Inventory control system and method for a filling plant that packages pourable food products in composite packages - Patent Application 20070122997

Abstract

An inventory control system is described for a filling plant (1) having at least one filling machine (6) performing a filling operation for forming composite packages (2) from a multi-layer composite packaging material and filling the composite packages (2) with a pourable food product, and a warehouse (20) having an inventory of packaging material elements (5) for forming the composite packages (2). The system comprises first tag elements (24) provided on respective storage units (22) designed to store a plurality of packaging material elements (5), each first tag element (24) comprising first inventory information relating to the packaging material elements (5) stored in the respective storage unit (22), a second tag element (26) provided on each packaging material element (5), said second tag element (26) comprising second inventory information relating to the associated packaging material element (5), and a processing arrangement (12, 16) for receiving operational data relating to a filling operation from the at least one filling machine (6), merging the first inventory information and the second inventory information with the operational data, and performing inventory management of the packaging material elements (5).

Description

[Technical Field]

[0001] The present invention relates to an inventory control system and method in a filling plant that packages pourable food products into composite packages. [Background technology]

[0002] As is well known, many liquid or pourable foods, such as fruit juice, UHT (ultra-high temperature processed) milk, wine, tomato sauce, etc., are distributed and sold using composite packages made of multi-layer composite packaging materials.

[0003] A typical example is the parallelepiped-shaped pourable food package known as Tetra Brik Aseptic®, which is made by sealing and folding a laminated strip packaging material. This packaging material has a multi-layer structure including a base layer of carton and / or paper covered on both sides with layers of heat-sealable plastic material, e.g., polyethylene. In the case of aseptic packages for long-term storage products, the packaging material includes a layer of oxygen barrier material, e.g., aluminum foil, which is laminated with a layer of heat-sealable plastic material and is further covered with another layer of heat-sealable plastic material that ultimately forms the inner surface of the package that comes into contact with the food.

[0004] Composite packages of this type are typically produced in fully automatic filling (or packaging) plants which at least form the composite package from a web of multi-layer composite packaging material (wound from a reel) and fill the composite package with a pourable food product.

[0005] A typical filling plant includes at least a filling machine that forms composite packages from the multi-layer composite packaging material and fills the composite packages with a pourable food product. Additionally, the filling plant may also include downstream processing equipment that receives the composite packages from the filling machine and performs additional processing on the composite packages. The downstream processing equipment may include, for example, one or more of a buffering unit for temporarily buffering the composite packages; an application unit for applying straws to the composite packages; or a grouping unit, such as a palletizer unit, for grouping multiple composite packages together in a storage unit (such as a pallet).

[0006] Filling plants are known to be capable of filling a wide variety of pourable food products into composite packages of various types and formats.

[0007] Therefore, there is a general need in such filling plants to properly manage warehouse inventory, such as, for example, packaging material reels onto which packaging material webs are wound, in order to optimize productivity and minimize waste.

[0008] In particular, the applicant has realized that, for example, partially used or completely unused reels that have passed their expiration date cannot be used in filling operations and must be properly disposed of, but that it is generally difficult to track and prevent the potential waste of packaging material.

[0009] Furthermore, for safety and quality reasons, it is a commonly desired desire to have proper traceability of the packaging materials used in a filling or packaging operation. The Applicant has realized that providing the desired traceability of the packaging materials used is generally a difficult task.

[0010] Although known filling plants are satisfactory, the applicant has realized that there is a need for an improved solution for warehouse inventory management. Summary of the Invention [Problem to be solved by the invention]

[0011] The object of the present solution is therefore to provide an improved system and method for inventory control in a filling plant, which allows to overcome at least some of the above-mentioned disadvantages.

