System and method for sealing food containers

Abstract

A food container sealing system is disclosed. The sealing system comprises a frame and a transport system for transporting each food container through the sealing system, the transport system being supported by the frame. A sealing section is configured to receive food containers from the transport system. The sealing section comprises a first sealing tool and a second sealing tool, the first and second sealing tools being supported by the frame and configured to press against each other to seal each food container placed between them. The transport system is further configured to carry the sealed food containers out of the sealing section. A power monitoring section is configured to measure or estimate the power consumption of at least the sealing section of the sealing system. A control section is configured to calculate the energy consumption per sealed food container based on the power consumption and the number of sealing operations performed per unit time, and to output an index derived from the calculated energy consumption per sealed food container.

Description

Technical Field

[0001] The present invention relates to a sealing system for food containers and a method for sealing food containers. In particular, the present invention is applicable to food containers such as food trays that can be sealed with a film-like lid. The present invention relates to outputting indications derived from power consumption in order to measure or estimate the power consumption of such a system and assist an operator in improving the energy efficiency and / or sealing performance of the system.

Background Art

[0002] In systems and methods for sealing food containers, it is often the case that high pressure generated between two sealing tools is utilized to seal the container. A specific example of such a system is a tray sealing system. In this system, heat and pressure are usually used to close the tray with a film-like lid and seal this film along the sealed seam around the tray. Another example of such a system is a vacuum packaging system. This system evacuates the air between the tray or sheet and the film-like cover to form a sealed container, and then seals the film over the food along the sealed seam generated using heat and pressure.

[0003] In these processes of using heat and pressure for sealing, factors that affect the quality of the seal include the time for which heat and pressure are applied, the temperature used in the sealing process, and the pressure used for sealing. An operator may periodically adjust these settings in order to achieve desirable sealing characteristics. Additional settings such as the standby time of the sealing part and the speed at which containers are conveyed within the system may also be adjusted according to the operating requirements.

[0004] Because these operating parameters can be adjusted manually, it is common to see sealing systems operating with settings that are inappropriate for the products being sealed. For example, operators may set the sealing temperature to a level far exceeding the required temperature for the film material, or the conveyor may be set to operate at a speed far faster than necessary for the number of containers being transported. In other words, sealing systems are often set to operate with low energy efficiency without providing any further benefits to the products being sealed.

[0005] Therefore, it is desirable to provide a system and method for sealing food containers that can help operators optimize the energy efficiency of sealing operations, thereby reducing the operating costs of the system. [Overview of the project]

[0006] According to a first aspect of the present invention, a sealing system for food containers is provided, comprising: a frame; a transport system for transporting each food container through the sealing system, the transport system being supported by the frame; a sealing section configured to receive food containers from the transport system, comprising a first sealing tool and a second sealing tool, the first and second sealing tools being configured to press against each other to seal each food container placed between them, the sealing section being supported by the frame, and the transport system being further configured to carry the sealed food containers out of the sealing section; a power monitoring unit configured to measure or estimate the power consumption of at least the sealing section of the sealing system; and a control unit configured to calculate the energy consumption per sealed food container based on the power consumption and the number of sealing operations performed per unit time, and to output an index obtained from the calculated energy consumption per sealed food container.

[0007] Thus, the present invention enables operators to improve the energy efficiency of a sealing system by providing feedback on energy usage during the operation of the sealing system, by measuring or estimating power consumption using a power consumption monitor and then outputting an index derived from the calculated energy consumption per sealed food container. On the other hand, in conventional sealing systems that are not configured to monitor power consumption or output information derived from measured or estimated power consumption, inappropriate operating parameters may be used, resulting in excessive energy consumption without the operator's knowledge.

[0008] It will be understood that when the first and second tools are pressed together, the tools may not physically touch each other because of the food container between them. Typically, one of the first and second sealing tools is connected to an actuator that moves the sealing tools together to press the first and second sealing tools together. Preferably, this actuator is configured to move the sealing tools linearly and reciprocally from an open position that can receive the food container to be sealed to a closed position that presses the sealing tools against the opposing sealing tools to seal the container.

[0009] Generally, the majority of the power consumption of a conveying system is determined by the power consumption of the sealing section, which is used to lift food containers, press sealing tools under high pressure, and heat-seal the containers using a heat sealer. Therefore, in some embodiments, when measuring or estimating the power consumption of only the sealing section and comparing the operation of systems with different sealing parameters, the contributions to power consumption from other parts of the system, such as the conveying system or display screens, may be ignored and generally canceled out. However, in some embodiments, a power monitoring unit may be provided that is configured to measure or estimate the power consumption of the sealing system, i.e., the entire sealing system, and this power monitoring unit may provide the most accurate information about power consumption.

