Machines for producing capsules

Abstract

A machine for producing capsules (C) containing a powdered product (R) is described. The machine comprises a plurality of processing stations (2) configured to perform respective processes for producing capsules (C) containing the powdered product (R) at respective predetermined processing times. The machine also comprises a moving means (3) configured to transport the capsules (C) along a processing path extending through the plurality of processing stations (2). In particular, the moving means (3) comprises a plurality of units (4) each designed to receive at least one capsule body, and at least one guide rail (5) extending along the processing path and defining a linear-type motor together with each unit (4).

Description

[Technical field]

[0001] The present invention relates to the technical field of packaging disposable containers containing doses of food, especially beverage, preparations, such as pods or capsules for coffee, tea or other infusion preparations.

[0002] In particular, the present invention relates to a machine and method for producing capsules containing a powdered product. [Background technology]

[0003] The popularity of disposable capsules and pods, especially for extracted beverages, continues to grow thanks to the simplicity, convenience and speed of use of these types of products, which are particularly valued for their efficiency and speed of use in workplace environments and are also increasingly being used in home environments.

[0004] Increasing demand therefore requires continuous optimization of manufacturing processes, particularly with regard to reducing the processing time required to produce a finished product.

[0005] In prior art manufacturing plants, capsules being manufactured move through a series of processing stations, each of which is designed to perform a specific procedure, such as, for example, inserting the product into the capsule, introducing further elements, applying a closure cover, etc.

[0006] From the various possible processing steps that can be carried out, it is clear that each of them may require a certain time that does not necessarily coincide with that of the other processes. Thus, within a machine designed to manufacture capsules, it is inevitable that there will be stations that take longer to process the capsules than others.

[0007] This means that in the time that a slower station processes a certain number of capsules, a faster station will process more capsules, thus slowing down production as a bottleneck occurs in feeding a slower station that receives too many capsules, or generating a supply that just barely meets the requirements of a faster station that receives too few capsules while waiting at a standstill, wasting machine time and therefore productivity. Summary of the Invention

[0008] In this context, the technical object forming the basis of the present invention is to propose a machine and a method for producing capsules that overcomes at least some of the abovementioned drawbacks of the prior art.

[0009] In particular, it is an object of the present invention to provide a machine and method for manufacturing capsules which makes the process of moving capsules along a processing path through the various stations more efficient so as to ensure at any one time that each station is supplied with the exact number of capsules that the station can process.

[0010] The stated technical and specified objects are substantially achieved by a machine and a method for manufacturing capsules, comprising the technical features recited in one or more of the appended claims.

[0011] The present invention describes a machine for manufacturing capsules containing a powdered product, comprising a plurality of processing stations configured to perform respective processes for manufacturing capsules containing a powdered product at respective predetermined processing times, and movement means configured to transport the capsules along a processing path extending through the plurality of processing stations.

[0012] The moving means comprises a plurality of units, each designed to receive at least one capsule body, and at least one guide rail extending along the processing path and defining, together with each unit, a linear type motor.

[0013] Advantageously, the particular type of coupling that exists between each unit and the guide rails allows the individual units to move efficiently and independently of one another.

[0014] The invention also relates to a method for manufacturing capsules containing a powdered product, comprising conveying in a mutually independent manner a series of units, each of which is designed to receive at least one capsule body along a processing path extending through a plurality of processing stations, using guide rails which together with each unit define a linear type motor.

[0015] Preferably, the method also comprises: placing at least one capsule body in a unit at a first processing station; dosing the powdered product at a second processing station and inserting the powdered product into at least one capsule body; creating a closure cover at a third processing station and applying the closure cover to the capsule body; and sealing a closure lid to the capsule body at a fourth processing station.

[0016] Advantageously, the steps described in the method herein make it possible to optimise the supply of capsules to the individual processing stations, preventing bottlenecks and ensuring that at any one time each processing station is supplied with the exact number of capsules it is capable of processing, maintaining high quality standards without wasting machine time, i.e. maximising productivity.

