raised and lowered vertically (e.g., along with the platen and / or input conveyor).

[0101] The transfer mechanism 14 may be reciprocating, repeatedly moving along a generally horizontal direction parallel to the x-axis shown in Figure 1a, and returning along the opposite direction. Thus, the position of the transfer mechanism 14 on the input conveyor, the platen, and the output conveyor may be varied. The transfer mechanism 14 may further be configured to removably support or hold the containers, and may be operated to transfer the containers from the input conveyor to the platen, and from the platen to the output conveyor. Thus, the transfer mechanism 14 may transfer each container along a transfer direction extending from the input conveyor towards the output conveyor, which is parallel to the x-axis as shown.

[0102] We now turn to the method illustrated in Figures 1b to 1j. In a first step of the method, a first batch B1 of containers C is received by the input conveyor 12. Specifically, as shown in Figure 1b, three containers C are received by the input conveyor 12. Each container C comprises an interior volume accessible by an upwardly facing opening. In a preferred example, a product (e.g. food product) is provided and held within the containers C.

[0103] FIG. 1c shows the input conveyor 12 and platen 11 as indicated by arrows L1 and L P 1 illustrates the configuration of the system 10 after being lowered as shown at , where the containers C on the input conveyor 12 are supported by the transfer mechanism 14. As the input conveyor 12 and platen are lowered, a vertical spacing or gap D is formed between the containers C and the container support surfaces 12a, 11a of the input conveyor 12 and platen 11. As shown, each container C of the first batch B1 is suspended in support above the input conveyor 12 by the transfer mechanism 14. As shown, the vertical spacing D between each container C and the input conveyor 12 and the vertical spacing D between each container C and the platen 11 are the same, although this is not required. The input conveyor 12 and platen 11 may be lowered simultaneously, although this is not required.

[0104] The transfer mechanism 14 is then actuated to move each container C downstream (i.e., in the x direction as shown in FIG. 1a) from the input conveyor 12 onto the platen 11 as shown in FIG. 1d. This movement of the transfer mechanism 14 and each container C it supports is generally horizontal, as shown by arrow M1. The transfer of each container C occurs without exposing the container C and its contents to excessive forces as it passes through the gap G between the input conveyor 12 and the platen 11, because there is no contact between each container C and the input conveyor 12 and the platen 11 during transfer. Thus, the risk of spillage or damage to sensitive contents within the container C is reduced. After transfer, each container C is supported above and directly above the platen 11, as shown in FIG. 1d.

[0105] In FIG. 1e, the platen 11 and input conveyor 12 (and their respective container support surfaces 11a and 12a) are raised and rotated as indicated by arrows R p and R I 1a and 1b. As the platen 11 rises, its upwardly facing container support surface 11a contacts the bottom surface of the container C, thereby supporting and bearing the weight of each container C. Each container C is then removed from the transfer mechanism 14 and remains in place on the platen 11.

[0106] Thus, each container C is transferred from the input conveyor 12 to the platen 11 without being subjected to significant forces in either the vertical or horizontal directions. Each container C is transported across the interface between the input conveyor 12 and the platen without falling or colliding with other containers C or components of the container handling and processing system 10.

[0107] Figure 1f illustrates an optional subsequent step in the method of sealing containers C using a traysealer formed by a platen 11 (lower tool part) and upper tool part 15. A film (not shown) is placed between each container C and the upper tool part 15. The platen 11 is raised to bring the platen 11 and upper tool part 15 into close proximity such that each container C on the platen 11 and the intervening film are engaged by the upper tool part 15 (i.e. the upper tool part 14 indirectly contacts the container C via the film). This movement of the platen 11 above the raised position initially shown in Figure 1a is indicated by arrow R in Figure 1f. P 1, the upper tool portion 15 is indicated by a solid line at 1′. The faces of the upper tool portion 15 that engage the containers C and the film are heated, activating the heat sealable film and bonding the film to each container C. In this manner, the film can be sealed around and extend across the opening of each container C to close the opening. In a further example, the platen 11 can be stationary and the upper tool portion 15 can be lowered to engage each container C during the sealing process.

[0108] Before, simultaneously with, or after the sealing process, the transfer mechanism 14 may be returned to the starting position shown in Figures 1a and 1b. This movement is indicated by arrow M2 in Figure 1f. In this manner, the transfer mechanism 14 has completed its reciprocating motion, positioning it to receive additional containers onto the input conveyor 12 and repeat the process described above.

[0109] In yet another example, each container may be processed in another manner after it is received on platen 11. For example, each container may be filled, inspected, labeled, weighed, printed, boxed, etc. after being transferred to the platen by transport mechanism 14.

[0110] Further optional subsequent steps of the method illustrated in Figures 1a to 1f will now be described with reference to Figures 1g to 1j which show how the method can be extended to process a continuous stream of individual containers C, C' through the system 10, where the containers C, C' are transferred in batches from an input conveyor 12 to a platen 11 and then from the platen 11 to an output conveyor 13.

[0111] Specifically, as shown in Figures 1g-j, a first batch B1 of containers C as described above is transferred from platen 11 to output conveyor 13 while a second batch B2 of containers C' is transferred from input conveyor 12 to platen 11. As can be seen, the first batch B1 of containers is downstream of the second batch B2 along the direction of movement of the containers C, C' (i.e., the x-direction in Figure 1a). The containers C, C' of each batch B1, B2 are preferably substantially identical in size, shape and contents.