[0010] Preferably, the control unit is configured to further calculate an energy efficiency measure of at least one sealing part of the sealing system based on a comparison of the energy consumption per sealed food container with a threshold energy consumption, and to output an index from the energy efficiency measure, the index derived from the energy consumption per sealed food container comprising an index obtained from the energy consumption measure. In this way, by utilizing the threshold energy consumption, the calculated energy efficiency measure takes into account the optimal energy use of the system, so that the sealing system can further assist the operator in optimizing energy efficiency. Therefore, the index obtained from the energy efficiency measure can guide the operator to achieve optimal system function.

[0011] Preferably, the sealing system further includes a data storage device located within the sealing section, where the threshold energy consumption is a predetermined threshold energy consumption, and data indicating the threshold energy consumption is stored in the data storage device. In this way, the threshold energy consumption may be linked to individual sealing sections.

[0012] Preferably, the control unit is configured to receive data indicating the characteristics associated with each food container to be sealed, and to determine a threshold energy consumption based on the characteristics associated with each food container to be sealed. In this way, the threshold energy consumption may be accurately determined and updated according to the dimensions, material, etc., of the food container.

[0013] Preferably, the characteristics related to each food container to be sealed include one or more of the sealing area of ​​each food container, the sealing material of each food container, and the material of each food container.

[0014] Preferably, the control unit is configured to receive data indicating threshold energy consumption from an external computing device. Thus, the threshold energy consumption may be adjusted and updated as needed.

[0015] Preferably, an external computing device is configured to receive energy consumption data from multiple other sealing systems for food containers, and the threshold energy consumption is calculated based on the energy consumption data. Thus, the threshold energy consumption may be adjusted and updated based on an analysis of data (such as big data) regarding the energy usage of other sealing systems.

[0016] Preferably, the control unit is configured to receive one or more operating parameters of the sealing system and, if it is determined that the energy consumption per sealed food container is greater than or less than a threshold energy consumption per sealed food container, it outputs a message (prompt) to adjust one or more operating parameters of the sealing system, the message being based on the energy consumption per sealed food container and one or more operating parameters. In this way, the control unit further assists the operator in improving the energy efficiency and / or sealing performance of the system by providing a message that adjusts the operating parameters considering the received operating parameters and the difference between the threshold energy consumption and the actual energy consumption. Thus, the operating parameters of the sealing process may be controlled in a continuous and guided manner based on real-time feedback.

[0017] Preferably, the control unit is configured to output a message to adjust one or more operating parameters of the sealing system when it is determined that the energy consumption per sealed food container is greater than the threshold energy consumption per sealed food container by a first percentage of the threshold energy consumption per sealed food container. In this way, the control unit assists the operator in optimizing the energy efficiency of the system. Alternatively, the control unit may be configured to output a message to adjust one or more operating parameters of the sealing system when it is determined that the energy consumption per sealed food container is greater than the threshold energy consumption per sealed food container by a predetermined first value.

[0018] Preferably, the control unit is configured to output a message to adjust one or more operating parameters of the sealing system when it is determined that the energy consumption per sealed food container is less than the threshold energy consumption per sealed food container by a second percentage of the threshold energy consumption per sealed food container. In this way, the control unit assists the operator in improving the sealing performance of the system, as particularly high energy efficiency may indicate that the container is not properly sealed. Alternatively, the control unit may be configured to output a message to adjust one or more operating parameters of the sealing system when it is determined that the consumption per sealed food container is less than the threshold energy consumption per sealed food container by a predetermined second value.

[0019] Preferably, the sealing system further includes strain gauges configured to measure the sealing force when a first sealing tool and a second sealing tool are pressed against each other, and one or more operating parameters include the sealing force, and the message includes an index for adjusting the sealing force.

[0020] Preferably, the sealing system further includes a temperature sensor configured to measure the sealing temperature when the first sealing tool and the second sealing tool are pressed together, one or more operating parameters include the sealing temperature, and the message includes an index for adjusting the sealing temperature.

[0021] Preferably, one or more operating parameters include at least one of the following: the speed of the transport system, the dwell time of the sealing section, and the waiting time of the sealing section, and the message includes an indicator for adjusting at least one of the following: the speed of the transport system, the dwell time of the sealing section, and the waiting time of the sealing section.

[0022] Preferably, the sealing system further comprises a display unit supported by a frame, and the control unit is configured to output an index on the display unit derived from the calculated energy consumption per sealed food container.

[0023] Preferably, the sealing section includes a heat-sealing tool configured to heat-seal a film-like lid to the container along the sealed seam.

[0024] As described above, the power monitoring unit may be configured to measure or estimate power consumption. In some embodiments, power consumption is measured directly, for example, by configuring the power monitoring unit to monitor the power supply to the sealing unit or to the entire system. Power consumption may also be measured by measuring the current consumption and combining this with the power supply voltage. However, in other embodiments, the power monitoring unit may be configured to estimate power consumption. For example, the power monitoring unit may be part of the control unit and estimate power consumption based on the control of the sealing unit or a broader sealing system.

[0025] In a particularly preferred embodiment, the power monitoring unit is configured to estimate the power consumption of at least the sealing portion of the sealing system based on at least the operating parameters of the sealing portion. These operating parameters are user-input parameters such as sealing temperature and pressure, and can be combined with predetermined power consumption information for those operating parameters. This power consumption information may be stored in a storage device or determined based on data analysis of the power consumption of other sealing systems, such as big data.

