Filling machine and method for operating the same

Abstract

A filling machine (100) is disclosed having a processing unit (600) including processing stations (612, 614, 616) and a conveyor system (601) configured for transporting container precursors through the processing stations. The conveyor system comprises a plurality of shuttles or transporters (602) configured for transporting the container precursors along a track (604) through the processing stations, and a shuttle propulsion system that allows each shuttle to be individually propelled along the track. Corresponding methods are also disclosed.

Description

Technical Field

[0001] (Technical Field) The present disclosure generally relates to a filling machine for producing cellulose-based multilayer composite containers filled with pourable food products.

[0002] Specifically, the present disclosure relates to a filling machine for forming a cellulose-based 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 Art

[0003] (Background) Filling machines for packaging containers made of cellulose-based multilayer composites, such as cardboard composite materials, with products, particularly liquid food products, are known from the prior art. For example, for the construction of known filling machines, EP 0936992 B1 (Patent Document 1) and US 10196163 B2 (Patent Document 2) are referenced.

[0004] The present disclosure is directed to various apparatuses and methods that can solve or at least reduce at least one of the aforementioned problems or challenges.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Patent Document 2

Summary of the Invention

Means for Solving the Problems

[0006] (Summary) The filling machine according to the present invention is characterized by the features of claim 1. The method according to the present invention is characterized by the features of claim 7. Preferred embodiments of the filling machine and method according to the present 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 a container precursor through the at least one processing station, the conveyor system comprising a plurality of shuttles or carriers configured to transport the container precursor along a track through the at least one processing station, and a shuttle propulsion system enabling each shuttle or carrier to be individually propelled along the track.

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

[0009] Each shuttle or carrier may comprise a single holder or receiver for transporting a container precursor or a plurality of holders or receivers configured to transport a plurality of container precursors in parallel through the at least one processing station.

[0010] The at least one processing station is - a bottom sealing station configured to bottom seal the container precursor, - a sterilization station configured to sterilize the container precursor, - a filling station configured to fill the container precursor with a pourable food product, - an upper sealing station configured to upper seal the container precursor and may comprise at least one of.

[0011] The filling machine may include a container precursor forming unit configured to form a bottom-sealed container precursor, and a transfer unit configured to transfer the bottom-sealed container precursor from the forming unit to a processing unit. The transfer unit may include a plurality of shuttles or carriers 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 carrier of the transfer unit to be individually propelled along the track.

[0012] The shuttle propulsion system of the transfer unit may include an electric long stator linear motor configured to individually propel each shuttle or carrier of the transfer unit along the track of the transfer unit.

[0013] According to another aspect, the present disclosure provides a method of operating a filling machine, the filling machine including a processing unit having at least one processing station for processing a container precursor. The method includes transporting the container precursor through at least one processing station within a plurality of individually propellable shuttles or carriers that travel along a track through the processing unit.