[0112] In Figure 1g, the platen 11 supporting the first batch B1 of containers C has been lowered after sealing each container C, so that the platen 11 has returned to its original position shown in Figure 1a. Thus, the container support surface 11a of the platen 11 is again flush with the container support surface 12a of the input conveyor 12. This generally vertical movement is indicated by arrow L in Figure 1g. P Further, a second batch B2 of containers C' is received on the input conveyor 12.

[0113] Thereafter, as shown in Figure 1h, the input conveyor 12 and platen 11 are lowered while the containers C, C' are supported by the transfer mechanism 14. This lowering process is substantially the same as that described with reference to Figure 1c. The input conveyor 12 and platen 11 (and their respective container support surfaces 12a, 11a) drop or move vertically downward such that a vertical gap D is formed between the containers C, C' supported by the transfer mechanism 14 and each of the input conveyor 12 and platen 11. Thus, a first batch B1 of containers C is supported above the platen 11 by the transfer mechanism 14, and a second batch B2 of containers C' is supported above the input conveyor 12 by the transfer mechanism 14. The transfer mechanism 14 may therefore comprise two supports: an upstream support configured to receive and support one batch of containers (second batch B2 of containers C') from the input conveyor, and a downstream support configured to receive and support one batch of containers (first batch B1) from the platen.

[0114] The transfer mechanism 14 is then operated to move horizontally as indicated by arrow M1 in FIG. 1i. This movement corresponds to the movement shown in FIG. 1d. Thus, the first batch B1 of containers C is discharged from the platen 11 and transferred from there to the output conveyor 12, while the second batch B2 of containers C' moves from the input conveyor 12 onto the platen 11. Note that the transfer of the second batch B2 of containers C' between the input conveyor 12 and the platen 11 also avoids excessive force on the open (i.e. unsealed) containers C' in the second batch B2. Meanwhile, the output conveyor 13 remains stationary throughout the method, but since the contents of the containers C of the first batch B1 are sealed (as described above), spillage is highly unlikely.

[0115] Then, the input conveyor 12 and the platen 11 rise, and the platen 11 and the input conveyor 12 return to their original positions. During this process, the container support surface 11a of the platen 11 contacts and supports the weight of each container C' of the upstream second batch B2. This movement is indicated by the arrow R in FIG. I and R P1, which is substantially the same as the operation of the platen 11 and input conveyor 12 described with reference to FIG. 1e.

[0116] The containers C, C' may then be removed by a transfer mechanism. Each container C of the downstream first batch B1 may then be transported off the platen (e.g. for labelling, printing, boxing, packaging, sale and / or distribution) by an output conveyor. Meanwhile, the containers C' of the upstream second batch B2 may be sealed in the same way as described for the first batch B1 with reference to Fig. 1f and are then discharged using the same steps as were carried out for the first batch B1 in Figs. 1g to 1j. In fact, this process may be repeated continuously as further batches of containers arrive at and are received by the input conveyor 11. This method, in which containers are simultaneously discharged from and received on the platen 11, is a particularly fast and efficient way of handling the containers.

[0117] Further features of the particular container handling system 20 will now be described with reference to Figures 2a, 2b and 2c, which is capable of carrying out a method substantially similar to that described above with reference to Figure 1 and may be combined with any of the features of the above-described systems.

[0118] FIG 2a is a perspective view of a container handling system 20 including a platen 21, an input conveyor 22, an output conveyor 23, an infeed conveyor 24, and a phaser mechanism, with two transport arms 25 of the transfer mechanism shown. FIG 2b and FIG 2c are side views of the system 20, with the output conveyor 23 omitted for clarity. The platen 21, the input conveyor 22, and the infeed conveyor 24 include container support surfaces 21a, 22a, 24a, respectively, that are configured to be raised and lowered. The transfer mechanism transfers containers from the adjacent input conveyor 22 and output conveyor 23 to and from the platen 21 when the container support surfaces 21a, 22a, 24a of the platen 21, the input conveyor 22, and the infeed conveyor 24, respectively, are in their lowered positions.

[0119] More specifically, the platen 21, the input conveyor 22, the output conveyor 23 and the delivery conveyor 24 each have an upwardly facing container support surface 21a, 22a, 23a, 24a, respectively, on which a container may be placed. The delivery conveyor 24, the input conveyor 22, the platen 11 and finally the output conveyor 23 are arranged in this order along the x-direction, which is the direction in which a container is transferred from a location upstream to a location downstream during use.

[0120] The input conveyor 22, the output conveyor 23 and the loading conveyor 24 are belt conveyors. Each conveyor 22, 23, 24 comprises a conveyor belt, the outer surface of which forms a respective container support surface 24a, 22a, 23a. The conveyor belt is an endless belt and runs around internal rollers (not shown) with each conveyor 22, 23, 24. The conveyor belt of each conveyor 22, 23, 24 is driven by a respective drive mechanism 24b, 22b, 23b to rotate around the internal rollers. As a result, the conveyors 22, 23, 24 are configured to transport containers along the x-direction extending from the loading conveyor 24 to the output conveyor 23. Each drive mechanism 24b, 22b, 23b comprises an electric motor and appropriate gearing.