[0017] The dependent claims, which are incorporated herein by reference, relate to different embodiments of the invention. [Brief description of the drawings]

[0018] Further features of the invention and its advantages will become more apparent in the following non-limiting description with reference to preferred but non-exclusive embodiments of a machine for manufacturing capsules, as illustrated in the accompanying drawings, in which: [Figure 1] 1 shows a capsule that can be processed using the machine and / or method according to the present invention. [Diagram 2] 1 shows a machine for manufacturing capsules according to a possible embodiment. [Diagram 3] 4 shows a machine for manufacturing capsules according to a further possible embodiment. [Figure 4A-4F] 1 shows diagrammatically some possible execution steps of a method for manufacturing a capsule according to the invention; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] In the accompanying drawings, the numeral 1 generally indicates a machine for producing capsules "C" containing a powdered product "R", which machine will hereinafter be referred to simply as machine 1.

[0020] The machine according to the invention comprises a plurality of processing stations 2 and transfer means 3 arranged to transport the capsules “C” during processing through the various processing stations 2 .

[0021] By way of example, the capsule "C" may comprise a capsule body made by molding a metallic material, in particular aluminum or an aluminum alloy.

[0022] As seen in FIG. 1 (showing a capsule as a non-limiting example), the capsule "C" may have the shape of a substantially frusto-conical hollow solid of revolution, with a vertex located at the bottom and a slight taper, closed at the bottom by a circular base "B", with a circular opening "A" at the top, and with an edge wall "P" defined by a horizontally lying circular crown.

[0023] More generally, it should be noted that the invention is applicable to any type of capsule, even types not shown.

[0024] One or more inserts "I" may also be inserted inside the capsule "C".

[0025] Generally, the multiple processing stations 2 are configured to carry out respective processes aimed at producing capsules "C" containing a powdered product "R" at respective predetermined processing times.

[0026] In other words, each processing station 2 is characterized by a relative processing time, which may differ from the processing time of at least one other processing station 2, and which specifies the duration of the processing that the processing station 2 is designed to perform and therefore the time that the capsule "C" needs to be held in order to be correctly processed.

[0027] For example, the machine 1 may comprise a number of processing stations 2 including at least one of a feeding station configured to feed capsule bodies to the respective units 4, a dosing and filling station where the powdered product "R" is dosed and introduced inside the capsule bodies, a station for making a closing cover, and a sealing station where the cover is stably fixed to the capsule bodies.

[0028] The plurality of processing stations 2 may also comprise at least one weighing station, at which a qualitative check may be performed on the produced or in-production capsules "C", and / or at least one insertion station configured to apply an insert "I", e.g. an insert made of a filtering material, to the capsule body.

[0029] The moving means 3 , on the other hand, are configured to transport the capsules “C” along a processing path extending through the plurality of processing stations 2 .

[0030] In other words, the processing path extends in the machine 1 such that each capsule "C" is transported to or within various processing stations 2, enabling said processing stations to act on the capsule.

[0031] Structurally, the moving means 3 comprises a plurality of units 4 each designed to receive at least one capsule body "C", and at least one guide rail 5 extending along the processing path.

[0032] In particular, each unit 4 together with a guide rail 5 forms a linear type motor.

[0033] According to a first embodiment, the guide rail 5 defines the stator of the motor, which can be made, for example, of a series of magnetizable electric elements (electromagnets), while each unit 4 is equipped with one or more magnets (permanent magnets).

[0034] A series of magnetisable electric elements (electromagnets) in the guide rail 5 are arranged to generate a magnetic field which induces in the magnets of the unit 4 a current which acts by repelling the induced magnetic field, according to Faraday's law.

[0035] According to an alternative embodiment, the guide rail 5 may be made of a series of fixed conductive elements, such as, for example, rings, solenoids or simple metal pieces, while each unit 4 includes one or more electromagnets configured to generate a magnetic field that induces a current in the conductors of the guide rail 5 that acts by repelling the induced magnetic field, according to Faraday's law.

[0036] This interaction generates forces that allow the unit 4 to move along the processing path.

[0037] Advantageously, therefore, each unit 4 can be controlled independently, since it defines, together with the guide rails 5, an independent and autonomous linear motor which can therefore move without being constrained by the movements of the other units 4 forming part of the movement means 3.