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

[0015] The distance between adjacent shuttles or carriers may not be constant as the shuttles or carriers travel through the processing unit. For example, the distance between adjacent shuttles or carriers may be expanded as the shuttles or carriers travel through the 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 a container precursor through the at least one processing station, the conveyor system comprising a plurality of shuttles or carriers configured to transport the container precursor along an orbit through the at least one processing station, and a shuttle propulsion system enabling each shuttle or carrier to be individually propelled along the orbit, the filling machine comprising a container precursor forming unit configured to form a bottom-sealed container precursor, and a transfer unit configured to transfer the bottom-sealed container precursor from the forming unit to the processing unit, the transfer unit comprising a plurality of shuttles or carriers configured to transport the container precursor along the orbit from the forming unit to the processing unit, and a shuttle propulsion system enabling each shuttle or carrier of the transfer unit to be individually propelled along the orbit, the transfer unit comprising a transfer station configured to receive the case precursor within a single row and transfer the case precursor to the processing unit within 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 suitable combinations in other aspects of the invention. This 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 convey a container precursor (102) through the at least one processing station (612, 614, 616), the conveyor system (601) comprising a plurality of shuttles or carriers (602) configured to transport the container precursor along a track (604) through the at least one processing station (612, 614, 616), and a shuttle propulsion system enabling each shuttle or carrier (602) to be individually propelled along the track (604). (Item 2) The filling machine (100) according to item 1, wherein the shuttle propulsion system comprises an electric long stator linear motor configured to individually propel each shuttle or carrier (602) along the track (604). (Item 3) The filling machine (100) according to any one of the preceding items, wherein each shuttle or carrier (602) comprises a single holder or receiver (606) for transporting a container precursor or a plurality of holders or receivers (606) configured to transport 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 to bottom seal the container precursor (102), - a sterilization station (402) configured to sterilize the container precursor, - a filling station (404) configured to fill the container precursor with a pourable food product, and - a top sealing station (406) configured to top seal the container precursor The filling machine (100) according to any one of the preceding items, comprising at least one of the above. (Item 5) A filling machine (100) according to any one of the preceding items, 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) includes a plurality of shuttles or carriers (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 carrier (402) of the transfer unit (400) to be individually propelled along the track (404). (Item 6) The filling machine (100) according to item 5, wherein the shuttle propulsion system of the transfer unit (400) includes 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) including a processing unit (600, 600', 600'') having at least one processing station (612, 614, 616) for processing a container precursor. The method is characterized by transporting the container precursor through the at least one processing station (612, 614, 616) within a plurality of individually propellable shuttles or carriers (602) traveling along a track (604) through the processing unit (600, 600', 600''). (Item 8) The method according to item 7, characterized by transporting the container precursor through a first one of the at least one processing station (612, 614, 616) within a first index and transporting the container precursor through a second one of the at least one processing station (612, 614, 616) within a second index different from the first index. (Item 9) The method according to any one of items 7 and 8, characterized in that the distance between adjacent shuttles or carriers (602) is not constant as the shuttle or carrier (602) progresses through the processing unit (600, 600’, 600’’). (Item 10) The method according to item 9, characterized in that the distance between adjacent shuttles or carriers (602) is extended as the shuttle or carrier (602) progresses through the filling station (614) of the processing unit (600, 600’, 600’’).

Brief Description of the Drawings

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

[0019]

Figure 1

[0020]

Figure 2

[0021]

Figure 3

[0022]

Figure 4

[0023]

Figure 5

Modes for Carrying Out the Invention

[0024] In the drawings, like reference numerals are used to indicate common parts, elements, or features, unless otherwise explicitly described or implicitly understood in a different context.

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

[0026] FIG. 1 discloses a filling machine 100 comprising a forming unit 200, a transfer unit 400, and a processing unit 600. FIG. 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 planar folded composite covering or sleeve from a storage unit (not disclosed). The flat folded container precursor is raised to a tubular form and bottom-sealed within the bottom seal station 202 of the forming unit 200. Depending on the type of container to be produced within the filling machine 100, the container precursor 102 may also include, for example, an opening device 104 that includes 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 stepwise and having a plurality of parallel receiving portions 206 extending outwardly in the radial direction. The receiving portions 206 conventionally take the form of a mandrel on which a tubular container precursor is pushed and subsequently bottom-sealed. In this embodiment, the bottom sealing station 202 comprises two transport wheels and is thus configured to bottom-seal two container precursors in parallel.

[0029] Once the container precursors are bottom-sealed, they are released from the mandrel 206 and transferred to the transfer unit 400. The transfer unit 400 comprises a plurality of shuttles or carriers 402 each configured to receive a container precursor that is bottom-sealed but open at the top 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 for this purpose comprises a single holder or receiver 406.

[0030] In operation, the shuttle 402 travels along the track 404 in a single row, forming a closed loop that extends between the forming unit 200 and the processing unit 600. The transfer unit 400 comprises a shuttle propulsion system that enables each shuttle 402 to be individually propelled along the track 404, i.e., enables each shuttle 402 to move along the track 404 independently of its downstream and upstream neighbors. To enable such propulsion, the track 404 may comprise a guide rail and an electric long stator linear motor extending along the track 404, the guide rail being configured to transport the shuttle 402 along the track 404 and the linear motor being for individually propelling each shuttle 402 along the guide rail using permanent magnets. The propulsion system may be based on, for example, any one of the systems commercially available under the trade names SUPERTRAK and ACOPOSTRAK.

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

[0032] At the 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 within the processing unit 600. The shuttle 602 then moves adjacent to the grouped shuttles 402, and the container precursors will be transferred from the shuttle 402 to the 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, the shuttle 602 travels in a single column through the processing unit 600 along a track 604 that comprises a set of substantially parallel guide rails 608 (see FIG. 1).