[0026] In some embodiments, the power monitoring unit is configured to measure or estimate the power consumption of at least one sealing unit of the sealing system based on the operating power and duty cycle of at least one module of the sealing unit, and one or more of the current consumption by at least one module of the sealing unit and the voltage supplied to the module. Here, the term “module” refers to individual components of the sealing unit that use power independently and may include a heat welding module with a heat welding plate that consumes power and converts it into heat, a lifting module that consumes power to lift a lower tool and press it against an upper tool, and a cutting module that consumes power to operate a cutting tool for cutting film. For example, the sealing unit may use one or more heat welding tools having known wattages, and therefore the power consumption of the heat welding tools may be determined based on the known wattage and the duty cycle of the heat welding tool, i.e., the ratio of the time the heat welding tool is on to the time it is off. In another example, the sealing unit may use servo motors to lift the welding tools and generate sealing pressure, and each servo motor may record the current it consumes over time and determine the power consumption in combination with the supply voltage. The power consumption of various modules in the sealing section may be measured or estimated in various ways and combined to determine the overall power consumption.

[0027] According to a second aspect of the present invention, there is provided a sealing system for a food container, comprising: a frame; a conveying system for conveying each food container through the sealing system, the conveying system being supported by the frame; a sealing unit configured to receive the food container from the conveying system, the sealing unit including a first sealing tool and a second sealing tool, the first and second sealing tools being configured to be pressed against each other to seal each food container disposed therebetween, the sealing unit being supported by the frame, the conveying system being configured to carry out the sealed food container from the sealing unit; a power monitoring unit configured to measure or estimate at least the power consumption of the sealing unit of the sealing system; and a control unit configured to calculate a measure of the power efficiency of the sealing system based on a comparison between the power consumption and a measure of the power consumption, and output an index derived from the measure of the power efficiency of the sealing system.

[0028] Preferably, the control unit is further configured to calculate the energy consumption per sealed container based on the power consumption and the number of sealing operations performed per unit time, and output an index of the electrical energy consumption per sealed container.

[0029] Preferably, the sealing system further includes a data storage device disposed within the sealing unit, the threshold power consumption is a predetermined threshold power consumption, and data indicating the threshold power consumption is stored in the data storage device.

[0030] Preferably, the control unit is configured to receive data indicating characteristics related to the container to be sealed, and the control unit is configured to determine the threshold power consumption based on the characteristics related to the container.

[0031] Preferably, the control unit is configured to receive data indicating a threshold power consumption from an external computing device. Preferably, the external computing device is configured to receive energy consumption data from several other sealing systems for food containers, and the threshold power consumption is calculated based on the energy consumption data.

[0032] Preferably, the control unit is further configured to receive one or more operating parameters of the sealing system and output a message to adjust one or more operating parameters of the container sealing system if it is determined that the power consumption is greater than a threshold power consumption or less than a threshold power consumption, and the message is based on the power consumption and one or more operating parameters.

[0033] Preferably, the control unit is configured to output a message to adjust one or more operating parameters of the sealing system when it is determined that the power consumption is greater than the threshold power consumption by a first percentage of the threshold power consumption. Alternatively, the control unit may be configured to output a message to adjust one or more operating parameters of the sealing system when it is determined that the power consumption is greater than the threshold power consumption by a predetermined first value.

[0034] Preferably, the control unit is configured to output a message to adjust one or more operating parameters of the sealing system when it is determined that the power consumption is less than the threshold power consumption by a second percentage of the threshold power consumption. Alternatively, the control unit may be configured to output a message to adjust one or more operating parameters of the sealing system when it is determined that the power consumption is less than the threshold power consumption by a predetermined second value.

[0035] Preferably, the ceiling system further includes a display unit, and the control unit is configured to output an index derived from a measure of the power efficiency of the ceiling system on the display unit.

[0036] A third aspect of the present invention provides a method for operating a food container sealing system, comprising the steps of: transporting each food container to a sealing section equipped with a first sealing tool and a second sealing tool using a transport system; pressing the first and second sealing tools together to seal each food container located between them; measuring or estimating the power consumption of at least the sealing section of the sealing system using a power monitoring unit; calculating the energy consumption per sealed food container using a control unit based on the power consumption and the number of sealing operations performed per unit time; and outputting an index derived from the energy consumption per sealed food container using the control unit.

[0037] A fourth aspect of the present invention provides a method for operating a food container sealing system, comprising the steps of: transporting each food container to a sealing section equipped with a first sealing tool and a second sealing tool using a transport system; sealing each food container located between the first and second sealing tools by pressing them together; measuring or estimating the power consumption of at least the sealing section of the sealing system using a power monitoring unit; calculating a measure of the power efficiency of at least the sealing section of the sealing system based on a comparison of power consumption and threshold power consumption using a control unit; and outputting an index derived from the measure of the power efficiency of at least the sealing section of the sealing system using a control unit.

