Filling machine and method for operating the same

Abstract

To provide a suitable filling machine and a method for operating it.SOLUTION: A filling machine (100) having a processing unit (600) comprising processing stations (612, 614, 616) and a conveyor system (601) configured to transport container precursors through the processing stations is disclosed. The conveyor system comprises a plurality of shuttles or carriers (602) configured to transport the container precursors along a track (604) through the processing stations, and a shuttle propulsion system that enables each shuttle to be propelled individually along the track. Corresponding methods are also disclosed.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] (Technical field) FIELD OF THE DISCLOSURE The present disclosure relates generally to a filling machine for producing pourable food-filled multi-layer cellulosic composite containers.

[0002] In particular, the present disclosure relates to a filling machine for forming a cellulosic multilayer composite container precursor, filling and sealing the container precursor, and forming the container. The present disclosure also relates to a method of operating the filling machine. [Background technology]

[0003] (background) Filling machines for filling packaging containers made of a cellulosic multilayer composite, such as a cardboard composite, with products, in particular liquid food products, are known from the prior art. Reference is made, for example, to EP 0 936 992 B1 and US 10 196 163 B2 for the construction of known filling machines.

[0004] SUMMARY OF THE DISCLOSURE The present disclosure is directed to various apparatus and methods that may solve or at least reduce at least one of the aforementioned problems or challenges. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] European Patent No. 0936992 [Patent Document 2] U.S. Patent No. 10,196,163 Summary of the Invention [Means for solving the problem]

[0006] (summary) The filling machine according to the invention is characterized by the features of claim 1. The method according to the invention is characterized by the features of claim 7. Preferred embodiments of the filling machine and method according to the invention are characterized by the features of the dependent claims.

[0007] According to one aspect, the present disclosure provides a filling machine, the filling machine comprising a processing unit comprising at least one processing station and a conveyor system configured to transport container precursors through the at least one processing station, the conveyor system comprising a plurality of shuttles or transporters configured to transport the container precursors along a track through the at least one processing station, and a shuttle propulsion system that enables each shuttle or transporter to be individually propelled along the track.

[0008] The shuttle propulsion system may include an electric long-stator linear motor configured to individually propel each shuttle or vehicle along the track.

[0009] Each shuttle or transporter may comprise a single holder or receiver for transporting a container precursor or multiple holders or receivers configured for transporting multiple container precursors in parallel through at least one processing station.

[0010] At least one processing station comprises: a bottom sealing station configured for bottom sealing the container precursor; a sterilization station configured for sterilizing the precursor container; a filling station configured for filling the precursor containers with a pourable food product; a top sealing station configured for top sealing the container precursor; may comprise at least one of:

[0011] The filling machine may comprise a container precursor forming unit configured to form a bottom-sealed container precursor, and a transfer unit configured to transport the bottom-sealed container precursor from the forming unit to a processing unit, the transfer unit comprising a plurality of shuttles or transporters configured to transport the container precursor from the forming unit to the processing unit along a track, and a shuttle propulsion system that enables each shuttle or transporter of the transfer unit to be propelled individually along the track.

[0012] The shuttle propulsion system of the transport unit may comprise an electric long stator linear motor configured to individually propel each shuttle or carriage of the transport unit along said track of the transport unit.

[0013] According to another aspect, the present disclosure provides a method of operating a filling machine, the filling machine including a processing unit including at least one processing station for processing container precursors, the method including transporting the container precursors through the at least one processing station in a plurality of individually propulsable shuttles or transporters traveling along a track through the processing unit.

[0014] The method may include transporting a container precursor through a first one of the at least one processing stations in a first index and transporting the container precursor through a second one of the at least one processing stations in a second index different from the first index.

[0015] The distance between adjacent shuttles or transporters may not be constant as the shuttles or transporters progress through a processing unit, for example, the distance between adjacent shuttles or transporters may increase as the shuttles or transporters progress through a filling station of the processing unit.

[0016] According to a further aspect, the present disclosure provides a filling machine comprising a processing unit comprising at least one processing station and a conveyor system configured to transport container precursors through the at least one processing station, the conveyor system comprising a plurality of shuttles or transporters configured to transport the container precursors along a track through the at least one processing station, and a shuttle propulsion system that enables each shuttle or transporter to be individually propelled along the track; the filling machine comprising a container precursor forming unit configured to form bottom-sealed container precursors, and a transfer unit configured to transfer the bottom-sealed container precursors from the forming unit to the processing unit, the transfer unit comprising a plurality of shuttles or transporters configured to transport the container precursors from the forming unit to the processing unit along the track, and the shuttle propulsion system that enables each shuttle or transporter of the transfer unit to be individually propelled along the track; and the transfer unit comprising a transfer station configured to receive box precursors in a single file and transport the box precursors to the processing units in two or more parallel processing lanes.