[0012] According to the present solution, an inventory management system and method are provided in accordance with the accompanying claims. [Means for solving the problem]

[0013] Non-limiting embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0014] [Figure 1] 1 is a schematic diagram of a filling plant with an inventory control system according to an embodiment of the present solution; [Figure 2] 2 shows a table containing exemplary inventory control information for use in the inventory control system of FIG. 1; [Figure 3] 2 shows a table containing exemplary inventory control information for use in the inventory control system of FIG. 1; [Figure 4] 2 shows a table containing exemplary inventory control information for use in the inventory control system of FIG. 1; [Figure 5] FIG. 2 is a schematic flow diagram of operations performed by the inventory control system of FIG. 1. DETAILED DESCRIPTION OF THE INVENTION

[0015] Figure 1 shows diagrammatically a filling plant 1 for packaging pourable food products, in particular liquid food products such as milk, cream, fruit juice, wine, tomato sauce, sugar, salt, emulsions, solutions containing solid particles (e.g. pulses), in composite packages 2 formed from multi-layer composite packaging material.

[0016] The multi-layer composite packaging material may comprise at least one layer of fibrous material, such as a layer of paper or cardboard, and at least two layers of heat-sealable plastic material, such as polyethylene, sandwiching the layers of fibrous material between them, with one of the two layers of heat-sealable plastic material defining the inner surface of the composite package 2 that will ultimately contact the pourable food product packaged within the same composite package 2.

[0017] The multilayer composite packaging material may include a layer of gas and light barrier material, such as aluminum foil or ethylene vinyl alcohol (EVOH) film, disposed between one of the layers of heat-sealable plastic material and the layer of fibrous material. Preferably, the multilayer composite packaging material may include a further layer of heat-sealable plastic material interposed between the layer of gas and light barrier material and the layer of fibrous material.

[0018] According to the particular embodiment disclosed and shown with reference to FIG. 1, the multi-layer composite packaging material is provided in the form of a web 4, in particular wound onto a packaging material reel 5, from which it is fed to a filling machine 6.

[0019] The filling machine 6 is operably connected to the packaging material reel 5 and is configured to process the web 4 to obtain composite packages 2 and to fill the same composite packages 2 with pourable food product, which is received from an inlet duct 8 (which is fluidly connected to a tank or similar storage element in a manner not shown here).

[0020] More particularly, web 4 may comprise a series of connected blanks. In particular, the blanks are defined by a series of repeating patterns provided on web 4 of multi-layer composite packaging material, preferably each pattern at least partially defining the aesthetic appearance of the finished composite package 2. Alternatively, the multi-layer composite packaging material may be provided in the form of a single package blank, which is formed and filled in singular during use.

[0021] Each composite package 2 may extend along a longitudinal axis and have a longitudinal seam portion (extending along the respective longitudinal axis) and a pair of transverse seal bands, in particular a transverse upper seal band and a transverse lower seal band. In particular, each composite package 2 may have a substantially parallelepiped structure.

[0022] Additionally, each composite package 2 may comprise at least two lateral walls disposed on opposite sides of the composite package 2 (transverse to the respective longitudinal axes) and a plurality of side walls extending between the lateral walls.

[0023] More specifically, one respective lateral wall of each composite package 2 may define a bottom wall and each other lateral wall may define a top wall, in particular the bottom wall may define a support surface adapted to be placed on a (horizontal) plane, such as a shelf in a distribution point, and the top wall faces the bottom wall.

[0024] In a known manner (not described or shown in detail herein), filling plant 1 may include a pourable food preparation device for preparing the pourable food product. The pourable food preparation device may be connected to filling machine 6 so as to direct the pourable food product to filling machine 6 via inlet duct 8.

[0025] More specifically, the filling machine 6 may include at least the following components. - a conveying device for advancing the web 4 of multi-layer packaging material along an advance path; - a tube forming device for forming a tube from an advancing web 4 of multi-layer packaging material; -sealing device for longitudinally sealing the tube; a filling device connected to the injection duct 8 for filling the tubes with pourable food product; a package forming unit for forming the tube and sealing the tube transversely to form a composite package 2 from the tube filled with the pourable food product;

[0026] More specifically, the package forming unit may have at least the following features. - a forming device adapted to form, transversely seal and transversely cut a tube to obtain a composite pack, in particular a pillow pack; a final folding device configured to receive the composite pack from the forming device and to form a composite package 2 from the composite pack, in particular a pillow pack.

[0027] More particularly, the forming apparatus may include multiple pairs of one respective operating assembly and one respective counter-acting assembly, each operating assembly and each counter-acting assembly configured to cooperate to form, transversely seal, and cut the tube to form one respective composite pack.