[0038] Preferably, the method of the third or fourth embodiment may be carried out using the system of the first or second embodiment. [Brief explanation of the drawing]

[0039] The present invention will be described with reference to the following drawings. [Figure 1] Perspective view of a food tray sealing system. [Figure 2]Front view of a food tray sealing system, showing the system in the open position. [Modes for carrying out the invention]

[0040] Referring to Figure 1, an example of the system is described below. The system shown in Figure 1 is a tray sealing system 1, which may also be called a sealing system for food containers. System 1 comprises a frame 100 that supports various elements of System 1. The frame 100 may comprise a number of housing panels that close the frame 100 to form housings for each element of the system. System 1 comprises a film supply unit 10 having a film supply reel 11 that supplies film into the system as a web along a film transport path 13 and supplies excess film to a take-up reel 12. System 1 further comprises a sealing unit 20 that lifts a food tray, seals the film to the tray, and cuts the film from the wound state. The food tray is also called a food container. As will be described later, the sealing unit 20 comprises an upper tool 21 (e.g., a first sealing tool) and a lower tool 22 (e.g., a second sealing tool), and in part of this sealing process, these tools are pressed together by an actuator 25 connected to the lower sealing tool 22. The system further includes a display unit 30 (e.g., an HMI display) with a user interface for controlling the operation of the system, and a transport system 40 for transporting trays through the system. The display unit 30 is configured to display information regarding the operation of system 1, as will be described later. Additionally or alternatively, the operation of system 1 may be controlled using an external computing device, for example, via a network connection to system 1. The transport system 40 is located within the frame 100 and includes a first transport belt 41 that receives trays to be sealed at the input end of the system and transports the trays to the sealing unit 20. From there, the trays are transported into the sealing unit 20 by, for example, a gripping arm, where they are sealed within the unit and then transported out of the sealing unit 20. A second transport belt 42 receives the sealed trays and transports each tray to the output end of system 1.

[0041] As best shown in Figure 2, the sealing section 20 is located approximately in the center of the system 1. The sealing section 20 includes an upper sealing tool 21 that is substantially fixed to the frame 100, although it usually includes movable parts within the upper tool 21. The sealing section 20 is configured to perform tray sealing or vacuum packing. For this purpose, the upper sealing tool 21 usually includes a heat-sealing plate for heat-sealing film transported along the film transport path 13 to the edge of a support such as a tray, and a cutting tool for cutting off a portion of the film that has been sealed to the support such as a tray. The lower sealing tool 22 usually includes a receiving section configured to receive the support such as a tray to be sealed. The actuator 25 may lift the lower sealing tool 22 and press it against the upper sealing tool 21 to perform sealing. When the upper sealing tool 21 and the lower sealing tool 22 are closed, the actuator 25 further lifts the lower sealing tool 22, which may cause relative movement of parts within one or both of the upper and lower sealing tools 21 and 22. For example, the upper tool 21 comprises a heat-sealing plate and a cutting tool attached by springs to the body or housing of the upper sealing tool 21, and the body or housing of the upper sealing tool 21 moves upward when pressed by the lower tool 22, causing the heat-sealing plate and cutting tool to protrude from the body or housing of the upper sealing tool 21 and contact the tray. Such a configuration of the heat-sealing plate and cutting tool in the upper sealing tool is described in concurrently pending application PCT / GB2021 / 052230. A temperature sensor 70 is provided in the frame 110 and is positioned to measure the sealing temperature during each sealing operation, for example, the temperature of the heat-sealing plate. For example, the temperature sensor 70 may be located on or adjacent to the heat-welding plate.

[0042] A strain gauge 121 is coupled to the frame 100 and is configured to measure the sealing force when the upper sealing tool 121 is pressed against the lower sealing tool 122 during sealing work. In particular, the strain gauge 121 is configured to measure the force transmitted through the frame 100 during sealing, and this force can be decomposed as a sealing force. For example, the strain gauge 121 may be installed on a portion of the frame 100 that is parallel to the direction in which the sealing tools 121, 122 are pressed and is under pure tension, thereby allowing the sealing force to be easily decomposed. The strain gauge 121 may be, for example, a two-hole bolt-on strain gauge sensor.

[0043] Those skilled in the art will understand that it may be necessary to calibrate the strain gauge 121 before use during normal operation. This calibration may involve placing a load cell on the sealing tool 120 and using the actuator 25 to press the upper sealing tool 121 and the lower sealing tool 122 together with the load cell, generating a force within the range detectable by the load cell. While pressing the upper sealing tool 121 and the lower sealing tool 122 against each other, the output from the strain gauge 121 is recorded, and the output of the strain gauge 121 is plotted against the force measured by the load cell. From this, the measured value of the strain gauge and the sealing force (typically mV·kN) can be determined. -1 The relationship between ) can be derived. Afterwards, the load cell may be removed before using System 1 under normal conditions.