[0038] According to a first possible embodiment, shown diagrammatically in FIG. 2, the guide rail 5 defines a closed path having an outward section 6 and a return section 7 facing a plurality of processing stations 2 along the processing path.

[0039] Preferably, the return section 7 is located below the forward section 6 so as to optimise the use of space and reduce the overall dimensions of the guide rail.

[0040] Alternatively, it is possible to arrange the return section 7 alongside the forward section 6 or in any case at the same position as the forward section 6 .

[0041] In this way, once a capsule body has passed through all the processing stations 2 of the machine 1 and the processing to produce a capsule "C" is complete, it is possible to extract the capsule from the respective unit 4 and return that unit 4 to the start of the processing path from which it can receive further capsule bodies to be processed by the machine 1.

[0042] According to a second possible embodiment, shown diagrammatically in FIG. 3, the movement means 3 comprises a first guide rail 5a defining a front section 6 of the unit 4 and a second guide rail 5b defining a return section 7 of the unit 4.

[0043] In particular, a first guide rail 5a is arranged at a number of stations 2 along the processing path and a second guide rail 5b is arranged at, preferably below, the first guide rail 5a.

[0044] Again, it is possible to place the return section 7 alongside the front section 6 by simply placing the second guide rail 5b alongside the first guide rail 5a, or in either case in the same position.

[0045] According to this embodiment, the moving means 3 also comprises at least one actuator device 8 configured to move the unit 4 from the first guide rail 5a to the second guide rail 5b and from the second guide rail 5b to the first guide rail 5a.

[0046] In particular, the at least one actuator device 8 is designed to move the unit 4, which has traversed the entire processing path and its capsule body which has undergone all the processing in the various processing stations 2 forming part of the machine 1, from the first guide rail 5a to the second guide rail 5b so that the unit 4 can move along the return section.

[0047] The at least one actuator device 8 is also configured to move the unit 4 from the second guide rail 5b to the first guide rail 5a so as to feed the unit 4 to the front section along which the unit 4 passes through all the various processing stations of the machine 1.

[0048] Preferably, the at least one actuator device 8 comprises a first robot arm 8a arranged in an initial section of the processing path coinciding with an initial section of the first guide rail 5a and a final section of the second guide rail 5b, and a second robot arm 8b arranged in a final section of the same processing path coinciding with the final section of the first guide rail 5a and the initial section of the second guide rail 5b, for the reasons mentioned above.

[0049] In particular, the robotic arms 8a, 8b are equipped with manipulators capable of engaging and gripping the units 4 and then moving and transferring them from one guide rail to the other.

[0050] Furthermore, the machine 1 comprises a control unit 100 connected to each unit 4 and operating on them to control their operation, for example to modulate the magnetic fields that each of them is capable of generating (i.e. the magnetic fields acting on them).

[0051] According to one aspect of the invention, the control unit 100 is configured to supply each processing station 2 with a respective predetermined number of units 4 and to operate each unit 4 so as to cause them to undergo the same processing simultaneously.

[0052] In other words, the control unit 100 controls the movement of the units 4 so that each processing station 2 receives exactly the number of units it is designed to process.

[0053] In particular, the number of given units 4 supplied to each processing station 2 is determined as a function of the processing time of the particular processing station 2 and / or as a function of the number of capsules "C" it can process simultaneously.

[0054] In this way, it is possible to optimize the entire treatment process, since each station receives as input the exact number of units 4 that it can act on in a given time interval, avoiding the creation of bottlenecks or the waste of machine time.

[0055] For example, the control unit 100 may be configured to supply more units 4 to a processing station 2 having a processing time longer than the processing times of other processing stations 2 of the machine 1 than are supplied to each of the other processing stations 2.

[0056] More generally, the unit 4 is therefore moved at variable speed along the section between the various processing stations 2 .

[0057] In this way, in a given time interval, the slower processing station 2 can process a number of capsules "C" equal to the number of capsules of the faster processing station 2.

