Automated line for filling and packaging liquid products

Abstract

FIELD: packaging.SUBSTANCE: in an automated line for filling and packaging liquid products the cup filling unit is equipped with a sensor for the presence of cups under the sockets, as well as a mechanism for automatically ejecting cups into containers. The liquid filling unit is equipped with a sensor for the presence of containers under the valves, shafts with 4 perforated blades, and augers mounted in a bearing unit connected to an electric drive via a coupling. The bearing unit is located on the lid, which also has a pipeline mounted in the middle with a valve for controlling the intake of liquid, as well as a liquid level sensor inside the hopper. The cup sealing unit is equipped with a film feed switch, a power switch, film presence sensors, container presence sensors in the unit, and a control panel.EFFECT: increase in the productivity of filling and packaging of liquid products.1 cl, 5 dwg

Description

[0001] The invention relates to automatic filling and packaging equipment and can be used in both the non-food and food industries for bottling and packaging various products, primarily liquid and viscous products, including dairy products such as sour cream, into plastic containers, such as cups, sealed at the end of the production cycle with aluminum foil or film. The invention is applicable to dosing and bottling liquid and viscous food products.

[0002] Currently, food processing companies have a wide variety of containers for bottling and sealing food products. But one of the most cost-effective and simple is the cup, which at the end of the production cycle must be sealed with a plate using a special sealing device.

[0003] Various devices based on this principle are known from the state of the art. Moreover, such installations perform their functions at certain points only with human assistance. For example, a packaging installation for dosing and sealing viscous products and milk in polymer containers is known [Russian Federation Utility Model No. 78769, IPC B65D 23 / 00, published 10.12.2008].], consisting of a frame with a base containing a control unit in the form of a work table, on which a spout, a control panel, a sealing mechanism containing an electromagnet and an iron with a protective casing, a cup magazine, a dies magazine and a rotary disk with an insert are fixed, characterized in that it contains a bactericidal lamp, a rotary disk placed on a support and secured with bolts, and the cup magazine and the dies magazine are fixed on height-adjustable stands with the help of clamps, wherein the control unit, placed on the base of the frame, contains a nipple connected to an impeller pump, which is connected to the spout with the help of a hose and a coupling, and on the body of the sealing mechanism a lock is installed for positioning the pitch of the rotary disk, and on the frame itself a removable table is fixed, the function of which is to accumulate sealed cups.

[0004] The disadvantages of this system include manual control of the sealing mechanism: cups inserted into the rotary disc, after the food liquid has been poured into them, are manually rotated by the operator toward the sealing device. At the same time, the operator places a sealing plate on the cup, and then the product is sealed. At the end of the cycle, the cups are manually removed from the disc. Consequently, a significant amount of time is spent producing a single batch of products, significantly reducing productivity.

[0005] Also known is a line for filling and packaging food products [RU Utility Model No. 63792, IPC B67C 7 / 00, published on 10.06.2007], containing conveyors, feeding and removing containers, and systems for rinsing containers, filling the product into containers and capping containers, interconnected by an endless transport circuit, characterized in that the transport circuit is made of carriages connected to each other in a set with grippers for containers, moving in a first direction of movement in a first technological plane and transported back in a second plane of return movement in a second direction of movement, which is parallel relative to the first direction of movement, wherein the system for rinsing containers is located on the return movement of the transport circuit in the second direction.

[0006] The main disadvantages of this system are the manual loading of containers onto conveyors for subsequent pickup by carriages, as well as the operator's release of containers from the pickups at the end of the production cycle for further packaging and transportation. Consequently, the production of a single batch of products takes a significant amount of time, significantly reducing productivity.

[0007] The closest in technical essence and achieved result is the line for filling and packaging of liquid products described in the article by Smus A.A., Galkina A.A., Shandybin I.M., Kukhtik M.P. "Development of a line for filling and packaging of liquid products with automatic container feeding" (Bulletin of the Volgograd State Technical University, 2024, No. 8 (291), pp. 66-69), the design of the proposed automated line for filling and packaging of liquid products includes four main units located on a conveyor belt: a container feeding unit, a cup filling unit, a liquid product filling unit, and an automatic cup sealing unit. A distinctive feature of this line from its analogue is a change in the sequence of the working cycle. Instead of the cup packing unit, which was in last place, a container feeding unit, located in first place, is added.

[0008] The most significant drawbacks of this design are the lack of a lid on top of the liquid filling hopper, a continuous liquid supply system, and electric drives with shafts and paddles for mixing the liquid. This line also lacks a release mechanism in the filling unit and container presence sensors under the valves. The sealing unit also lacks film feed switches, power switches, film presence sensors, container presence sensors, and a control panel.

[0009] The objective of the development of the claimed invention is to completely eliminate manual labor, as well as to increase the productivity of filling and packaging of liquid products.

[0010] The technical result of the claimed automated line for filling and packaging liquid products is an increase in the productivity of filling and packaging liquid products.