[0121] In FIG. 2a, three successive batches of containers 29 are shown. The three batches, each containing four containers 29, are supported on the container support surfaces 23a, 21a, 22a of the output conveyor 23, the platen 21, and the input conveyor 22, respectively. All of the containers 29 are substantially identical. It will be seen that each container 29 is a tray with an interior volume 29a in which a product (e.g., food product) is provided. This interior volume 29a is accessed through an upwardly facing opening 29b in the top surface of each container 29. The top surface of each container 29 is provided with a rim 29c that extends around the periphery of the opening 29b of the container 29, by which each container 29 can be grasped. For clarity, the product in the containers 29 is not shown. However, in many instances, product is dispensed into each container 29 either upstream of the container processing system 20 shown in FIGS. 2a-c or as the containers 29 pass through the container processing system 20.

[0122] As best seen in Figure 2a, the transfer arms 25 of the transfer mechanism are positioned on opposite sides of the conveyors 22, 23, 24 and the platen 21. Each transfer arm 25 moves back and forth along the x-direction (i.e., from the input conveyor 22 to the platen 21) to transfer containers 29 from the input conveyor 22 to the platen 21 and from the platen 21 to the output conveyor 23 and then back to the starting position. Specifically, in the arrangement of Figure 2a, each transfer arm 25 is provided in an upstream position, disposed beside the input conveyor 22 and the platen 21. This position is similar to the position of the transfer mechanism 15 shown in Figures 1a and 1b, for example. This is in contrast to a downstream position where the transfer arm 25 performs a transfer similar to the position of the transfer mechanism 15 shown in Figure 1d, for example.

[0123] Additionally, FIG. 2a illustrates an arrangement in which the transfer arms 25 have been removed, with each transfer arm 25 laterally spaced apart from the containers 29 supported on the platen 21 and conveyors 22, 23, 24. Thus, in the arrangement shown in FIG. 2a, the containers 29 are not held or gripped by the transfer mechanism. The transfer mechanism further reciprocates the opposing transfer arms 25 toward and away from each other in the z direction (perpendicular to the direction in which the containers are transferred during operation of the system), as indicated by arrow G. This movement of the transfer arms 25 toward each other allows the transfer mechanism to surround the containers 29 that were initially supported on the platen 21, input conveyor 22, and output conveyor 23. In this closed arrangement, each transfer arm 25 is positioned adjacent to and substantially surrounds the containers 29.

[0124] In the closed configuration, each container 29 is restrained and restricted from lateral (x- and z-direction) movement relative to the gripper arms 25a. The container support surfaces 21a, 22a of the platen 21 and input conveyor 22 are then lowered such that each container 29 rests on the surrounding transfer arms 25 and is supported above the underlying container support surfaces. In effect, lowering the container support surfaces 21a, 22a of the platen 21 and input conveyor 22 transfers the weight of the container 29 to the transfer arms 25, creating a vertical gap between the container 29 and the platen 21 and input conveyor 22. Each container 29 held by the transfer arms 25 can be similarly removed from the transfer mechanism by moving the transfer arms 25 away from each other to return to the open or removed configuration shown in FIG. 2a.

[0125] More specifically, each transfer arm 25 includes a number of support projections 25a that extend from the transfer arm 25 toward corresponding support projections 25a on the opposing transfer arm 25. The distance between adjacent support projections 25a on each transfer arm 25 is such that the container 29 can be accommodated. That is, the distance between the support projections 25a along the x-direction is at least as large as the width and / or length of the container 29 to be processed by the system. As described above, by moving the opposing transfer arms 25 toward each other, the supports 25a and the transfer arms 25 encircle the container 29 located on the container support surfaces 21a, 22a, 23a of the platen 21, the input conveyor 22, and the output conveyor 23. Thus, as described above, in this closed configuration, lateral movement of the container 29 relative to the transfer arm 25 is restricted, and the transfer mechanism can move the transfer arm 25 and the container 29 simultaneously (i.e., in unison).

[0126] The transfer arm 25 of the transfer mechanism is adapted to transfer multiple batches of containers 29 simultaneously. The support protrusions 25a of each transfer arm 25 are arranged in two opposing groups, each group adapted to receive and support the containers 29 of a corresponding batch. The support protrusions 25a of the first group are provided on the first support portion 25b on the downstream side of each transfer arm 25. The support protrusions 25a of the first group are adapted to receive and support each container 29 from the platen 21 and transfer these containers 29 from the platen 21 to the output conveyor 22. Meanwhile, the support protrusions 25a of the second group are provided on the second support portion 25c on the upstream side of each transfer arm 25. The support protrusions 25a of the second group are adapted to receive and support each container 29 from the input conveyor 21 and transfer these containers 29 from the input conveyor 22 to the platen 21. Thus, the two supports 25b, 25c of the transfer arm 25 are adapted to receive, support and transfer successive batches of containers 29. In other words, the support protrusion 25a of the first support 25b is adapted to receive, support and transfer a downstream batch of containers 29, while the support protrusion 25a of the upstream second support 25c is adapted to receive, support and transfer a successive upstream batch of containers 29. Both the x- and z-direction movements of the transfer arm 25 can be performed using any suitable means, including drive mechanisms comprising motors and / or pneumatic or hydraulic systems.

[0127] As mentioned above, each container 29 is preferably moved between the input conveyor 22 and platen 21 of the system 20, and from the platen 21 to the output conveyor 23, while the input conveyor 22, the input conveyor 24 and the container support surfaces 22a, 24a, 21a of the platen 21 are in their respective lowered positions. The means for moving the input conveyor 22, the input conveyor 24 and the container support surfaces 22a, 24a, 21a of the platen 21 will now be described with reference to the arrangement of the system 20 shown in Figures 2b and 2c.