[0044] System 1 further includes a power monitoring unit 60 configured to measure the power consumption of System 1, that is, the amount of energy consumed per unit time during the operation of System 1. The power monitoring unit 60 is supported by a frame 100 and positioned to monitor the input power supply to System 1. For example, the power monitoring unit 60 may be mounted at or near the power input port of System 1 so that the power input to System 1 can be measured by the power monitoring unit 60. Alternatively, control data may be provided to the power monitoring unit so that the power monitoring unit can determine the power consumption without directly measuring the input power supply. For example, if the wattage of the heat sealing plate is known, the power consumption can be estimated from its duty cycle. The time the heat sealing plate is actually heated may be determined from the control data. Furthermore, the actuator 25 coupled to the lower sealing tool 22 may include a servo motor that records the current usage over time. This current usage may be combined with the supply voltage to determine the power consumption associated with the operation of the actuator (e.g., lifting and pressing each sealing tool).

[0045] System 1 further includes a control unit 50 (e.g., a microprocessor) that is communicatively connected to a power monitoring unit 60. In other embodiments, the power monitoring unit may be part of the control unit 50 and monitor power based on data received by the control unit or operating parameters used by the control unit. In this embodiment, the control unit 50 receives data from the power monitoring unit 60 indicating the measured power consumption. As shown in Figure 1, the control unit 50 is supported by the frame 100 and is an independent component of the display unit 30. However, in another example, the control unit 50 may be as part of the display unit 30 or integrated within the display unit 30. In further examples, the control unit 50 may be located outside the frame 100, for example, in a different geographical location, and configured to communicate with components of System 1 via a network connection. In some embodiments, the control unit 50 may be referred to as a computing system or may be included within a computing system.

[0046] Generally, the purpose of the control unit 50 is to receive operational data from one or more components of the sealing system 1 and feed it back to the operator to help the operator optimize the energy use of the system 1. In conventional sealing systems, it is common for operators to perform sealing operations using inappropriate or excessive operational parameters, resulting in high power consumption without improving the quality, consistency, or speed of the sealing operation. Therefore, by providing a control unit 50 that can output an index of the energy usage of the system 1 to the user based on the power consumption measurement of the system 1, the operator is guided to improve the energy efficiency of the system 1, thereby reducing overall operating costs.

[0047] In particular, the control unit 50 is configured to calculate the energy consumption per sealed tray based on the power consumption measured by the power monitoring unit 60 and the number of sealing operations performed per unit time. For example, if the system's power consumption is measured at 120W and the number of sealing operations per second is 0.1, the energy consumption per sealed tray is calculated to be 1200J. The number of sealing operations performed per unit time is a pre-set parameter of the sealing operation, which is obtainable by the control unit 50 and can be programmed, for example, by user input on the display unit 30 or by an external computing device and transmitted to the control unit 50 via a network connection.

[0048] The control unit 50 is further configured to output an index derived from the calculated energy consumption per sealed tray. In the simplest example, this may be an index of the actual value of the calculated energy consumption per sealed tray (e.g., "1200 J per sealed tray"). Alternatively, the control unit 50 may calculate and output a value of the calculated energy consumption per production batch or a value of the calculated energy consumption per production shift. The index derived from the calculated energy consumption per sealed tray may include, or consist of, an index of a calculated measure of the energy efficiency of the system or an index derived therefrom, as will be further described below.

[0049] The control unit 50 may output an index derived from the calculated energy consumption per sealed tray via the display unit 30, so that the index derived from the energy consumption per sealed tray is displayed on the display unit 30. Alternatively or additionally, the control unit 50 may output the index derived from the calculated energy consumption per sealed tray via an external computing device. For example, data showing the calculated energy consumption per sealed tray may be transmitted to an external computing device via a network and displayed there. Based on this index, the operator is guided to adjust the operating parameters of System 1 to reduce energy consumption.

[0050] The control unit 50 is configured to calculate a measure of the energy efficiency of the sealing system 1 based on a comparison of the energy consumption per sealed tray with a threshold energy consumption. The threshold energy consumption can be considered as the optimal or target energy consumption per sealed tray. The control unit 50 may receive the threshold energy consumption in various ways. In the first example, the sealing unit 20 may include a data storage device (not shown) that can store data indicating the threshold energy consumption. The data indicating the threshold energy consumption may be pre-programmed and stored by, for example, the manufacturer before the sealing unit 20 is installed in the system 1. In the second example, the control unit 50 is additionally or alternatively configured to calculate the threshold energy consumption based on the characteristics of the tray and / or film (e.g., dimensions and material), which may be received via user input on the display unit 30. For example, the control unit 50 may receive data indicating the sealing area of ​​each tray, the material of the film used for sealing, and / or the material of each tray, and be configured to calculate the threshold energy consumption based on one or more of these characteristics. In the third example, the control unit 50 may be configured to receive threshold energy consumption from an external computing device, either additionally or alternatively. In particular, the control unit 50 may receive data indicating threshold energy consumption via a network connection to an external computing device. The external computing device may calculate the threshold energy consumption based on energy consumption data received from several other sealing systems for food trays.