[0058] Thus, in the faster processing stations 2, the processing of the capsules "C" is mainly sequential, i.e. they process, for example, a single unit 4 at a time, while in the slower stations, the processing is mainly parallel, i.e. they process several units 4 at a time, increasing in number in proportion to the specific processing time of the processing station 4.

[0059] Advantageously, the present invention achieves a preset objective of overcoming the drawbacks of the prior art by providing the user with a machine for manufacturing capsules which is able to move the individual units 4 (and thus a given number of capsules "C") autonomously and particularly efficiently, and thus selectively supply each processing station 2 with the exact number of capsules "C" which can be processed.

[0060] This prevents a bottleneck at the entrance to a processing station 2 or a situation occurring where not enough capsules "C" are supplied to a given processing station 2, thereby wasting machine time.

[0061] The invention also relates to a method for manufacturing capsules containing a powdered product, which can preferably be carried out using a machine 1 manufactured as described above.

[0062] The method comprises conveying a series of units 4 in a mutually independent manner, each unit 4 of the series of units 4 being designed to receive at least one capsule body.

[0063] In particular, the series of units is conveyed along a processing path extending through a plurality of processing stations 2 using guide rails 5 which define a linear type motor in association with each of the series of units 4 .

[0064] Along the processing path, the series of units 4 are then passed through various processing stations 2 so that the capsule bodies can be processed to produce capsules "C".

[0065] In particular, the manufacture of capsule "C" begins by placing at least one capsule body in unit 4 within first processing station 2a.

[0066] Subsequently, in a second processing station 2b, the powdered product "R" is dosed and at least one capsule body is filled with the powdered product "R".

[0067] In other words, in the second processing station 2b, the product it must contain is introduced inside the capsule body, after having been dosed to ensure that the correct amount of powdered product "R" is used.

[0068] Meanwhile, in the third processing station 2c, a cover for closing the capsule body is made and applied to the capsule body.

[0069] Finally, in the fourth processing station 2d, a closure lid is sealed onto the capsule body.

[0070] It should be noted that according to one embodiment, the creation and application of the cover to close the capsule body, as well as the associated sealing of the cover to the capsule body, may occur at a single (same) station.

[0071] In other words, in this embodiment, the third processing station 2c and the fourth station 2d may be grouped together in the same station.

[0072] The method may also include various further steps aimed at producing a particular capsule "C" as required for a particular embodiment.

[0073] For example, the method may include the step of inserting an insert "I" into the capsule body, preferably an insert made of a filter material, at a fifth processing station not shown in the accompanying drawings.

[0074] Furthermore, in order to check that the capsule "C" has been correctly manufactured and that the product can be effectively sold, it is possible to weigh the capsule body at the sixth processing station 2e to check that the correct amount of powdered product has been inserted into the capsule body or that no other anomalies have occurred (failure to apply the insert, closure cover or incorrect application thereof).

[0075] It is also possible that one or more processing stations 2 coincide, so that one or more operations can be performed without the need to move the unit 4 between one operation and the next.

[0076] In particular, the sixth station 2e, in which weighing takes place, can be formed inside another processing station 2, so as to check that the work process has been carried out correctly immediately upon completion thereof.

[0077] In general, the number of units 4 supplied at the inlet to each processing station 2 will differ from the number of units 4 supplied at the inlet to at least another processing station 2 .

[0078] In other words, the method involves using a transfer means 3 to supply, at the entrance to each processing station 2, a certain number of units 2 which varies between the various processing stations 2 as a function of a given processing time.

[0079] In particular, preferably, the number of units supplied to each processing station 2 is directly proportional to the duration of the respective processing time, such that a processing station 2 characterized by a longer processing time will receive more units 4 at its inlet than a processing station 2 characterized by a shorter processing time.

[0080] Furthermore, the number of units 4 undergoing a treatment at each treatment station 2 may be different from the number of units 4 undergoing a different treatment at at least one other treatment station 2 .

[0081] Similar to what has been described with respect to the feed treatment, the number of units 4 undergoing treatment at a given moment in a given treatment station 2 is established as a function of their respective predetermined treatment times.

[0082] In other words, a slower processing station 2 compensates for a longer duration of processing time by processing a greater number of units 2 simultaneously, while a faster processing station 2, for example, processes a series of units 4 individually in sequence.