[0128] FIG. 2b illustrates the system when the input conveyor 22, the infeed conveyor 24, and the container support surfaces 22a, 24a, 21a of the platen 21 are in their raised positions. Each container 29 is positioned and supported on the container support surfaces 22a, 21a of the input conveyor 22 and the platen 21, respectively. FIG. 2c, on the other hand, illustrates the container support surfaces 22a, 24a, 21a in their lowered positions. Each container 29 is held by a transfer arm 25 of the transfer mechanism and supported (i.e., suspended) above the input conveyor 22 and the platen 21 such that there is a vertical gap between the container 29 and the input conveyor 22 and the platen 21 below. In this lowered position, shown in FIG. 2c, each container 29 is laterally movable by the transfer mechanism from the input conveyor 22 to the platen 21 without contacting the input conveyor 22 or the platen 21.

[0129] The loading conveyor 24, the input conveyor 22 and the platen 21 are mechanically linked by a linking member 28. Thus, the container support surfaces 24a, 22a, 21a of each unit can be moved in unison using a single lifting mechanism 26 disposed below the platen 21 on a fixed beam 27. Specifically, the lifting mechanism 26 and the linking member 28 raise and lower the container support surfaces 22a, 21a of the input conveyor 22 and the platen 21, and rotate the container support surface 24a of the loading conveyor 24. Furthermore, the linking of the platen 21 to the loading-input conveyors 22, 24 allows the container support surface 21a of the platen 21 to be raised and lowered a greater vertical distance than the container support surfaces 22a, 24a of the loading-input conveyors 22, 24.

[0130] The lifting mechanism 26 comprises a hydraulic or pneumatic ram attached to the underside 21b of the platen 21 opposite the container support surface 21a of the platen 21. Raising or lowering the ram therefore directly raises or lowers the entire platen 21 (i.e., the platen moves as a single unit). As can be seen, the ram is extended in the raised configuration of Figure 2b, but retracted in the lowered configuration of Figure 2c.

[0131] In contrast to the platen 21, the input conveyor 21 and the input conveyor 24 do not move as a unit. The drive mechanisms 24b, 22b and drive rollers (not shown) of the input conveyor 24 and the input conveyor 22 are fixed in position and remain stationary while the freely rotating rollers (i.e., the non-driven rollers) of these conveyors 22, 24 are moved by the linkage 28 and the lift mechanism 26.

[0132] The lifting and lowering motion of the lifting mechanism 26 is transmitted from the platen 21 to the connecting member 28 via the platen connection portion 28a. However, this platen connection portion 28a moves freely within the connecting slot 21b of the end plate 21c of the platen 21. This allows the platen 21 to be raised and lowered in a vertical range corresponding to the height of the connecting slot 21b without applying force to the platen connection portion 28a of the connecting member 28. On the other hand, when the platen 21 is raised and lowered a longer distance such that the platen connection portion 28a contacts each end of the connecting groove 21b, the force from the lifting mechanism 26 is transmitted to the connecting member 28. Thus, the connecting member 28 (and the connected container support surfaces 22a, 24a of the input conveyor 22 and the input conveyor 24) are driven up and down as the platen 21 rises and falls. Thus, the provision of connecting slot 21b allows the platen to be raised and lowered a greater vertical distance than either of the downstream ends of container support surface 22a of the input conveyor and container support surface 24a of the infeed conveyor 24. In yet another example, the size of connecting slot 21b can be adjusted to change the difference in range of motion between various units of the system, or connecting slot 21b can be omitted entirely (e.g., so that the platen and input conveyor raise and lower a similar amount in unison).

[0133] Movement of linkage member 28 is transferred to input conveyor 21 by input conveyor connection 28b, which causes the movable, free-wheeling (i.e., undriven) rollers of input conveyor 21 to rise and fall along with linkage member 28, thereby raising and lowering the conveyor belt extending around those rollers and, consequently, the container support surface 22b defined by that belt.

[0134] Similarly, the movement of the linking member 28 is transferred to the downstream end of the input conveyor 24 by the input conveyor connection 28c, which causes the movable rotatable rollers (i.e., the non-driven rollers) at the downstream end of the input conveyor 24 to rise and fall with the linking member 28. However, the vertical position of the upstream end of the transfer conveyor 24 (i.e., the end furthest from the platen 21) is fixed by the stationary pivot 24c. Thus, as the linking member 28 is raised and lowered, the movable rotatable rollers of the input conveyor 24 and the input conveyor belt and container support surface 24a rotate about the stationary pivot 24c. Thus, as the input conveyor is raised and lowered, the downstream end of the container support surface 24a of the input conveyor 24 is maintained in the same vertical position as the container support surface 22a of the input conveyor 22a. On the other hand, the vertical position of the upstream end of container support surface 24a of input conveyor 24 remains stationary as support surface 24a rotates.

[0135] The stationary pivot 24c is positioned so that the upstream end of the container support surface 24a remains stationary at approximately the midpoint of the vertical movement of the container support surface 22a of the input conveyor 22 and the downstream end of the container support surface 24a of the delivery conveyor 22. Thus, as the downstream end of the container support surface 24a of the transfer conveyor 24 rises and falls, the container support surface 24a alternately tilts and drops relative to the horizontal x-axis. This can be seen by comparing the placement of the delivery conveyor 24 with the x-axis in Figures 2b and 2c. In Figure 2b, as the input conveyor 24 rises, the container support surface 24a of the delivery conveyor 24 is tilted relative to the horizontal plane. However, in Figure 2c, the input conveyor 24 is lowered and the container support surface 24a of the delivery conveyor 24 is tilted relative to the horizontal.