[0028] Additionally, the forming apparatus may include a transport unit configured to advance the operating assembly and the counter-operating assembly along the respective transport paths, the respective operating assembly and the respective counter-operating assembly of each pair configured to cooperate with one another to form, transversely seal, and cut the tube as they advance along the respective operating portions of the respective transport paths.

[0029] Additionally, each set of one acting assembly and one counter-acting assembly includes at least one respective lateral seal unit configured to, in use, seal the tube laterally.

[0030] Furthermore, the filling machine 6 a sterilization device arranged along the forward path upstream of the tube forming device and configured to sterilize the web 4 of multi-layer composite packaging material (e.g., by physical and / or chemical sterilization); may also be provided.

[0031] As shown in FIG. 1 , the filling plant 1 is configured to receive the composite packages 2 from the filling machine 6 via a conveying device 7 and may include downstream processing devices 9 that perform additional processing on the same composite packages 2, such as printing information (such as expiration dates and / or lot numbers) and / or images (such as graphic representations, barcodes, QR codes, data matrices, logos, symbols, etc.); applying straws to the composite packages; grouping multiple composite packages into storage units, such as packs or pallets, etc.

[0032] Furthermore, the filling plant 1 is provided with a control device 10, e.g. comprising a PLC (Programmable Logic Controller) or similar processing and computing device, configured to control the general operation of the same filling plant 1 and in particular to set the operating parameters of the filling machine 6 and downstream processing devices 9.

[0033] The control device 10 is operably coupled, for example via the Internet and / or an internal network, to a central server 12, for example a cloud server or a physical server at the plant site (which is also accessible from an external network), where operational data and information related to the filling plant 1 is received and stored in a database (DB) 14.

[0034] As shown in FIG. 1, an operator 15 of the filling plant 1 having a portable or mobile device 16 (e.g., a smartphone, tablet, phablet, or the like) can access the central server 12 and database 14 via a software application ("app") to access and obtain operational data and information related to the operation of the filling plant 1.

[0035] The operator 15 may communicate with the central server 12 via a stationary computer 18 (or similar processing device) equipped with a suitable graphical user interface. In an embodiment not shown, the computer 18 may also be part of the control device 10 of the filling plant 1.

[0036] The same operator 15 can also interact with the control device 10 directly or via a mobile device 16 .

[0037] The filling plant 1 further comprises a storeroom or warehouse 20 in which the packaging material is stored when not in use by the filling machine 6 and / or downstream processing equipment 9. In particular, the packaging material reels 5 are stored grouped into pallets (or similar grouping or storage units) 22, only one of which is shown by way of example in Figure 1.

[0038] According to one aspect of the solution, the inventory management system in the filling plant 1 provides for each pallet 22 to be provided with a first identifier or tag element 24 configured to be detected (read) in a contactless (or wireless) manner and is configured to store first inventory information relating to the pallet 22 and its contents, in particular first inventory information relating to all packaging material reels 5 carried by the same pallet 22.

[0039] The first tag element 24 is physically located on the pallet 22 and coupled to the pallet 22 at any suitable location so that it can be read.

[0040] The first tag element 24 may be passive or active, for example a radio tag or a beacon, in particular an RFID (Radio Frequency Identification) tag having a communication antenna (in a known manner not described in detail here) and a storage unit for storing the first inventory information. According to different embodiments, the first tag element 24 may be an NFC (Near Field Communication) tag, or a BLE (Bluetooth Low Energy), Wi-Fi or UWB (Ultra Wideband) beacon.

[0041] Alternatively, or additionally, the first tag element 24 may include a graphical code (such as a 2D or 3D barcode, a QR code, etc.) and / or an image to convey at least a portion of the first stock information. The same graphical code may be printed or applied to the pallet 22.

[0042] According to one aspect of the solution, the first inventory information stored in the first tag element 24 includes identification information of the pallet 22 (e.g., EAN, European part number, identification code, serial number, or any unique identifier) ​​and further information about each packaging material reel 5 carried by the pallet 22, including one or more of the following: production order, identification (e.g., EAN) code, expiration date, number of packages that can be produced on each packaging material reel 5 (other information and parameters can be included in the first tag element 24, the above list is exemplary).