[0051] A calculated measure of the sealing system's energy efficiency provides a relative measure of the system's energy consumption to the threshold energy consumption. Typically, the measure of energy efficiency may be the ratio or percentage of energy consumption per sealed food tray to the threshold energy consumption per sealed tray. For example, if the energy consumption per sealed tray is 1800 J and the threshold energy consumption per sealed tray is 1200 J, the measure of energy efficiency can be calculated as 1800 / 1200 = 1.5, meaning the energy consumption of system 1 is 150% of the target energy consumption. This would indicate that 50% extra energy is wasted to seal each tray. If the energy consumption per sealed tray is 900 J and the threshold energy consumption per sealed tray is 1200 J, the measure of energy efficiency can be calculated as 900 / 1200 = 0.75, meaning the energy consumption of system 1 is 75% of the target energy consumption. This would indicate that the system may not be functioning correctly, such as the tray not being properly sealed.

[0052] In another embodiment, the measure of energy efficiency may be the ratio or percentage of the threshold energy consumption per sealed food tray to the energy consumption per sealed tray (e.g., threshold energy consumption per sealed food tray / energy consumption per sealed tray).

[0053] The control unit 50 is further configured to output an index derived from the calculated energy efficiency measure, which corresponds to the aforementioned index obtained from the calculation of energy consumption per sealed tray. The index derived from the calculated energy efficiency may be a display of the actual value of the calculated energy efficiency measure (e.g., "150%"). Alternatively or additionally, this index may be a graphic, image, or other representation that provides the operator with an indicator of the energy efficiency of System 1, such as a RAG status. For example, if the calculated energy efficiency falls below a first upper threshold (e.g., if the energy consumption of System 1 is below 105% of the target energy consumption), the control unit 50 may output an indicator of "good" energy efficiency, such as a green status display shown on the display unit 30. If the calculated energy efficiency is between or equal to the first lower threshold and the second upper threshold (for example, if the energy consumption of system 1 is 105% or more of the target energy consumption but less than 120% of the target energy consumption), the control unit 50 may output an indicator on the display unit 30, such as a yellow status display, indicating that the energy efficiency is "poor." If the calculated energy efficiency exceeds the second threshold (for example, if the energy consumption of system 1 exceeds 120% of the target energy consumption), the control unit 50 may output an indicator of "poor" energy efficiency on the display unit 30, such as a red status display. In this way, the operator may be further assisted in optimizing the energy efficiency of system 1 based on indicators obtained from the calculated energy efficiency measure.

[0054] The control unit 50 is further configured to receive one or more operating parameters of System 1 and to output messages or recommendations for improving the energy efficiency of System 1 based on these operating parameters and the calculated energy consumption per tray. The one or more operating parameters may include sealing force, sealing temperature, waiting time of the sealing unit 20 (i.e., time between each sealing operation), residence time of the sealing unit 20 (i.e., duration of contact between the sealing unit, film and tray), speed of the transport system 40, and / or other operating parameters of System 1. A first subset of the one or more operating parameters may be measured by various sensors of System 1, such as a temperature sensor 70 for measuring sealing temperature and a strain gauge 121 for measuring sealing force. Such sensors are communicateably connected to the control unit 50 and configured to transmit the measured operating parameters (data indicating them) to the control unit 50. A second subset of the one or more operating parameters may be pre-configured sealing operation parameters obtainable by the control unit 5, which are programmed, for example, via user input on the display unit 30 or programmed on an external computing device and transmitted to the control unit 50 via a network connection. These pre-configured parameters include the waiting time of the sealing unit 20, the dwell time of the sealing unit 20, and the speed of the transport system 40.

[0055] The messages are intended to assist the operator in improving the energy efficiency and / or sealing performance of System 1. Specifically, the messages may include indicators for adjusting one or more operating parameters of System 1, such as "reduce sealing force" or "sealing temperature is too high." The control unit 50 is configured to output messages via the display unit 30, and the messages may be displayed on the display unit 30. Alternatively or additionally, the control unit 50 may be configured to output messages via an external computing device, for example, by sending data indicating the message to an external computing device via a network, where the message may be displayed.

[0056] Messages may be output only under specific operating conditions. In particular, the control unit 50 may be configured to output a message in response to the determination that the energy consumption per sealed container is greater than the threshold energy consumption per sealed tray (for example, by a first percentage greater than the threshold energy consumption per sealed tray), or in response to the determination that the energy consumption per sealed tray is less than the threshold energy consumption per sealed tray (for example, by a second percentage less than the threshold energy consumption per sealed tray). In the former case, the message is intended to adjust operating parameters that reduce energy efficiency without significantly improving sealing performance, i.e., operating parameters are set too high or too low, resulting in high energy consumption. For example, even though the sealing unit is programmed to operate with a short waiting time, operators tend to operate the conveyor belt at high speed. In this case, since a high speed of the transport system 40 may lead to poor energy efficiency, the control unit 50 would output a message instructing the operator to reduce the (unnecessarily high) speed of the transport system 40. Also, operators tend to increase the sealing force beyond what is necessary to seal the film to the tray. This is likely to reduce energy efficiency, so the control unit 50 may output a message containing an indicator for reducing the sealing force. On the other hand, in the latter case, especially with high energy efficiency, it may indicate that not enough energy is being applied to seal and the tray is not properly sealed, so the message aims to adjust the operating parameters to improve the sealing performance of system 1. Therefore, the control unit 50 may output a message containing recommendations for improving sealing performance based on the operating parameters and the calculated energy consumption per tray.For example, the message may include indicators for increasing the sealing force and / or sealing temperature.