[0136] Specifically, container supporting surface 22a of input conveyor 22 and the upstream end of container supporting surface 24a of carry-in conveyor 24 rise and fall 20 mm between their respective raised and lowered positions. Meanwhile, container supporting surface 24a of carry-in conveyor 24 rotates within a range of approximately +1.28 degrees to -1.28 degrees with respect to the horizontal plane.

[0137] A more detailed description of the potential connections between the coupling members and the input conveyor will now be given with reference to Figures 3a, 3b and 3c. Figures 3a and 3b show a cross-section of the system 30 from the opposite direction to the example of Figures 2b and 2c (as can be seen by the opposite axes of these figures), and Figure 3c shows a side view of the system from the corresponding position in Figures 2b and 2c. In practice, this system 30 may comprise any of the additional features of the systems 10, 20 shown in Figures 1 and 2, and may be used to couple and control any of the aforementioned conveyors.

[0138] For clarity, Figure 3c shows the platen 31, input conveyor 32, infeed conveyor 34, linkage 38 and end plate 31c, as well as container 39 and transfer arm 35, whereas Figures 3a and 3b show only the input conveyor 32, linkage 38 and end plate 31c of the platen. Additionally, belts 32', 34' of input conveyor 32 and infeed conveyor 34 are shown in Figure 3c but omitted from Figures 3a and 3b for clarity. Each of the components in Figures 3a-3c are similar to the equivalent components with corresponding reference numbers shown in Figures 2a-2c and share many of the corresponding features and advantages.

[0139] The input conveyor 32 is a belt conveyor with a continuous conveyor belt 32' that defines an upwardly facing container-supporting surface 32a of the input conveyor 32, as shown in Figure 3c. The belt 32' is driven by a drive mechanism 32b (e.g., a motor) to extend and move around a series of rollers within the input conveyor, which are shown in cross-section in Figures 3a and 3b.

[0140] Specifically, the input conveyor 32 includes four non-driven or free-running rollers 32c, 32d, 32e, 32f. Three of the free-running rollers 32c, 32d, 32e are movable and can be raised and lowered using a linkage 38. The input conveyor 32 further includes a stationary drive mechanism 32b and a stationary drive roller 32k, both of which are centered about point D. In use, a continuous conveyor belt 32' extends around and encircles the free-running rollers 32c, 32d, 32e, 32f. The outer surface of the conveyor belt defines the container support surface of the input conveyor 32. As shown by the dashed lines in the various figures, the outer surface of the conveyor belt extends around and engages drive roller 32k. Thus, the system 30 uses a drive mechanism to rotate drive rollers 32k to cause movement of the conveyor belt of the input conveyor 32 (eg, to transport containers thereon).

[0141] The movable free rotating rollers 32c, 32d, 32e are attached to the movable side plate 32g of the input conveyor 32, while the stationary drive roller 32k, the stationary drive mechanism, and the stationary free rotating roller 32f are attached to the stationary side plate 32h of the input conveyor 32. Specifically, the movable free rotating rollers 32c, 32d, 32e and the movable side plate 32g can be raised and lowered relative to the stationary drive roller 32k, the stationary drive mechanism, the stationary side plate 32h, and the stationary free rotating roller 32f to raise and lower the conveyor belt and container support surface of the input conveyor 32. Thus, the container support surface can be raised and lowered relative to a transfer mechanism thereover configured to receive and support containers from the input conveyor 32 and to support the containers above the input conveyor 32.

[0142] Coupling member 38 is coupled to movable side plate 32g of input conveyor 32 by two input conveyor connections 38b (bolts) that each connect to an "L" shaped rotating bracket 32i. By raising and lowering coupling member 38 (e.g., by raising and lowering the mechanically coupled platen as described above), rotating bracket 32i can be rotated, thereby raising and lowering the movable parts of input conveyor 32, i.e., movable rotating rollers 32c, 32d, 32e and movable side plate 32g.

[0143] Figure 3a shows the movable parts of the input conveyor 32 and the connecting member 38 in a raised position, while Figure 3b shows these parts in a lowered position. As can be seen, in Figure 3a the positions of the movable rotatable rollers 32c, 32d, 32e, the movable side plate 32g and the connecting member 38 are lower relative to the drive mechanism of the input conveyor 32 and the rest positions of the drive roller 32k (point D) and the stationary side plate 32h in Figure 3b than in Figure 3a. The rotation of the rotatable bracket 32i between these positions is indicated by the arrow R'.

[0144] In use, the coupling member 38 is coupled to the platen by a platen connection 38a (see FIG. 3c) which is free to move within a connection slot 31b in the platen end plate 31c, but is also coupled to the infeed conveyor by an infeed connection 38c. As can be seen, the connection slot 31b in FIGS. 3a and 3b is much longer than the connection slot 21b shown in FIGS. 2a to 2c. This longer slot 31b allows the platen and its container support surface to be raised further above the container support surface of the input conveyor 32 while still maintaining a mechanical connection between the platen 31 and the input conveyor 32. This allows the platen to be raised above the input conveyor 32 so that each container on the platen engages the upper tool portion of the tray sealer during the sealing process, similar to the method described in relation to FIGS. 1a to 1j.