[0034] The guide rail 608 is configured to guide the shuttle 602 through a sterilization station 612 configured to sterilize the container precursors. The filling station 614 is configured to fill the container precursors with pourable food, and the top seal station 616 is configured to top seal the container precursors. Such stations are thus well known in the art and will not be discussed further herein. After the top seal station 616, the containers completed here are discharged from the shuttle 602 or transferred to an external feed station 618, discharged from the processing unit 600, and prepared for further distribution.

[0035] When the containers are transferred from the shuttle to the discharge station 618, the shuttle 602 is returned to the start of the track 604 via the return conveyor 610 to receive a new group of container precursors. In this embodiment, the return conveyor 610 comprises a belt conveyor with two parallel belts configured to convey 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 to the return conveyor 610, and a second elevator 622 is configured to raise the shuttle 602 from the return conveyor 610 to the guide rail 608.

[0036] During operation, the shuttle 604 travels in a single column along the track 604. Similar to the transfer unit 400, the conveyor system 601 includes a shuttle propulsion system that enables each shuttle 602 to be individually propelled along the track 604, i.e., without interlinking the shuttles with other shuttles, and thus enables each shuttle 602 to move along the track 604 independently of 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, which are configured such that the linear motor individually propels each shuttle 602 along the guide rail 608. Similar to the transfer unit 400, the propulsion system may be based on any one of the systems commercially available under the trade names SUPERTRAK and ACOPOSTRAK, for example.

[0037] As shown in FIG. 4, shuttle 604 can be advanced one by one through processing unit 600, for example, within a single index. Alternatively, shuttle 604 can be configured to move through processing units 600 in a cohort, for example, a group of two (double index) as disclosed in FIG. 1, a group of three (triple index) as disclosed in FIG. 5, or any other group size. Also, since each shuttle 604 can be individually propelled along track 604, the shuttle can be configured to move through, for example, one processing station within a first index in a cohort of two (double index) and through a subsequent processing station within a second index in a cohort of three (triple index). For example, the shuttle may be configured to move through sterilization station 612 in a double index and through filling station 614 in a triple index. Furthermore, due to shuttle 604 being individually propellable, the distance between adjacent shuttles can be adjusted along track 604. For example, it may be advantageous to have a longer distance between adjacent shuttles within the filling station than in the sterilization station.

[0038] By enabling each shuttle 604 to proceed independently through processing unit 600, the residence time within each processing station can be adopted to the most preferred residence time of that processing station. Also, for several reasons, if shuttle 604 is prevented from continuously proceeding through processing unit 600, the downstream shuttle can continue through processing unit 600 without being disrupted, thus preventing an immediate shutdown of the processing unit and providing time to resolve the situation without immediately halting container production.

[0039] In the embodiment shown in FIGS. 1 - 3, the processing unit 600 has three parallel processing lanes, and as a result, each shuttle 602 comprises 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, for example, two, four, or even only one processing lane. In such cases, the shuttle 602 may comprise a corresponding number of parallel holders or receivers 608, and the transfer unit 400 may be employed to gather a corresponding number of shuttles 402 at the transfer station 408. As a result, the disclosed conveyor system of the processing unit can be easily adopted to address different throughput requirements and different processing station configurations.

[0040] An alternative embodiment of the processing unit 600' is shown in FIG. 4, where the shuttle 602' of the conveyor system 601' comprises five parallel holders or receivers 606', and as a result, the processing unit 600' comprises five processing lanes. Also, the processing unit 600' operates within a single index, i.e., the shuttle 604 is advanced one by one through the processing unit 600'.

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

[0042] For the sake of clarity, it should be understood that certain features of the present invention, which are described above in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, for the sake of brevity, various features of the present invention, which are described in the context of a single embodiment, may also be provided separately or in any suitable sub - combination.

[0043] In particular, it should be understood that features described in relation to one particular embodiment may be replaceable with features described in relation to 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 numbers, systems, and configurations have been set forth in order 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, which will be apparent to those of ordinary skill in the art to which the disclosed subject matter pertains, are considered to be within the scope of the invention as defined by the following claims.