[0083] Note that there may be any number of units 4 being processed simultaneously at each processing station (based on the cycle time of each station).

[0084] For example, and by way of non-limiting example, the second station 2b and the third station 2c can each process two units 4 simultaneously, while the fourth station 2d can process three units.

[0085] Once the manufacturing process is completed, the method includes removing each capsule body from unit 4 in a final section of the processing path so that the freshly manufactured capsule "C" can be fed to further processes downstream, such as, for example, a process for packaging the capsule "C".

[0086] The unit 4 from which the capsule bodies have been extracted is then conveyed from the final section of the processing path to an initial section which is preferably located in the first processing station 2a.

[0087] 4A-4F show diagrammatically several successive time intervals of a possible operating configuration of the method according to the invention.

[0088] In particular, Figures 4A-4B each represent separate and successive time intervals during which the first, second, third and sixth processing stations 2a, 2b, 2c, 2e can carry out their respective processing with a predetermined processing time equal to the indicated time intervals, while the fourth processing station 2d, which corresponds to the proposed example for the station where the closure cover is sealed to the capsule body, can carry out its processing process with a predetermined processing time equal to twice the indicated time intervals.

[0089] In FIG. 4A, the first three processing stations 2a, 2b and 2c are respectively a first unit 4a, a second unit 4b and a third unit 4c which act on each of the capsule bodies contained therein.

[0090] In FIG. 4B, the first unit 4a waits at the entrance of the fourth processing station, the second and third units 4b, 4c are both fed to their respective subsequent processing stations 2b, 2c, and the fourth unit 4d is fed to the entrance of the first processing station 2a.

[0091] In FIG. 4C the first and second units 4a, 4b are fed to a fourth processing station 2d which takes twice as long to process them as the other processing stations 2, and at the same time the third and fourth units 4c, 4d are both fed to the next processing stations 2b, 2c to what they were in the situation shown in FIG. 4B.

[0092] In FIG. 4D, the fourth processing station 4d is finalizing the process for treating the first and second units 4a, 4b, while the third unit 4c is waiting at its entrance and the fourth unit 4d is treated by the third processing station 4c.

[0093] In FIG. 4E, the first and second units 4a, 4b are extracted from the fourth processing station 2d and moved respectively into the sixth processing station 4e and wait at its entrance, while the third and fourth units 4c, 4d begin to be processed simultaneously in the fourth processing station 2d.

[0094] Finally, in FIG. 4F, the first unit 4a has completed the manufacturing process so that the respective capsule bodies can be extracted, after which unit 4a will be moved to the start of the processing path.

[0095] At the same time, the second unit 4b is being processed in the sixth processing station and the third and fourth units 4c, 4d are finishing up in the fourth processing station 2d.

[0096] According to another embodiment, upstream of the second processing station with respect to the processing path there is a first buffer zone configured to accommodate at least one unit 4 that has not been processed.

[0097] According to yet another embodiment, downstream of the second processing station and upstream of the at least first processing station 2a, 2b, 2c, 2e with respect to the processing path, there is a second buffer zone for accommodating at least one unit 4 that has not been processed.

[0098] Advantageously, the present invention achieves the preset objective of overcoming the drawbacks of the prior art by providing the user with a method for manufacturing capsules that allows optimizing the management of available resources, in particular with regard to the use of machine time in the various processing stations 2.