[0145] It will be appreciated from the above description that the lift mechanism 26 is in fact a single mechanism configured to both lower the container support surfaces 21a, 22a of the platen 21 and input conveyor 22 to create a separation or spacing between the container support surfaces and the containers supported by the transfer arm 25 (as shown in FIG. 2c) and to raise the container support surface 21a of the platen 21 so that each container placed thereon can be processed. For example, the lift mechanism may be configured to raise the container support surface 21a of the platen 21 so that each container placed thereon can be engaged and sealed by a heated surface of an upper tool portion (not shown) of the tray sealer. A single lift mechanism 26 that performs both the lowering of the container support surface 21a for container transfer and the raising of the platen for sealing (or an alternative processing step) is particularly space and resource efficient, and avoids the need for separate components to perform the separate steps of lowering and raising the container support surface 21a. The optional connecting slot 31b allows the platen 21 to be raised relative to the input conveyor 22 during sealing or other processing steps, minimizing resource requirements, avoiding interruptions to the transport of containers by the input conveyor 22, and allowing (for example) the input conveyor to hold a subsequent batch of containers.

[0146] The input conveyor 32 further includes a tension bar 32j that can be selectively positioned to tension the conveyor belt 32 of the input conveyor 32 via a stationary free rotating roller 32f (although other rollers could be used as well). The tension in the conveyor belt 32 is maintained at a substantially constant level when the movable free rotating rollers 32c, 32d, 32e (and thus the container support surfaces thereof) are in their respective raised and lowered positions because the arrangement of the free rotating rollers 32c, 32d, 32e, 32f and the drive roller 32k is selected to ensure that the conveyor belt extends a substantial perimeter therearound in each position. Furthermore, the arrangement of the free rotating rollers 32c, 32d, 32e, 32f and the drive roller 32k is selected so that the contact distance between the conveyor belt and the drive roller 32k is similar in both the raised and lowered positions of the movable free rotating rollers 32c, 32d, 32e (and thus the raised and lowered positions of the container support surface), as can be seen by comparing the dashed lines in Figures 3a and 3b.

[0147] The systems 20, 30 shown in Figures 2 and 3 are single lane systems. Thus, each individual container moves through the system in a single file. The width of each conveyor and platen is approximately the same as the width of the container. However, this is not required and in further examples, a two lane or multiple lane system may be provided that operates in substantially the same manner as the above examples. In these examples, two or more parallel lines of containers may be transported through the system in unison. In such examples, there may be one or more center fences positioned between adjacent rows of containers, which together with a transfer arm support the containers above the input conveyor and platen as they are lowered, and transfer the containers between the input conveyor and platen.

[0148] Preferred arrangements of containers and transfer mechanisms, and methods of handling and supporting containers using the transfer mechanisms, are specifically described below with reference to Figures 4a-4d, 5a-5d, and 6a-6d. These methods and containers may be combined with any of the systems or methods described above with reference to Figures 1, 2, and 3.

[0149] Each figure is a schematic cross-sectional view of a container 40, 50, 60 on a movable container support surface 45, 55, 65 (e.g., a container support surface of any of the platens or conveyors mentioned above). The containers 40, 50, 60 are, respectively, containers enclosing an interior volume 40a, 50a, 60a for receiving, for example, products. The width of each container 40, 50, 60 (i.e., the dimension of the container 40, 50, 60 in the x-direction) increases from a bottom surface 41, 51, 61 (adjacent to the respective container support surface 45, 55, 65) to a free top surface 42, 52, 62 of the container 40, 50, 60. In particular, the container 40 of Figures 4a-4d is provided with a draft angle θ such that the side wall 43 of the container 43 is angled. Thus, the width of the container 40 increases continuously from its bottom surface 41 to its top surface 42. Container 50 of Figures 5a-5d includes stepped sides with protrusions 53a extending outwardly from each sidewall 53 of container 50 and a lip 52a extending around the periphery of top surface 52 of container 50, such that the width of container 50 increases discontinuously along its height. Finally, container 60 of Figures 6a-6d includes a draft angle θ, such that sidewall 63 is angled relative to the base and lip 65 of container 60.

[0150] Thus, as the container support surface 45, 55, 65 is lowered through the steps of the method shown in each of the series of successive figures, each container is supported and lifted from the lower container support surface 45, 55, 65 by a transfer mechanism. The transfer mechanism comprises a transfer arm 46, 56, 66 (e.g. a transfer arm with support lugs as described with reference to Figure 2 above). In Figures 4b, 5b and 6b, the transfer arms 46, 56, 66 are positioned on either side of the container 40, 50, 60 at a distance greater than the width of this portion of the container 40, 50, 60, such that the transfer arms 46, 56, 66 do not contact the container 40, 50, 60 but have a width less than the maximum width of the container 40, 50, 60. Thereafter, the container support surfaces 45, 55, 65 are lowered as shown by arrow L1 to bring the transfer arms 46, 56, 66 into contact with the containers 40, 50, 60, so that the containers 40, 50, 60 can be held and supported by the transfer arms 46, 56, 66 (see Figs. 4c, 5c, 6c). Next, the container support surfaces 45, 55, 65 are further lowered as shown by arrow L2, and the containers 40, 50, 60 are supported (i.e., suspended) above the container support surfaces 45, 55, 65 by the transfer mechanism. In this manner, by lowering the container support surfaces 45, 55, 65, the weight of the containers 40, 50, 60 is transferred to the transfer arms 46, 56, 66, and a vertical gap is formed between the containers 40, 50, 60 and the underlying surfaces 45, 55, 65.