[0043] According to a further aspect of the solution, the inventory management system of the filling plant 1 further envisages providing, on each packaging material reel 5, a respective second tag element 26 (for clarity, only one of which is shown in Figure 1), which tag element 26 is also configured to be detected (read) in a contactless (or wireless) manner and configured to store second inventory information relating to each packaging material reel 5.

[0044] The second tag element 26 may also be a passive or active type, for example a wireless tag or beacon, in particular an RFID tag, or an NFC tag, or a BLE, Wi-Fi, or UWB beacon, having a communication antenna (which is a known method and will not be described in detail here) and a storage unit for storing the second stock information.

[0045] Alternatively or additionally, the second tag element 26 may include a graphical code and / or image (such as a 2D or 3D barcode, QR code, etc.) to convey at least a portion of the second stock information.

[0046] The second tag element 26 is physically located at any suitable location on the packaging material reel 5 (eg, at its core) so that it is accessible for reading.

[0047] According to one aspect of the solution, the second inventory information stored by the second tag element 26 includes the identification of the packaging material reel 5 (e.g., EAN identification code) and one or more of the following: production order; expiration date; number of packages produced, number of packages discarded or number of packages remaining (i.e., a counter of packages that may still be produced using the particular packaging material reel 5); and an indication of the filling machine 6 that used the packaging material for a packaging operation.

[0048] In particular, the number of packages remaining is a variable counter that is updated based on the actual usage of packaging material reels 5 in the filling plant 1 for packaging operations.

[0049] The identification (eg, EAN) code of the packaging material reel 5 may indicate a particular multi-layer composite packaging material and / or a composite package 2 formed from a particular multi-layer composite packaging material.

[0050] The identification code may indicate one or more of the following: the volume of the final composite package 2 (formed from the multi-layer composite packaging material and filled with the pourable food product); the volume of the pourable food product filled in the final composite package 2; the pourable food product and its characteristics (such as the type of pourable food product); recipe information; details of the multi-layer composite packaging material; a repeating pattern printed on the multi-layer composite packaging material; the type and / or format of the final composite package 2; the name of the producer, contractor or distributor of the composite package 2; an indication as to the target market.

[0051] According to a possible embodiment, the information content of the first tag element 24 can be written / updated automatically as soon as each packaging material reel 5 is placed on the pallet 22. For example, a wireless communication can be performed between the first tag element 24 and the second tag 26, which wireless communication is initiated by their proximity when the packaging material reel 5 is placed in the pallet 22.

[0052] Alternatively, the information content may be written by the intervention of an operator 15, who uses a dedicated function of a portable device (e.g. the same mobile device 16) to scan the second tag element 26 of the packaging material reel 5 contained in the pallet 22, after which the full data is written (as first inventory information) to the first tag element 24 of the same pallet 22.

[0053] In particular, writing / updating the first tag element 24 in the pallet 22 can be performed both at the converting plant (i.e., after the packaging material reel 5 has been assembled and placed on the pallet 22 for shipment to the customer) and at the customer site (i.e., at the filling or packaging plant 1) if the customer wishes to store a different packaging material reel 5 (e.g., a partially used reel) on a particular pallet 22 by resetting / updating the information stored in the "built-in" first tag element 24.

[0054] As shown in FIG. 1 , the filling plant 1 may be arranged, for example, in a warehouse 20 and may include a gate 28 configured to read first inventory information stored in first tag elements 24 of pallets 22 stocked in the same warehouse 20, transmit the read inventory information to the central server 12, and store it in the database 14 (associated with the corresponding filling plant 1), and equipped with a suitable detection unit.

[0055] Additionally or alternatively, the first tag elements 24 of the pallets 22 stocked in the warehouse 20 may be read by the operator 15 using a suitable reading device (e.g., an RFID tag reading device) or using the same portable or mobile device 16 if configured to read the first tag element 24 (e.g., if the first tag element 24 comprises a barcode or a QR code).

[0056] As shown in FIG. 1, in a further aspect of the inventory management system in the filling plant 1, the filling machines 6 have respective detection units 30, such as RFID tag readers, configured to read the second tag elements 26 of the packaging material reels 5 operably connected to the same filling machines 6 during the packaging operation.