Claims

1. A machine for producing capsules (C) containing a powdered product (R), comprising: a plurality of processing stations (2) adapted to carry out respective processes at respective predetermined processing times in order to produce capsules (C) containing a powdered product (R); a moving means (3) configured to transport said capsules (C) along a processing path extending through said plurality of processing stations (2); a control unit (100) in communication with said moving means (3) for moving said moving means (3) along said plurality of processing stations (2), The moving means (3) comprises a plurality of units (4) and at least one guide rail (5) extending along the processing path; Each unit (4) defines a linear type motor together with the guide rail (5); Each unit (4) magnetically interacts with said at least one guide rail (5); the plurality of processing stations comprises a first processing station (2a, 2b, 2c, 2e) having a first processing time (T1) and a second processing station (2d) having a second processing time (T2) greater than the first processing time (T1); the control unit (100) is programmed to operate the plurality of units (4) independently of one another to supply a first predetermined number of the units (4) to the first processing station (2a, 2b, 2c, 2e) and a second predetermined number of the units (4) to the second processing station (2d); the second predetermined number of said units (4) is greater than the first predetermined number of said units (4); Each of the plurality of units (4) is configured to accommodate at least one capsule body having a cup shape; The first processing station comprises a dosing and filling station for dosing the powdered product (R) and filling the at least one capsule body with the powdered product (R), and the second processing station comprises a sealing station for sealing a closure lid onto the at least one capsule body.

2. 2. The machine of claim 1, wherein the dosing and filling station has a processing time equal to the first processing time (T1) and the sealing station has a processing time equal to the second processing time (T2).

3. 3. The machine according to claim 1 or 2, wherein the control unit (100) is configured to control the moving means (3) to supply to the second processing station (2d) twice the number of units (4) supplied to the first processing station (2a, 2b, 2c, 2e).

4. 4. The machine according to claim 1, wherein upstream of the second processing station with respect to the processing path there is a first buffer zone configured to accommodate at least one unit (4) that has not been processed.

5. 5. The machine according to claim 1, wherein downstream of the second processing station and upstream of the at least first processing station (2a, 2b, 2c, 2e) with respect to the processing path there is a second buffer zone for accommodating at least one unit (4) that has not been processed.

6. 6. A machine according to any one of claims 1 to 5, wherein the guide rail (5) defines a closed path having an outward section (6) arranged at the plurality of processing stations (2) along the processing path, and a return section (7).

7. The moving means (3) - first guide rails (5a) defining outward sections (6) for said plurality of units (4), said first guide rails (5a) being arranged along said processing path at said plurality of processing stations (2); a second guide rail (5b) defining a return section (7) for said plurality of units (4); and at least one actuator device (8) configured to move the plurality of units (4) from the first guide rail (5a) to the second guide rail (52) and from the second guide rail (52) to the first guide rail (5a).

8. 8. The machine according to claim 7, wherein the at least one actuator device (8) comprises a first robot arm (8a) arranged in an initial section of the processing path and a second robot arm (8b) arranged in a final section of the processing path.

9. A machine as claimed in claim 6 or 7, wherein the return section (6) is arranged below the outward section (6).

10. 10. The machine according to any one of claims 1 to 9, wherein each of the plurality of units (4) is configured to accommodate a plurality of the capsule bodies.

11. A method for producing a capsule (C) containing a powdered product (R), comprising the steps of: - conveying a series of units (4) in a mutually independent manner along a processing path extending through a plurality of processing stations (2) by means of guide rails (5) defining, together with each unit (4), a linear motor, each unit (4) being configured to receive at least one capsule body having a cup shape; - placing at least one capsule body in one of said series of units (4) in a first processing station (2a); dosing said powdered product (R) in a second processing station (2b) and filling said at least one capsule body with said powdered product (R); - in a third processing station (2c), creating a closing lid and applying said closing lid to said at least one capsule body filled with said powdered product (R); and in a fourth processing station (2d), sealing said closure lid onto said at least one capsule body, A method according to claim 1, wherein the number of units (4) supplied to said fourth processing station (2d) is greater than the number of units (4) supplied to said second processing station (2b).

12. 12. The method according to claim 11, wherein the number of units (4) undergoing a treatment at each of the plurality of treatment stations (2) is different from the number of units (4) undergoing a different treatment at at least one other treatment station (2) of the plurality of treatment stations (2) and is determined as a function of a predetermined treatment time of said treatment station (2).

13. Removing each capsule body from the plurality of units (4) in a final section of the processing path; and returning the plurality of units (4) from the final section of the processing path to an initial section.

14. Inserting an insert (I) inside the capsule body in a fifth processing station (2); and weighing the capsule bodies in a sixth processing station (2e).

15. 15. The method according to claim 14, wherein the insert (I) is made of a filter material.

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