[0011] The technical result is achieved in that the automated line for filling and packaging liquid products, consisting of units for feeding containers, filling cups, pouring liquid products and sealing cups, successively located on a conveyor belt, wherein the container feeding unit, made in the form of a rectangular box with openings for cups, is a vertical tray with a pair of tongs and a pusher located in its lower part, equipped with sensors for the presence of containers in the tongs and the presence of containers on the conveyor belt; the cup filling unit is made in the form of a metal body with nests for cups and augers; the liquid product filling unit is made in the form of a hopper with pouring valves;the cup sealing unit is made in the form of a metal housing, a press built into it with heating elements, film feed shafts and a guide lock, a stand for used film, a guide and a film feed switch, wherein the cup filling unit is equipped with a sensor for the presence of cups under the sockets, as well as a mechanism for automatically dumping cups into a container; the liquid product filling unit is equipped with a sensor for the presence of containers under the valves, shafts with 4 blades provided with perforation, and augers installed in a bearing unit connected to an electric drive through a coupling, the bearing unit is located on the cover, into which a pipeline with a valve for controlling the intake of liquid is also built in the middle, as well as a liquid level sensor inside the hopper; the cup sealing unit is equipped with a film feed switch, a power switch, film presence sensors, container presence sensors in the unit, and a control panel.

[0012] Equipping the cup filling unit with a sensor for detecting the presence of cups under the slots, as well as a mechanism for automatically ejecting cups into containers, improves the reliability and accuracy of cup positioning relative to container openings, eliminates the possibility of missed cup placement (underfilling due to a lack of containers), and ensures full automation of the filling process, which reduces production cycle time and the proportion of manual labor.

[0013] The liquid filling unit is equipped with a container presence sensor under the liquid valves, eliminating the possibility of product dispensing if the cup is missing or misaligned. This prevents product spillage onto the conveyor mechanisms and into the tray, and ensures that each dose is dispensed precisely into the intended container.

[0014] The liquid filling unit, equipped with four-blade perforated shafts and augers, generates greater shear force and captures larger product volumes than standard two-blade mixers. This allows for the efficient pumping and dosing of viscous products (sour cream, pastes, creams).

[0015] Equipping a liquid filling unit with a bearing assembly on the lid and a pipeline with a valve for controlling the liquid intake allows for the automation of the filling process of the supply container, eliminating its overflow or dry operation, and also reduces the impact of the jet on the walls or the already poured product, reducing foaming.

[0016] Equipping the liquid filling unit with a liquid level sensor inside the hopper allows for the automation of the hopper filling process, eliminating the need for constant operator monitoring, and promptly signals the need to replenish the product stock in the storage tank, also preventing its overfilling or emptying, which ensures the protection of the drive and dosing elements from running without product.

[0017] Equipping the cup sealing unit with film presence sensors prevents line shutdowns due to unexpected consumable runout, alerting the operator to the need to replace the roll. Equipping the cup sealing unit with a container presence sensor prevents the hot press from lowering without a container, protecting the equipment from premature wear. Equipping the cup sealing unit with a control panel allows for monitoring the heating element temperature, holding time, and adjusting sealing modes for different film types.

[0018] Fig. 1 shows a general view of an automated line for filling and packaging liquid products, in Fig. 2. - a container feeding unit; in Fig. 3. - a cup filling unit; in Fig. 4. - a liquid product bottling unit; in Fig. 5. - a cup sealing unit.

[0019] The automated line for filling and packaging liquid products consists of four sequentially located units on a conveyor belt: a container feeding unit, a cup filling unit, a liquid product bottling unit, and a cup sealing unit.

[0020] The container feeding unit 1 (which is a box), shown in Fig. 2, is a structure consisting of a vertical tray 2 with a through hole 3, tongs 4 located inside the tray 2, which hold the container 1 from falling to the bottom 5 of the tray 2, a control device 6 and pushers 7. The structure is also equipped with a sensor 8 for the presence of the container 1 on the conveyor belt 9 and a sensor 10 for the presence of the container 1 in the tongs 4.

[0021] The cup filling unit shown in Fig. 3 comprises an auger 11 and cup sockets 13 located on a metal frame 12. Also installed on the filling unit is a sensor 14 for the presence of empty containers 1 under the sockets 13, mounted in the metal frame 12, and a mechanism 15 for automatically ejecting cups into the container 1.

[0022] The liquid product filling unit shown in Fig. 4 is a structure consisting of a metal bin body 16, a sensor 17 for the presence of containers 1 mounted in it under drain valves 18, shafts 22 with blades 23 provided with perforations and augers 24 connected through a coupling 20 to an electric drive 21. The bin 16 is closed at the top by a lid 25, on which the bearing unit 19 and the electric drive 21 are fixed. The bin 16 is a funnel-shaped container, in the lower part of which a bushing 26 is fixed, having longitudinal protrusions on the inner cylindrical surface. That part of shaft 22, where blades 23 are fixed, is located in hopper 16, and auger 24 is located in the cavity of sleeve 26. The lower end of sleeve 26 is provided with drain valves 18, which, with the help of springs 27, supported on flange 28, through rods 29 with their plate 30, block the outlet of liquid from hopper 16.The labyrinth in the loading unit is formed by the shell 31 and ring 32 of the loading hatch of hopper 16. The labyrinth of the unloading unit is formed by the cap 33 and ring 34 of the mixer hatch. Valve 36 is installed on pipeline 35 to control the liquid intake into hopper 16. The dispenser is equipped with a sensor 17 for the presence of container 1 under valves 18 and a sensor 37 for the liquid level inside hopper 16.