[0057] The control device 10 may be configured to set the operating parameters of the same filling machine 6 depending on the identification code of the packaging material reel 5 contained in the second tag element 26 .

[0058] These operating parameters may include one or more of the following: operating parameters of the conveying device, such as the advancement speed of the web 4; operating parameters of the tube forming device; operating parameters of the sealing device, such as the sealing force; operating parameters of the filling device, such as the flow rate; operating parameters of the package forming device, such as the sealing force of the transverse sealing unit, the advancement speed of the operating and counter-acting assemblies, the hit position where the operating and / or counter-acting assemblies begin to contact the tube during use; and operating parameters of the sterilization device.

[0059] Furthermore, due to the fact that the packaging material information is stored in the second tag element 26, an interlock function with the actual filling machine data may be implemented in order to prevent the use of the wrong packaging material reel 5 in the filling machine 6. For example, the use of packaging material that has expired or has characteristics that do not match the product order can be automatically prevented and avoided by the control device 10.

[0060] The control device 10 may be configured to allow the operator 15 to modify one or more of the above operating parameters after automatic setting of the same. In this way, the operator 15 may have the possibility to modify and / or optimize some of the operating parameters. Such modifications may also be possible during the formation and filling of the composite package 2.

[0061] More specifically, at least some or all of the operating parameters may define production conditions for all or at least part of the filling plant 1. Additionally or alternatively, at least some or all of the operating parameters may define quality control protocols for determining and / or controlling the quality of the composite package 2, test plans for in-use evaluation of hygiene information during the formation and filling of the composite package 2, cleaning-in-place protocols, sterilization-in-place protocols.

[0062] Therefore, the operation of the inventory management system at the filling plant 1 involves reading first inventory information stored by the first tag element 24 on the pallet 22 to retrieve information related to packaging materials available at the filling plant 1.

[0063] In particular, the reading of the first tag element 24 on the pallet 22 is performed (automatically by a gate 28 or with the intervention of an operator 15) when the pallet 22 is first received by a customer and introduced into the filling plant 1, e.g. the warehouse 20. Thus, inventory information relating to all packaging material reels 5 contained in the pallet 22 (production order, EAN code, expiration date, number of packages available to be produced, etc.) is retrieved and conveniently transmitted to the central server 12 and stored in the database 14.

[0064] Furthermore, for pallets 22 stored in the warehouse 20, further readings of the first tag elements 24 can be performed periodically to obtain up-to-date information regarding available packaging material, in particular remaining or remaining packaging material reels 5 (i.e. packaging material reels 5 that have only been partially used for past production orders).

[0065] Thus, an operator 15 accessing the central server 12 (e.g., via a software application on a mobile device 16) can monitor available resources and schedule future production and new packaging material supplies. Preferably, when planning or starting a new production, the application may provide the operator 15 with a list of available (new or only partially used) packaging material reels 5 suitable for that production. This ensures that all available packaging material reels 5 are used and avoids material waste. Time- and cost-saving optimization criteria may be implemented by the application to automatically determine and provide the list of packaging material reels 5 to be used to the operator 15.

[0066] Additionally, by accessing the information stored in the database 14 on the central server 12, the converting plant (or producer) can determine whether the pallet 22 was properly loaded, the time of loading, and the correct location at the customer site. Any missteps, such as if a packaging material reel 5 was delivered to the wrong location or if expired packaging material was delivered, can be immediately detected. If the customer only pays attention to the number of packages produced or only good packages (regardless of the number of packaging material reels 5 received and used), this allows the converting plant to verify that the customer received a specific packaging material reel 5 and also tracks potential packaging material waste (partially used and / or unused reels).

[0067] Furthermore, the operation of the inventory management system in the filling plant 1 assumes that the filling machine 6 detects (reads) the second tag element 26 on the currently used packaging material reel 5, automatically records data relating to the filling operation, transmits these data to the central server 12 and stores them in the database 14 in association with the same packaging material reel 5 (the recording of data can be carried out at regular intervals or on specific occasions, for example late at night, after each change in product speed or product quantity, etc.).