[0057] In some embodiments, the control unit 50 determining that the energy consumption per tray is greater than the threshold energy consumption per sealed container by a first percentage of the threshold energy consumption per sealed container may be equivalent to the control unit 50 determining that the calculated energy efficiency exceeds a first upper limit threshold energy efficiency. Similarly, the control unit 50 determining that the energy consumption per tray is less than the threshold energy consumption per sealed container by a second percentage of the threshold energy consumption per sealed container may be equivalent to the control unit 50 determining that the calculated energy efficiency is below a lower threshold energy efficiency.

[0058] Generally, the control unit 50 is configured to receive one or more of the above operating parameters and output a message that includes an index for adjusting one or more of these operating parameters based on the calculated energy consumption per sealed tray and one or more of the operating parameters. The message may be generated based on multiple operating parameters (e.g., sealing temperature and sealing force), but the message does not necessarily include an index for adjusting all of these operating parameters (for example, the message may include only an index for adjusting the sealing temperature and not an index for adjusting the sealing force).

[0059] In the first example, the operating parameters received by the control unit 50 include sealing temperature, sealing force, waiting time of the sealing unit 20, and residence time of the sealing unit 20. The control unit 50 determines that the waiting time of the sealing unit 20 exceeds a threshold waiting time (i.e., it indicates inefficient container throughput, such that the sealing unit 20 is frequently inactive). Therefore, in order to improve the energy efficiency of system 1, the message generated by the control unit 50 includes indicators to reduce the sealing temperature, sealing force, and waiting time of the sealing unit 20, and to increase the residence time of the sealing unit 20. By increasing the time that the sealing unit 20 is in contact with each container, the sealing temperature and sealing force can be reduced without adversely affecting the sealing quality. In this way, the energy efficiency of system 1 can be improved.

[0060] In the second example, the control unit 50 determines whether the first operating parameter among the received operating parameters is above or below a first threshold, and whether the second operating parameter among the received operating parameters is above or below a second threshold. Therefore, the message generated by the control unit 50 includes an index for adjusting the first and second operating parameters so that they approach the first and second thresholds, respectively. The index may include a recommended adjustment of the first and second operating parameters calculated so that the production rate of system 1 (i.e., the throughput of sealed containers) does not change.

[0061] In the above embodiment, the control unit 50 was described as being configured to calculate the energy consumption per sealed tray, output an index derived from the energy consumption per sealed tray, calculate a measure of energy efficiency based on the energy consumption per sealed tray and a threshold energy consumption per sealed tray, output an index derived from the measure of energy efficiency (corresponding to the index derived from the energy consumption per sealed tray), and output a message based on the energy consumption per sealed tray and one or more operating parameters. However, it will be understood that in an alternative embodiment, the control unit 50 may instead be configured to output an index derived from power consumption, calculate a measure of power efficiency based on power consumption and a threshold power consumption, output an index derived from the measure of power efficiency (corresponding to the index derived from the power consumption per sealed tray), and output a message based on power consumption and one or more operating parameters. In other words, power consumption may not be normalized based on the number of sealing operations per unit time, and instead subsequent calculations may be based on the measured power consumption. In further embodiments, power consumption may instead be normalized based on the number of production shifts per unit time or the number of production batches per unit time.

Claims

1. A sealing system for food containers, Frame and, A conveying system for transporting each food container through the sealing system, comprising a conveying system supported by the frame, A sealing section configured to receive food containers from the transport system, comprising a first sealing tool and a second sealing tool, wherein the first and second sealing tools are configured to press against each other to seal each food container placed between them, the sealing section is supported by the frame, and the transport system is further configured to carry out the sealed food containers from the sealing section. A power monitoring unit configured to measure or estimate the power consumption of at least the sealing portion of the sealing system, A control unit, Based on the aforementioned power consumption and the number of sealing operations performed per unit time, the energy consumption per sealed food container is calculated. A sealing system comprising: a control unit configured to output an index derived from the calculated energy consumption per sealed food container.

2. The control unit further, Based on a comparison of the energy consumption per sealed food container and the threshold energy consumption per sealed food container, a measure of the energy efficiency of at least the sealing portion of the sealing system is calculated. A sealing system according to claim 1, configured to output an index derived from the energy efficiency scale, wherein the index derived from the energy consumption per sealed food container comprises the index obtained from the energy consumption scale.