[0017] The preferred and / or optional features discussed above for each aspect of the present disclosure may be used alone or in any suitable combination in other aspects of the invention. The present specification also provides, for example, the following: (Item 1) A filling machine (100) comprising a processing unit (600, 600', 600'') having at least one processing station (612, 614, 616) and a conveyor system (601) configured to transport container precursors (102) through the at least one processing station (612, 614, 616), the conveyor system (601) comprising a plurality of shuttles or transporters (602) configured to transport the container precursors along a track (604) through the at least one processing station (612, 614, 616), and a shuttle propulsion system that enables each shuttle or transporter (602) to be individually propelled along the track (604). (Item 2) Item 1. The filling machine (100) of item 1, wherein the shuttle propulsion system comprises an electric long-stator linear motor configured to individually propel each shuttle or transporter (602) along the track (604). (Item 3) A filling machine (100) according to any one of the preceding items, wherein each shuttle or transporter (602) comprises a single holder or receiver (606) for transporting a container precursor or a plurality of holders or receivers (606) configured for transporting a plurality of container precursors in parallel through the at least one processing station (612, 614, 616). (Item 4) The at least one processing station comprises: a bottom sealing station (202) configured for bottom sealing the container precursor (102); a sterilization station (402) configured to sterilize said precursor containers; a filling station (404) configured for filling said precursor containers with a pourable food product; a top sealing station (406) configured for top sealing said container precursor; 10. The filling machine (100) of any one of the preceding items, comprising at least one of: (Item 5) 10. The filling machine (100) of claim 1, comprising: a container precursor forming unit (200) configured to form a bottom-sealed container precursor; and a transfer unit (400) configured to transfer the bottom-sealed container precursor from the forming unit (200) to the processing unit (600, 600', 600''), the transfer unit (400) comprising: a plurality of shuttles or transporters (402) configured to transport the container precursor from the forming unit (200) to the processing unit (600, 600', 600'') along a track (404); and a shuttle propulsion system that enables each shuttle or transporter (402) of the transfer unit (400) to be propelled individually along the track (404). (Item 6) Item 6. A filling machine (100) as described in item 5, wherein the shuttle propulsion system of the transfer unit (400) comprises an electric long-stator linear motor configured to individually propel each shuttle or carrier (402) of the transfer unit (400) along the track (404) of the transfer unit (400). (Item 7) A method of operating a filling machine (100), the filling machine (100) comprising a processing unit (600, 600', 600'') having at least one processing station (612, 614, 616) for processing container precursors, the method being characterized by transporting the container precursors through the at least one processing station (612, 614, 616) in a plurality of individually propellable shuttles or transporters (602) that travel along a track (604) through the processing unit (600, 600', 600''). (Item 8) 8. The method of claim 7, characterized by transporting the container precursor through a first one of the at least one processing stations (612, 614, 616) in a first index and transporting the container precursor through a second one of the at least one processing stations (612, 614, 616) in a second index different from the first index. (Item 9) 9. The method according to any one of items 7 and 8, characterized in that the distance between adjacent shuttles or transporters (602) is not constant as the shuttles or transporters (602) progress through the processing unit (600, 600', 600''). (Item 10) 10. The method according to claim 9, characterized in that the distance between adjacent shuttles or transporters (602) is increased as the shuttles or transporters (602) progress through a filling station (614) of the processing unit (600, 600', 600''). [Brief explanation of the drawings]

[0018] The following drawings are included to facilitate understanding of the present invention.

[0019] [Figure 1] FIG. 1 is a schematic diagram of an embodiment of a filling machine.

[0020] [Figure 2] FIG. 2 is a schematic diagram of a transfer unit of the filling machine according to FIG. 1 in a first process case.

[0021] [Figure 3] FIG. 3 is a schematic diagram of the transfer unit according to FIG. 2 in a second process case.

[0022] [Figure 4] FIG. 4 is a schematic diagram of an alternative embodiment of a processing unit.

[0023] [Figure 5] FIG. 5 is a schematic diagram of yet another alternative embodiment of a processing unit. DETAILED DESCRIPTION OF THE INVENTION

[0024] In the drawings, like reference numerals are used to designate common parts, elements, or features unless otherwise expressly stated or implicitly understood by context.