Claims

1. A filling machine (100), wherein the filling machine (100) comprises: A container precursor forming unit (200) configured to form a bottom-sealed container precursor; At least one processing station (612, 614, 616); and a conveyor system (601) configured to convey the bottom-sealed container precursor (102) through the at least one processing station (612, 614, 616), the conveyor system (601) comprising a plurality of first shuttles or carriers (602) configured to convey the bottom-sealed container precursor along a first track (604) through the at least one processing station (612, 614, 616), and a first shuttle propulsion system enabling each first shuttle or carrier (602) to be individually propelled along the first track (604), a processing unit (600, 600', 600''); A transfer unit (400) configured to transfer the bottom-sealed container precursor from the container precursor forming unit (200) to the processing unit (600, 600', 600''); Comprising; The transfer unit (400) comprises a plurality of second shuttles or carriers (402) configured to convey the bottom-sealed container precursor from the forming unit (200) to the processing unit (600, 600', 600'') along a second track (404), and a second shuttle propulsion system enabling each second shuttle or carrier (402) of the transfer unit (400) to be individually propelled along the second track (404); The transfer unit (400) further comprises a transfer station (408), the transfer station (408) being configured to receive the plurality of second shuttles or carriers (402) in a single row and transfer the bottom-sealed container precursor to the processing unit (600, 600', 600'') in two or more parallel processing lanes, a filling machine (100).

2. The filling machine (100) according to claim 1, wherein the first shuttle propulsion system comprises an electric long stator linear motor configured to individually propel each first shuttle or carrier (602) along the first orbit (604).

3. The filling machine (100) according to claim 1 or 2, wherein each first shuttle or carrier (602) comprises a plurality of holders or receivers (606) configured to transport a plurality of bottom-sealed container precursors in parallel through the at least one processing station (612, 614, 616).

4. The container precursor forming unit (200) comprises a bottom sealing station (202) configured to bottom-seal the container precursor (102), The at least one processing station is - a sterilization station (612) configured to sterilize the bottom-sealed container precursor, - a filling station (614) configured to fill the bottom-sealed container precursor with a pourable food product, - and an upper sealing station (616) configured to upper-seal the bottom-sealed container precursor The filling machine (100) according to any one of claims 1 to 3, comprising at least one of.

5. The filling machine (100) according to any one of claims 1 to 4, wherein the second shuttle propulsion system comprises an electric long stator linear motor configured to individually propel each second shuttle or carrier (402) along the second orbit (404).

6. A method of operating a filling machine (100), wherein the filling machine (100) is a container precursor forming unit (200) configured to form a bottom-sealed container precursor, At least one processing station (612, 614, 616) for processing a container precursor, and a conveyor system (601) configured to convey the bottom-sealed container precursor (102) through the at least one processing station (612, 614, 616), the processing unit (600, 600', 600'') comprising: the conveyor system (601) includes a plurality of first shuttles or carriers (602) configured to convey the bottom-sealed container precursor along a first track (604) through the at least one processing station (612, 614, 616), and a first shuttle propulsion system that enables each first shuttle or carrier (602) to be individually propelled along the first track (604). A transfer unit (400) configured to transfer the bottom-sealed container precursor from the forming unit (200) to the processing unit (600, 600', 600''). Comprising The transfer unit (400) includes a plurality of second shuttles or carriers (402) configured to convey the bottom-sealed container precursor from the forming unit (200) to the processing unit (600, 600', 600'') along a second track (404), a second shuttle propulsion system that enables each second shuttle or carrier (402) of the transfer unit (400) to be individually propelled along the second track (404), and a transfer station (408). The method is characterized in that the plurality of second shuttles or carriers (402) are received at the transfer station (408) in a single row, the bottom-sealed container precursor is transferred to the processing unit (600, 600', 600'') in two or more parallel processing lanes, and the bottom-sealed container precursor is conveyed through the at least one processing station (612, 614, 616) in the plurality of first shuttles or carriers (602) traveling along the first track (604). Claim 7 Conveying the bottom-sealed container precursor through a first one of the at least one processing station (612, 614, 616) within a first index and conveying the bottom-sealed container precursor through a second one of the at least one processing station (612, 614, 616) within a second index different from the first index, the method according to claim 6, characterized thereby.

8. The method according to any one of claims 6 and 7, characterized in that the distance between adjacent first shuttles or carriers (602) is not constant as the plurality of first shuttles or carriers (602) travel through the processing unit (600, 600', 600'').

9. The method according to claim 8, characterized in that the distance between adjacent first shuttles or carriers (602) is expanded when the plurality of first shuttles or carriers (602) travel through the filling station (614) of the processing unit (600, 600', 600'').

Images