[0023] The cup sealing unit shown in Fig. 5 comprises a stand 38 for used film 39, a device for feeding 40 film 39, a control panel 41, a power switch 42, a sensor 43 for the presence of film 39, a sensor 44 for the presence of container 1 in the unit, a feed shaft 45 for film 39, a fixation shaft 46 for the guide, a feed roller 47 for film 39, guides 48, a stand 49, a press with heating elements 50.

[0024] The automated liquid product filling and packaging line operates as follows.

[0025] As an example of the operation of an automated line for filling and packaging liquid products, let us consider an automated line for filling and packaging sour cream in containers 1.

[0026] Container 1 (box) with four openings drops from container feed unit 1 onto the conveyor belt via pushers 7, which detects container 1 presence sensor 9 on conveyor belt 10 and begins moving toward the filling unit. Using augers 11 and automatic ejection mechanism 15, two cups, followed by two more cups, are lowered into the slots of container 1; container 1 presence sensor 14 beneath slots 13 detects their presence, after which container 1 with empty cups moves toward the filling unit.

[0027] Upon reaching a certain position beneath drain valves 18, as detected by container presence sensor 17 beneath valves 18, the filling unit's operating cycle begins. Sour cream flows through pipeline 35 into hopper 16, where the level is detected by liquid presence sensor 37. Valve 36 then closes, and the mixing stage begins for subsequent extrusion into container 1. Because sour cream has a viscosity different from that of milk and other liquid products, the installation of four blades 23 on shafts 22 within filling unit 4, as well as the perforation of these blades 23, facilitates more uniform and intensive mixing.

[0028] Next, the product is extruded through drain valves 18 into cups, and the full container 1 moves to the sealing unit. Here, container 1 presence sensor 44 in the unit sends data to the main programmable logic controller (not shown in the figures), after which film 39 begins to wind onto film feed roller 45, the press with heating element 50 is lowered, the product is sealed with film 39, and the entire production cycle is completed.

[0029] Thus, equipping the cup filling unit with a sensor 14 for the presence of containers 1 under the sockets 4 and a mechanism for automatically dumping cups 15 into containers 1; equipping the liquid product filling unit with a sensor 17 for the presence of containers 1 under valves 18 installed in the bearing unit 19 and connected through a coupling 15 with an electric drive 10, shafts 22 with four perforated blades 23 and augers 24, as well as a pipeline 35 with a valve 36 for controlling the intake of liquid, mounted in the central part of the cover 25 of the hopper 16; equipping the cup sealing unit with a device 40 for feeding film 39 and a power switch 42, sensors 43 for the presence of film 39, sensors 44 for the presence of containers 1 in the unit and a control panel 41 - makes it possible to: automate the process of positioning and dropping cups, eliminating the possibility of their deformation or missing the installation;ensure forced and uniform mixing of both low-viscosity and high-viscosity products immediately before dosing, preventing their stratification and guaranteeing the stability of the medium density; synchronize the filling cycle with the movement of the conveyor by accurately determining the presence of containers 1 under the drain valves 18, eliminating product spillage and idle operation of the dispenser; stabilize the liquid level in the hopper 16 due to the central location of the inlet pipeline 35, which eliminates foaming and hydraulic hammer; prevent unplanned line stops by monitoring the presence of consumables (film 39) and adjusting the sealing modes in real time from the control panel 41, which overall ensures an increase in the productivity of filling and packaging of liquid products by reducing downtime, minimizing process defects, reducing the share of manual labor and ensuring cycle stability at all stages of the process line.

Claims

An automated line for filling and packaging liquid products, consisting of units for feeding containers, filling cups, bottling liquid products, and sealing cups, sequentially located on a conveyor belt, wherein the container feeding unit, made in the form of a rectangular box with openings for cups, is a vertical tray with a pair of tongs and a pusher located in its lower part, equipped with sensors for the presence of containers in the tongs and the presence of containers on the conveyor belt; the cup filling unit is made in the form of a metal body with nests for cups and augers; the liquid product bottling unit is made in the form of a hopper with pouring valves; the cup sealing unit is made in the form of a metal body, a press with heating elements, film feed shafts and a guide lock, a stand for used film, a guide and a film feed switch built into it;characterized in that the cup filling unit is equipped with a sensor for the presence of containers under the sockets, as well as a mechanism for automatically dropping cups into containers; the unit for filling liquid products is equipped with a sensor for the presence of containers under the valves, shafts with 4 blades equipped with perforations, and augers installed in a bearing unit connected to an electric drive through a coupling, the bearing unit is located on the lid, into which a pipeline with a valve for controlling the intake of liquid is also mounted in the middle; the cup sealing unit is equipped with a film feed device, a power switch, film presence sensors, container presence sensors in the unit, and a control panel.

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