[0151] As can be seen, the process of lowering the container support surface 45, 55, 65 has two stages. In the first stage (between Figs. 4b, 5b, 6b and 4c, 5c, 6c), the container 40, 50, 60 is lowered by the container support surface 45, 55, 65 so that the weight of the container 40, 50, 60 is transferred to the transfer arm 46, 56, 66. In effect, the container 40, 50, 60 settles on the stationary transfer arm 46, 56, 66. In the second stage (between Figs. 4c, 5c, 6c and 4d, 5d, 6d), the container support surface 45, 55, 65 continues to lower so that a gap is formed between the container 40, 50, 60 and the container support surface 45, 55, 65. Thus, the container 40, 50, 60 is supported on or above the container support surface 45, 55, 65. In a preferred embodiment, during each of the first and second stages the container support surfaces 45, 55, 65 are lowered by 10 mm, and during the entire lowering process the container support surfaces 45, 55, 65 are lowered a total of 20 mm.

[0152] It will be appreciated that in the above-described processes, substantially no lateral or horizontal forces are applied to the containers 40, 50, 60 or their contents as they are lifted off and supported on the container support surfaces 45, 55, 65. The transfer mechanism can then move the containers 40, 50, 60 laterally without contact between the containers 40, 50, 60 and the underlying container support surfaces 45, 55, 65. This further minimizes lateral forces applied to the containers 40, 50, 60 and their contents during the container processing steps previously described.

[0153] Containers with a draft angle (e.g., the examples of Figures 4 and 6) are particularly preferred because if there is a misalignment between the container and the transfer arm, this misalignment tends to be corrected as the container support surface lowers and the container settles onto (i.e., engages) the transfer arm of the transfer mechanism.

[0154] The process shown in each figure can also be reversed to remove the respective container 40, 50, 60 from the transfer arm 46, 56, 66. Specifically, a container support surface (such as the illustrated container support surface 45, 55, 65) is raised to contact the container 40, 50, 60 and lift the container 40, 50, 60 away from the transfer arm 46, 56, 66. This process is performed after the container 40, 50, 60 has been transferred as described above. Again, this method avoids substantial lateral movement or forces. The transfer arm 46, 56, 66 can then be removed from either side of the container 40, 50, 60 to, for example, process or transfer the container.

[0155] In each of Figures 4d, 5d and 6d, it can be seen that each container 40, 50, 60 is supported by the transfer arm 46, 56, 66 at a position closer to the top surface 42, 52, 62 than to the respective bottom surface 41, 51, 61 (i.e., at a position farther than half the distance from the bottom surface 41, 51, 61 to the top surface 42, 52, 62). In effect, in such an arrangement, the container 40, 50, 60 is held above its center of mass and (in most cases) above the center of mass of the container 40, 50, 60 and its respective contents. This improves the stability of the container 40, 50, 60 as it is lifted, grasped and then laterally transferred by the transfer mechanism. Similar arrangements in which the container is supported by a transfer mechanism closer to its top surface than to its bottom surface and above its center of mass are also shown in Figures 1c, 1d, 1h, 1i and 2c. Such an arrangement increases the stability of the container and its contents and reduces the risk of the contents spilling out of the container when the container is transported.

[0156] In the examples shown in Figures 4b, 5b and 6b, the transfer arms 46, 56, 66 are initially closed around the containers 40, 50, 60, with the transfer arms 46, 56, 66 adjacent to the containers 40, 50, 60. In this arrangement, the transfer arms 46, 56, 66 limit the movement of the containers 40, 50, 60 in a lateral direction (e.g., in the x-axis as shown), but the containers 40, 50, 60 can move vertically relative to the transfer arms 46, 56, 66, so that when the container support surfaces 45, 55, 65 are lowered, the containers 40, 50, 60 can rest gently on the transfer arms 46, 56, 66. A similar method is described with reference to the system shown in Figures 2 and 3. This avoids the transfer arms exerting large lateral forces on the containers, although this is not essential. Indeed, in further examples of the invention, the transfer arms may close in unison laterally, such that they contact and grip the containers between them. For example, the distance between the transfer arms is equal to or less than the width of the container to be transferred. Gripping the container in this manner restricts movement of the container in any direction relative to the transfer arms. The underlying container support surface (e.g., the container support surface of an input conveyor or platen) is then lowered, and the gripped container is supported above the container support surface and can be transported laterally without contact. It will be appreciated that during this lowering process, the gripped container cannot move relative to the transfer arms, so that the weight of the container is quickly transferred to the transfer mechanism.

[0157] All of the above methods minimize the forces (especially lateral forces) exerted on each container during handling. This reduces the occurrence of damage to the container and its contents. In addition, spillage or other leakage of product from the container can also be reduced. Thus, product quality is improved, maintenance and cleaning requirements are reduced, and container throughput is increased. This advantage is particularly applicable in the food industry, especially in the handling and packaging of foods containing liquids.

Claims

1. A method performed by a system comprising a platen, an input conveyor, and a transfer mechanism, the method for processing one or more containers, wherein the platen and the input conveyor each comprise a movable container support surface, receiving the one or more containers on the input conveyor; lowering the container support surfaces of the input conveyor and the platen so that each container is supported by the transfer mechanism above the input conveyor; transferring each container from above the input conveyor to above the platen using the transfer mechanism; raising the container support surfaces of the input conveyor and the platen so that each container is supported by the platen; removing each container from the transfer mechanism.