[0025] (Detailed explanation) In the following, embodiments of the filling machine will be described in more detail with reference to the drawings. However, it is specifically intended that the claimed invention is not limited to the embodiments and figures contained herein, but rather includes modified forms of the embodiments, including portions of the embodiments and combinations of elements of different embodiments, as falling within the scope of the following claims. In developing any such actual implementation, it will be understood that, as in any engineering or design project, many implementations, specific decisions must be made to achieve the developer's specific goals, such as compliance with system- and / or business-related constraints, which may vary from one implementation of the invention to another. It will also be understood that such development efforts may be complex and time-consuming, but would nevertheless be a routine undertaking of design, engineering, and manufacture for those of ordinary skill in the art having the benefit of this disclosure.

[0026] Figure 1 discloses a filling machine 100 comprising a forming unit 200, a transfer unit 400 and a processing unit 600. Figure 2 discloses the forming unit 200 and the transfer unit 400 in more detail.

[0027] The forming unit 200 is configured to receive a container precursor in the form of a flat, folded composite jacket or sleeve from a storage unit (not disclosed). The flat, folded container precursor is raised to a tubular form and bottom sealed in a bottom sealing station 202 of the forming unit 200. Depending on the type of container to be produced in the filling machine 100, the container precursor 102 may also be provided with an opening device 104, e.g., with a reclosable cap within the forming unit 200 (see FIG. 2).

[0028] In this embodiment, the bottom sealing station 202 comprises a transport wheel 204 configured to rotate in stages and to have a plurality of radially outwardly extending parallel receivers 206. The receivers 206 conventionally take the form of a mandrel over which a tubular precursor container is pressed and subsequently bottom sealed. In this embodiment, the bottom sealing station 202 comprises two transport wheels and is therefore configured to bottom seal two precursor containers in parallel.

[0029] Once the container precursors are bottom sealed, they are released from the mandrels 206 and transferred to a transfer unit 400. The transfer unit 400 comprises a plurality of shuttles or carriers 402, each configured to receive a bottom-sealed but top-open container precursor from the forming unit 200 and transfer the container precursor to the processing unit 600. In this embodiment, each shuttle 402 is configured to receive and transport only a single container precursor and comprises a single holder or receiver 406 for this purpose.

[0030] In operation, the shuttles 402 travel in a single file along the track 404, forming a closed loop extending between the forming unit 200 and the processing unit 600. The transfer unit 400 includes a shuttle propulsion system that allows each shuttle 402 to be individually propelled along the track 404, i.e., to move along the track 404 independently of its downstream and upstream neighbors. To enable such propulsion, the track 404 may include a guide rail configured to carry the shuttles 402 along the track 404 and an electric long-stator linear motor extending along the track 404, the guide rail configured to carry the shuttles 402 along the track 404, and the linear motor utilizing permanent magnets to individually propel each shuttle 402 along the guide rail. The propulsion system may be based, for example, on any one of the systems commercially available under the trademarks SUPERTRAK and ACOPOSTRAK.

[0031] Processing unit 600 includes a conveyor system 601 configured to guide container precursors through processing unit 600. Conveyor system 601 includes a plurality of shuttles or carriers 602 configured to receive bottom-sealed but open-top container precursors from transfer unit 400 and guide them through processing unit 600. In the embodiment shown in FIGS. 1-3 , processing unit 600 has three parallel processing lanes. Accordingly, in this embodiment, each shuttle 602 includes three holders or receivers 606 (see FIG. 3 ) that enable each shuttle 602 to guide three container precursors in parallel through processing unit 600.

[0032] At a transfer station 408 at the end of the transfer unit 400 facing the processing unit 600, the shuttles 402 are configured to gather in groups of three, i.e., a number corresponding to the number of parallel processing lanes in the processing unit 600. A shuttle 602 then moves adjacent to the shuttles 402 of the gathered group, and the container precursors will be transferred from shuttle 402 to shuttle 602. As a result, in this embodiment, the transfer unit 400 has two container precursor inputs and three container precursor outputs. In other words, the transfer unit 400 is configured to receive two box precursors in parallel and output three box precursors in parallel.

[0033] In operation, shuttles 602 travel in single file through processing unit 600 along track 604, which comprises a set of generally parallel guide rails 608 (see FIG. 1).

[0034] Guide rails 608 are configured to guide shuttle 602 through a sterilization station 612 configured to sterilize the precursor containers, a filling station 614 configured to fill the precursor containers with pourable food products, and a top sealing station 616 configured to top seal the precursor containers. Such stations are therefore well known in the art and will not be discussed further here. After top sealing station 616, the now completed containers are transferred from shuttle 602 to an ejection or external feed station 618, where they are ejected from processing unit 600 and prepared for further dispensing.