3. The sealing system according to claim 2, further comprising a data storage device disposed within the sealing portion, wherein the threshold energy consumption is a predetermined threshold energy consumption, and data indicating the threshold energy consumption is stored in the data storage device.

4. The sealing system according to claim 2, wherein the control unit is configured to receive data indicating characteristics related to the food container to be sealed, and the control unit is configured to determine the threshold energy consumption based on the characteristics related to the food container to be sealed.

5. The sealing system according to claim 4, wherein the characteristics related to the food container to be sealed include one or more of the sealing area of ​​each food container, the sealing material of each food container, and the material of each food container.

6. The ceiling system according to claim 2, wherein the control unit is configured to receive data indicating the threshold energy consumption from an external computing device.

7. The sealing system according to claim 6, wherein the external computing device is configured to receive energy consumption data from a plurality of other sealing systems for food containers, and the threshold energy consumption is calculated based on the energy consumption data.

8. The control unit further, The system receives one or more operating parameters of the sealing system. The sealing system according to any one of claims 1 to 7, wherein the sealing system is configured to output a message to adjust one or more operating parameters of the sealing system when it is determined that the energy consumption per sealed food container is greater than the threshold energy consumption per sealed food container, or when it is determined that the energy consumption per sealed food container is less than the threshold energy consumption per sealed food container, and the message is based on the energy consumption per sealed food container and the one or more operating parameters.

9. The sealing system according to claim 8, wherein the control unit is configured to output a message to adjust one or more operating parameters of the sealing system when it is determined that the energy consumption per sealed food container is greater than the threshold energy consumption per sealed food container by a first percentage of the threshold energy consumption per sealed food container.

10. The sealing system according to claim 8 or 9, wherein the control unit is configured to output a message to adjust one or more operating parameters of the sealing system when it is determined that the energy consumption per sealed food container is less than the threshold energy consumption per sealed food container by a second percentage of the threshold energy consumption per sealed food container.

11. The sealing system according to any one of claims 8 to 10, further comprising a strain gauge configured to measure the sealing force when the first sealing tool and the second sealing tool are pressed against each other, wherein one or more operating parameters include the sealing force, and the message includes an index for adjusting the sealing force.

12. The sealing system according to any one of claims 8 to 11, further comprising a temperature sensor configured to measure the sealing temperature when the first sealing tool and the second sealing tool are pressed together, wherein one or more operating parameters include the sealing temperature, and the message includes an index for adjusting the sealing temperature.

13. The sealing system according to any one of claims 8 to 12, wherein the one or more operating parameters include at least one of the speed of the transport system, the dwell time of the sealing section, and the waiting time of the sealing section, and the message includes an indicator for adjusting at least one of the speed of the transport system, the dwell time of the sealing section, and the waiting time of the sealing section.

14. The sealing system according to any of the preceding claims, further comprising a display unit supported by the frame, wherein the control unit is configured to output the index derived from the calculated energy consumption per sealed food container on the display unit.

15. The sealing system according to any of the preceding claims, wherein the sealing portion comprises a heat-sealing tool configured to heat-seal a film-like lid to the container along the sealed seam.

16. The sealing system according to any of the preceding claims, wherein the power monitoring unit is configured to estimate the power consumption of at least the sealing portion of the sealing system based at least on the operating parameters of the sealing portion.

17. The sealing system according to any of the preceding claims, wherein the power monitoring unit is configured to measure or estimate the power consumption of at least the sealing unit of the sealing system based on one or more of the operating power and duty cycle of at least one module of the sealing unit, and the current usage by at least one module of the sealing unit and the voltage supplied to the module.

18. A sealing system for food containers, Frame and, A conveying system for transporting each food container through the sealing system, comprising a conveying system supported by the frame, A sealing unit configured to receive food containers from the transport system, comprising a first sealing tool and a second sealing tool, wherein the first and second sealing tools are configured to press against each other to seal each food container placed between them, the sealing unit is supported by the frame, and the transport system is configured to carry out the sealed food containers from the sealing unit. A power monitoring unit configured to measure or estimate the power consumption of at least the sealing portion of the sealing system, A control unit, Based on a comparison between the aforementioned power consumption and a threshold power consumption, a measure of the power efficiency of at least the sealing portion of the sealing system is calculated. A sealing system comprising: a control unit configured to output an index derived from the scale of power efficiency of at least the sealing portion of the sealing system.

19. A method for operating a sealing system for food containers, A process of transporting each food container to a sealing section equipped with a first sealing tool and a second sealing tool using a conveying system, The process involves pressing the first and second sealing tools together to seal each food container located between them, A step of measuring or estimating the power consumption of at least the sealing portion of the sealing system using a power monitoring unit, A step of using a control unit to calculate the energy consumption per sealed food container based on the power consumption and the number of sealing operations performed per unit time, A method comprising the step of using the control unit to output an index derived from the energy consumption per sealed food container.

20. The method according to claim 19, which is performed using the system described in any one of claims 1 to 17.

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