2. The transfer mechanism comprises a transfer arm configured to support and transfer each container, and the method comprises closing the transfer arm around each received container on the input conveyor so that each container is supported by the transfer arm. The method according to claim 1.

3. The step of lowering each container support surface of the input conveyor and / or the platen comprises two steps: a first step of lowering each container support surface so that the weight of each container is supported by the transfer mechanism; a second step of further lowering each container support surface to form a gap between each container and each container support surface. The method according to claim 1.

4. The step of removing each container from the transfer mechanism comprises raising the container support surface of the platen. The method according to claim 1.

5. Each of the one or more containers received by the input conveyor comprises an unsealed opening. The method according to claim 1.

6. Each of the one or more containers received by the input conveyor contains food. The method according to claim 1.

7. The method according to claim 1, further comprising a subsequent step of sealing the one or more containers on the platen.

8. The step of sealing the one or more containers comprises providing a film across the opening of each container. The method according to claim 7.

9. Each of the sealed containers is airtight and / or waterproof. The method according to claim 7.

10. The method according to claim 1, wherein the system comprises a tray sealer.

11. The platen forms part of a lower tool portion of a tray sealer, and the step of sealing the one or more containers on the platen comprises: providing a film between each container on the platen and an upper tool portion; bringing the platen and the upper tool portion closer together so that the upper tool portion engages the film and the containers thereunder; heating the tool portion to bond the film to the containers; The method according to claim 7, comprising:

12. The method according to claim 11, wherein the step of bringing the platen and the upper tool portion closer together comprises raising the container support surface of the platen relative to the input conveyor.

13. The step of lowering the container support surfaces of the input conveyor and the platen comprises lowering the container support surface of the input conveyor and / or the container support surface of the platen so that a vertical gap between each container and its respective container support surface is 5 mm or more, preferably 8 mm, more preferably 10 mm or more, and each container is supported by the transfer mechanism. The method according to claim 1.

14. The method according to claim 1, wherein each container is supported by the transfer mechanism at a position above the center of mass of the container and / or the center of mass of the container and its contents.

15. The method according to claim 1, wherein the system comprises an input conveyor drive mechanism configured to drive the input conveyor, and the input conveyor drive mechanism is stationary when the container support surface of the input conveyor rises and falls.

16. The method according to claim 1, wherein the input conveyor is a belt conveyor comprising an input belt, and the container support surface is the outer surface of the input belt.

17. The method according to claim 16, wherein the tension of the input belt is substantially constant when the container support surface of the input conveyor rises and falls.

18. The method according to claim 16, wherein the system comprises an input conveyor drive mechanism configured to drive the input belt via a drive roller, and the contact length between the input belt and the drive roller is substantially the same when the container support surface of the input conveyor rises and falls.

19. The method according to claim 1, wherein the platen and the input conveyor are mechanically connected such that the container support surfaces between the platen and the input conveyor are simultaneously raised and lowered by a single lifting mechanism.

20. The system comprises a single lifting mechanism, and the lifting mechanism lowers the container support surface of the platen so that each of the gripped containers is supported by the transfer mechanism, raises the container support surface of the platen to enable processing of each container disposed thereon, Preferably, the single lifting mechanism raises the container support surface of the platen so that each container disposed thereon is engaged by the upper tool portion of the tray sealer, the method according to claim 1.

21. The method according to claim 1, wherein each of the containers received on the input conveyor is received from an upstream loading conveyor.

22. The loading conveyor comprises a movable container support surface having a downstream end adjacent to the input conveyor and an upstream end farthest from the input conveyor, and the method comprises raising and lowering the downstream end of the container support surface of the loading conveyor as the container support surface of the input conveyor is raised and lowered, and preferably, keeping the upstream end of the container support surface of the loading conveyor stationary as the downstream end is raised and lowered, the method according to claim 21.

23. lowering the container support surface of the platen so that each of the containers is supported above the platen by the transfer mechanism; transferring each of the containers from the platen to an output conveyor using the transfer mechanism; removing each of the containers from the transfer mechanism; The method according to claim 1, further comprising a subsequent step comprising:

24. The method further comprises a subsequent step of unloading each of the containers from the platen using the output conveyor, the method according to claim 23.

25. The method according to claim 23, wherein the output conveyor and / or the container support surface of the output conveyor remains substantially stationary in the vertical direction throughout the method.

26. A method of processing two consecutive batches of containers, each batch comprising one or more containers, the two consecutive batches of containers comprising a downstream batch and a subsequent upstream batch, and the containers of each batch being processed according to the method of claim 1. A method for processing batches of the two successive containers further comprises a step of using the transfer mechanism to transfer the containers of the downstream batch from the platen to the output conveyor and simultaneously transfer the containers of the upstream batch from the input conveyor onto the platen. **Claim 27** a platen and an input conveyor each having a movable container support surface configured to move between a raised position and a lowered position, a reciprocating transfer mechanism, comprising the reciprocating transfer mechanism supports one or more containers previously received on the input conveyor when the container support surface of the input conveyor descends from the raised position to the lowered position, such that the one or more containers are supported by the transfer mechanism above the input conveyor, and is configured to transfer the one or more containers from the input conveyor onto the platen when the input conveyor and the platen are in their respective lowered positions, a container processing system. **Claim 28** A container processing system according to claim 27, configured to execute the method according to any one of claims 1 to 26.

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