[0068] In particular, as shown schematically in FIG. 2, for each packaging material reel 5 identified via the second tag element 26 (either automatically by the filling machine 6 or by intervention of the operator 15), the stored data includes one or more of the scan time, the start and end times of each production run using the particular packaging material reel 5, the production order, the reel number, the total number of packages available in the reel, the number of packages produced, and the number of packages discarded.

[0069] As mentioned above, at the end of reel use (or at any other desired time, e.g., after each packaging material splice), the second tag element 26 of the used packaging material reel 5 is preferably updated, particularly with respect to the number of packages, to reflect the total number of packages produced and discarded (other information may also be updated or written, e.g., the start and end of production as mentioned above, the identifier of the corresponding filling machine 6, etc.).

[0070] In particular, the utilization rate of the packaging material reel 5 can be determined as follows:

[0071] Usage rate = (number of packages produced + number of packages discarded) / target number of packages

[0072] Here, the target number of packages corresponds to the total number of packages that are estimated to be produced from the entire reel.

[0073] In particular, a packaging material reel 5 may be considered "complete" (or fully used / fully utilized) if its utilization is higher than a certain utilization threshold, e.g., 98% or higher. Conversely, a packaging material reel 5 may be considered "partially used" if its utilization falls within a certain utilization range, e.g., between 0.1% and 98%.

[0074] Based on the number of packages remaining on a particular packaging material reel 5, it is also possible to print an updated physical label to be affixed to a partially used reel with an updated number of packages remaining on that particular reel.

[0075] By integrating the second inventory information read from the second tag element 26 attached to each packaging material reel 5 with data regarding filling operations automatically recorded by the filling machine 6, the inventory control system can determine whether a particular reel has been used, in which machine it was used, the date and time the reel was used, the number of packages produced per reel, and the number of packages discarded.

[0076] Note that this information can also be used, for example, during root cause analysis in the event of a lack of sterility in the filled composite package 2. Preferably, reading the second tag element 26 provides the operator 15 with complete and immediate traceability of the packaging operation (even if the central server 12 is offline).

[0077] Furthermore, by integrating the first inventory information read by scanning the first tag elements 24 placed on the pallets 22 of the packaging material reels 5 with information related to the use of all packaging material reels 5, it becomes possible, for example, to: - Understand how many reels in Warehouse 20 are fully used (for example, usage rate is 98% or more); - Know how many reels are partially used (for example, between 0.1% and 98% used); -Know how many reels are still full (unused); -Calculate the inventory time from the date of receipt to the date of use; - Prior to commencing a particular production run, understand whether that particular production is feasible before actual production begins (e.g., based on the number of full and partial reels with the desired identification code that match the production run); - Improve the purchase of new packaging material reels 5 based on production forecasts and actual inventory in warehouse 20.

[0078] Furthermore, the inventory management system may, based on knowledge of the presence of partially used and unused packaging material reels 5, provide notifications / warnings before their expiry date in order to avoid wasting resources. Thanks to this signaling, customers can decide to adjust their production schedules in order to optimize the use of packaging material.

[0079] To avoid the disposal of partial reels, the inventory control system can suggest to the operator 15 that partially used reels with the same identification code or production order as the reel in use are available (to fit the current production / product), and suggest, for example, to reuse the partial reel before using a full reel.

[0080] In this regard, the warehouse 20 may use a long-range reader (e.g., RFID type) possibly built into the mobile device 16 of the operator 15 to determine whether a pallet 22 with a particular identification code is present in order to perform a desired action (e.g., to retrieve a pallet 22 containing a particular packaging material reel 5 with a desired identification and production order, or for inventory purposes).

[0081] All of the above inventory control operations may be performed by software applications running on the central server 12 and / or on the operator's mobile device 16, based on data stored in the database 14. The same inventory control operations may also be performed at an external processing facility (if the central server 12 is located at a customer site, for example).

[0082] In particular, the software application on the mobile device 16 of the operator 15 may provide a suitable user interface for performing inventory management operations, for example, providing information related to fully used packaging material reels 5, partially used packaging material reels 5, and unused packaging material reels 5 in the warehouse 20 (including the number of packages remaining) and suggestions for using particular packaging material reels 5 based on partial usage and expiration dates.