[0035] Once the containers have been transferred from the shuttle to the discharge station 618, the shuttle 602 is returned via a return conveyor 610 to the start of the track 604 to receive a new batch of container precursors. In this embodiment, the return conveyor 610 comprises a belt conveyor comprising two parallel belts configured to carry the shuttle back to the start of the track 604. However, in principle, any type of return conveyor can be used. A first elevator 620 is configured to lower the shuttle 602 from the guide rail 608 onto the return conveyor 610, and a second elevator 622 is configured to raise the shuttle 602 from the return conveyor 610 onto the guide rail 608.

[0036] In operation, the shuttles 604 travel in a single file along the track 604. Similar to the transfer unit 400, the conveyor system 601 includes a shuttle propulsion system that allows each shuttle 602 to be propelled along the track 604 individually, i.e., without interlocking with other shuttles, and thus allowing each shuttle 602 to move along the track 604 independently from its upstream and downstream neighbors. To enable such propulsion, an electric long-stator linear motor (not shown) may extend along at least one of the guide rails 608, with the linear motor configured to propel each shuttle 602 individually along the guide rails 608. As in the transfer unit 400, the propulsion system may be based, for example, on any one of the systems commercially available under the trademarks SUPERTRAK and ACOPOSTRAK.

[0037] The shuttles 604 can be propelled through the processing units 600 one at a time, e.g., in a single index, as disclosed in FIG. 4 . Alternatively, the shuttles 604 can be configured to move through the processing units 600 in synchronous groups, e.g., groups of two (double index) as disclosed in FIG. 1 , groups of three (triple index) as disclosed in FIG. 5 , or any other group size. Also, because each shuttle 604 is individually propellable along the trajectory 604, the shuttle can be configured to move through one processing station, e.g., in a first index in a synchronous group of two (double index), and through a subsequent processing station, e.g., in a second index in a synchronous group of three (triple index). For example, the shuttle may be configured to move through the sterilization station 612 in double index and through the filling station 614 in triple index. Furthermore, due to the shuttles 604 being individually propellable, the distance between adjacent shuttles can be adjusted along the trajectory 604. For example, it may be advantageous to have a longer distance between adjacent shuttles in a filling station than in a sterilization station.

[0038] By allowing each shuttle 604 to progress independently through processing unit 600, the residence time within each processing station can be adapted to the most preferred residence time for that processing station. Also, if for some reason a shuttle 604 is prevented from continuing to progress through processing unit 600, the downstream shuttle can continue unimpeded through processing unit 600, thus preventing an immediate shutdown of the processing unit and providing time to resolve the situation without immediately halting container production.

[0039] 1-3 , the processing unit 600 has three parallel processing lanes, such that each shuttle 602 includes three holders or receivers 606. However, it should be understood that in other embodiments, the processing unit may have a different number of parallel processing lanes, e.g., two, four, or even only one processing lane. In such cases, the shuttle 602 may include a corresponding number of parallel holders or receivers 608, and the transfer unit 400 may be employed to collect the corresponding number of shuttles 402 at the transfer stations 408. As a result, the disclosed conveyor system of the processing unit can be easily adapted to address different throughput requirements and different processing station configurations.

[0040] An alternative embodiment of a processing unit 600' is shown in Figure 4, in which a shuttle 602' of a conveyor system 601' comprises five parallel holders or receivers 606', such that the processing unit 600' comprises five processing lanes. Also, the processing unit 600' operates in a single index, i.e., the shuttle 604 is propelled through the processing unit 600' one at a time.

[0041] Additionally, an alternative embodiment of a processing unit 600'' is shown in FIG. 5, where the processing unit 600'' is a five-lane triple-index system.

[0042] It will be appreciated that certain features of the invention which are, for clarity, described above in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable subcombination.

[0043] In particular, it should be understood that features described in connection with one particular embodiment may be interchangeable with features described in connection with other embodiments.

[0044] In the foregoing description, various aspects of the filling machine have been described with reference to illustrative embodiments. For purposes of explanation, specific values, systems, and configurations have been set forth to provide a thorough understanding of the apparatus and its operation. However, this description is not intended to be construed in a limiting sense. Various modifications and variations of the illustrative embodiments of the apparatus, as well as other embodiments, that are obvious to those skilled in the art to which the disclosed subject matter pertains are deemed to be within the scope of the present invention, as defined by the following claims.

Claims

[Claim 1] The invention described in this specification.

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