[0083] Additionally or alternatively, the above information and notifications may be provided to the operator 15 through a web-based interface implemented on the central server 12 .

[0084] An operator 15 with a mobile device 16 can also read data directly from the first and second tag elements 24, 26 on the pallet 22 and packaging material reel 5, and the read data is optionally stored and synchronized in a database 14 on the central server 12.

[0085] Figure 3 shows an exemplary report that may be provided to the operator 15 (e.g., via a software application) that is the result of merging the data read from the first and second tag elements 24, 26 with the data recorded by the filling machine 6 during the filling operation.

[0086] The report references a pallet 22 storing a number of packaging material reels 5 and provides identification and usage data for every reel based on actual production data provided by the filling machine 6 .

[0087] Figure 4 shows a further report that may be provided to the operator 15 (e.g. via a software application), as a result of the merging of the data described above, this time relating to a single packaging material reel 5 and reporting all production involving the same reel, specifying, for example, the start and end of production, the identity of the filling machine 2 involved, the number of packages produced and the number of packages discarded.

[0088] With reference to FIG. 5 and taking into account the above, operation of the inventory control system in the filling plant 1 includes one or more of the following steps. a) reading a first tag element 24 on a pallet 22; b) reading the second tag element 26 on the packaging material reel 5; c) receiving operational data from the filling machine 2; d) merging the information read from the first tag element 24 and the second tag element 26 with the operational data received from the filling machine 2; e) Supports inventory management of packaging materials based on merging information.

[0089] In particular, the step of assisting in managing the inventory of packaging materials includes one or more of the following steps: f) Providing information on the number of reels that have been fully used, partially used or not yet used; g) Calculate the inventory time from the date of receipt to the date of use; h) before starting a particular production, indicating the feasibility of that particular production and providing suggestions on the optimal use of the available packaging material reels 5; i) Plan reel purchases of packaging materials based on production forecasts and available inventory.

[0090] The advantages of the described inventory management solution are apparent from the foregoing description.

[0091] In any case, it is emphasized once again that the proposed solution improves inventory management of packaging materials in filling plants, minimizes waste and optimizes production.

[0092] Additionally, improved traceability of the packaging materials used to manufacture the package is provided.

[0093] Furthermore, by using tag elements on the packaging material reels and a corresponding reader on the filling machine, all information related to the packaging material can be automatically recorded, which brings the following benefits: it reduces the operator's workload and allows them to concentrate on other tasks; it prevents operator insertion errors; and it eliminates the risk of missing traceability information because no identification information is inserted.

[0094] However, modifications may be made to what is described herein without departing from the scope of protection defined in the appended claims.

[0095] It is emphasized in particular that the solutions discussed may be applied to any additional materials and / or consumables used to package the product into the composite package 2, such as strips, caps, straws, etc.

[0096] As an example, the second tag element 26 may be applied to strip bobbins used (in a known manner) to seal the composite package 2, in which case the first tag element 24 is applied to a box or similar housing or storage unit of the same strip bobbins.

Claims

1. 1. An inventory management system for a filling plant (1) having at least one filling machine (6) for performing a filling operation to form composite packages (2) from multi-layer composite packaging material and fill the composite packages (2) with a pourable food product, and a warehouse (20) having an inventory of packaging material elements (5) for forming the composite packages (2), the system comprising: a first tag element (24) provided on each storage unit (22) designed to store a plurality of packaging material elements (5), each first tag element (24) including first inventory information relating to the packaging material elements (5) stored in the respective storage unit (22); a second tag element (26) provided on each packaging material element (5), said second tag element (26) containing second inventory information relating to the associated packaging material element (5); a processing arrangement (12, 16) for receiving operational data relating to a filling operation from said at least one filling machine (6), merging said first inventory information and said second inventory information with said operational data, and performing inventory control of said packaging material elements (5); A system comprising:

2. said packaging material elements (5) being reels of packaging material and said storage units (22) being pallets each containing a plurality of said reels of packaging material; The system of claim 1 .

3. the first inventory information stored in the first tag element (24) includes an identification code of the respective storage unit (22) and further information about each packaging element (5) stored by the respective storage unit (22); the information about each packaging element (5) stored by each storage unit (22) includes one or more of a production order, an identification code, an expiration date, and a total number of packages that can be produced; the second inventory information stored in the second tag element (26) includes one or more of the following: an identification of each packaging material element (5), a production order, a best-by date, a counter indicating packages that have been produced, discarded, and / or may still be produced using each packaging material element (5), which counter is variable and updated based on operational data from the filling machine (6), and an indication of the filling machine (6) that has used the packaging material element (5); The system of claim 1 .

4. the processing arrangement (12, 16) comprises a central server (12) having a database (14) for storing the first inventory information, the second inventory information and the operational data, and a mobile device (16) carried by an operator (15) of the filling plant (1), operably coupled to the central server (12), and running an inventory management application for managing an inventory of the packaging material elements (5), The system of claim 1 .

5. The system includes a gate (28) disposed in a warehouse (20) in which the storage unit (22) is placed, the gate (28) including a detection unit that reads the first inventory information stored in the first tag element (24) of the storage unit (22) and transmits the read first inventory information to the central server (12) for storage in the database (14). The system of claim 4.

6. said processing arrangements (12, 16) providing information about which packaging material elements (5) are in stock and their respective usage rates; The system of claim 1 .

7. the processing arrangement (12, 16) provides, for each packaging material element (5), information on which filling machine (6) the packaging material element (5) was used, the date and time of each filling operation, the number of packages produced and the number of packages discarded, based on which the respective usage rate is determined; The system of claim 6.

8. The processing arrangement (12, 16) Number of completely used packaging material elements (5); the number of partially used packaging material elements (5); the number of packaging material elements (5) not yet used and the respective number of remaining packages; the shelf life of the packaging material element (5) from the date of receipt to the date of use; configured to provide at least a portion of The processing arrangement (12, 16) further provides instructions on which packaging material elements (5) to use for a particular production run based on available unused or partially used packaging material elements (5) that match the production run. The system of claim 6.

9. the processing arrangement (12, 16) providing a notification to the operator (15) of the filling plant (1) prior to the expiry date of unused or partially used packaging material elements (5) present in the warehouse (20); The system of claim 6.

10. the filling plant (1) comprising a control device (10) configured to control its operation, the filling machine (6) reading the second tag element (26) on the packaging material element (5) to obtain an identification code indicative of the associated multi-layer composite packaging material and / or the associated composite package (2) and providing the identification code to the control device (10); the control device (10) automatically sets the operating parameters of the filling plant (1) according to the identification code; The system of claim 1 .

11. The control device (10) inhibits the filling operation if the operating parameters associated with the identification code do not match the current production volume. The system of claim 10.

12. the information content in the first tag element (24) is designed to be automatically written or updated when the packaging material element (5) is placed on the respective storage unit (22); The system of claim 1 .

13. the first tag element (24) and the second tag element (26) are RFID tags; The system of claim 1 .

14. A filling plant (1) comprising a system according to claim 1.

15. The filling machine (6) a conveying device for advancing the web (4) of multi-layer composite packaging material along an advancing path; a tube forming device for forming a tube from the web (4) of the multi-layer composite packaging material; a sealing device for longitudinally sealing the tube; a filling device for filling the tube with the pourable food product; a package forming unit for forming the tube and sealing the tube transversely to at least partially form the composite package (2); Equipped with 15. A filling plant according to claim 14.

16. 1. A method for inventory control in a filling plant (1) having at least one filling machine (6) for performing a filling operation to form composite packages (2) from multi-layer composite packaging material and fill said composite packages (2) with a pourable food product, and a warehouse (20) having an inventory of packaging material elements (5) for forming said composite packages (2), the method comprising: reading first tag elements (24) provided on respective storage units (22) storing each of the plurality of packaging material elements (5), each first tag element (24) including first inventory information relating to the packaging material elements (5) stored in said respective storage units (22); reading a second tag element (26) provided on each packaging material element (5), said second tag element (26) containing second inventory information relating to said associated packaging material element (5); receiving operational data relating to a filling operation from at least one filling machine (6); merging the first inventory information and the second inventory information with the operational data to perform inventory control of the packaging material elements (5); The method includes:

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