Method for identifying a residue from a previously processed product batch in a product packaging line, related system and cleaning method

Abstract

A method for identifying a residue from a batch of product previously processed in a machine for a product packaging line (100) comprises the following steps: a) providing a product packaging line (100) comprising one or more machines (1, 2, 3, 4) equipped with cameras installed on camera supports (22, 23, 24, 25, 26, 27, 28, 29, 29', 29' ') inside a machine protection casing (210, 310, 410), for detecting residues of a batch of product previously processed in the product packaging line (100); b) acquiring visual information associated with the inspection area (220, 230, 280), provided by at least one of the cameras; c) determining, by means of a control unit (20), from the visual information acquired, the presence or absence of residues in the inspection area (220, 230, 280); d) once the presence of residues in the inspection area (220, 230, 280) has been determined by the control unit (20), determining, in the control unit (20), a detected residue signal. A method for cleaning a product packaging line (100) comprises the steps of the identification method and the step of removing any product residues detected. A system for identifying a residue from a batch of product previously processed comprises at least two machines (1, 2, 3, 4), cameras installed inside the machines (1, 2) and a control unit (20) connected to the cameras, configured to determine, from the visual information acquired by the cameras, the presence or absence of residues in each inspection area (220, 230, 280).

Description

METHOD FOR IDENTIFYING A RESIDUE FROM A PREVIOUSLYPROCESSED PRODUCT BATCH IN A PRODUCT PACKAGING LINE, RELATED SYSTEM AND CLEANING METHOD" DESCRIPTIONField of application

[0001] The present invention falls within the field of automation systems , in machines , or sets of machines , or production lines , which may include feeding, inspection, filling, packaging, labelling systems as well as other related functions , globally identifiable as machines for product packaging lines , for example specifically designed for the pharmaceutical and cosmetic fields .

[0002] In particular, the present invention relates to a method and a system for identifying a residue from a batch of product previously processed in a machine for a product packaging line using cameras and / or sensors and / or vision systems . Furthermore, the present invention also relates to a method and a system for cleaning a product packaging line from possible residues of a batch of product previously processed .State of the art

[0003] Automation systems in product packaging lines involve the use of various machines and technologies to optimise the packaging process . These systems typicallyinclude labelling machines , case packers and cartoners , which work together to package products efficiently . Cameras , sensors and vision systems are often integrated into these machines to monitor and control the packaging process , especially for quality checks . The applications of these systems extend to fields such as pharmaceuticals , cosmetics and consumer goods, wherein precise and reliable packaging is crucial .

[0004] In the product packaging lines of the above- mentioned fields , the primary objective is to ensure that the products are packaged correctly and efficiently, minimising errors and maximising productivity . This involves several key tasks , including applying labels , inserting products into cartons and sealing cartons for shipment . Automation systems aim to reduce human intervention, improve the accuracy of these tasks and maintain high quality control standards . In addition, these systems seek to improve the overall efficiency of the packaging process , reducing downtime and operating costs .

[0005] A significant challenge in achieving these objectives is the transition between different product batches . During this transition, residues from the previous batch, such as labels , bottles , cartons and leaflets , may remain in the packaging line . Theseresidues can lead to product mix-ups , contamination and other quality-control issues and / or interruptions . Ensuring that the packaging line is free of such residues before starting a new batch is essential to maintaining product integrity, compliance with industry standards and preventing waste of products or even entire production batches .

[0006] It is known from the prior art that manual verification methods are commonly used to check for the presence of residues in the packaging line during batch transitions . At the end of the production of a batch of products , operators typically follow a standard procedure, inspecting critical points on the machines and clearing the machine regions if a residue is detected by visual inspection .

[0007] However, these manual methods are timeconsuming, subject to human error, and may not provide the level of accuracy and reliability required for high- volume production environments .

[0008] There is therefore the need for an automated system capable of efficiently and accurately verifying the presence of residues in the packaging line during production batch transitions . Such a system would reduce reliance on visual inspections performed by an operator, minimise the risk of human error and improve the overallefficiency and reliability of the packaging process .

[0009] In summary, therefore, in a product packaging line, the transition from one batch of a product to another batch or to a different product presents significant challenges . Residues from the packaging process of the previous batch may remain, leading to potential product mix-ups and contamination . For example, labels may remain in the product feeding system of the labelling machine, a bottle may remain in the bottle transport system, cartons may remain in the carton feeding device, leaflets may be near the carton transport device during processing, and cartons may remain in the feeding device of filled cartons destined for the cartoner .

[0010] Therefore, there is a strong need to ensure that the packaging line is free of such residues before starting a new batch .Summary of the invention

[0011] One of the aims of the present invention is to overcome the above-mentioned limitations and to provide a method for identifying a residue from a batch of product previously processed in a machine for a product packaging line, and a related system capable of efficiently and accurately verifying the presence of residues in the packaging line during batch transitions ,reducing dependence on manual inspections and minimising the risk of human errors .

[0012] This aim is achieved by a method for identifying a residue from a batch of product previously processed in a machine for a product packaging line, by a related residue identification system and by a method for cleaning a product packaging line, in accordance with the attached independent claims . The dependent claims describe advantageous embodiments .

[0013] According to one aspect of the present invention, a method for identifying a residue from a batch of product previously processed in a machine for a product packaging line comprises the following steps :

[0014] a) providing a product packaging line comprising one or more machines equipped with cameras installed on camera supports inside the casing of said one or more machines of the product packaging line, for detecting residues of a batch of product previously processed in the product packaging line in a predefined inspection area of said one or more machines ;

[0015] b) acquiring visual information associated with the inspection area provided by at least one of the cameras ;

[0016] c) determining, by means of a control unit , from the visual information acquired, the presence orabsence of residues in the inspection area ;

[0017] d) once the presence of residues in the inspection area has been determined by the control unit , determining, in the control unit , a detected residue signal .

[0018] According to another aspect , the method for identifying a residue, during the step of acquiring the visual information by means of the cameras , provides for communicating with an electronic processing unit of said one or more machines to instruct said one or more machines to carry out specific movements of the machine parts in order to verify that the machine ( s ) is / are free of residues .

[0019] According to a further aspect , the method for identifying a residue comprises carrying out the step of communicating with the electronic processing unit to instruct the machine ( s ) to carry out specific movements of the parts of the packaging machine ( s ) , with at least one of the doors of the machine protection casing open .

[0020] According to another aspect , the method for identifying a residue provides for stopping the machine ( s ) if the presence of at least one residue is detected by the control unit in the inspection area .

[0021] According to a further aspect , the method for identifying a residue comprises displaying a visualindication on a display of the machine ( s ) if a residue from the previous batch is detected by the control unit .

[0022] According to another aspect , the method for identifying a residue comprises preventing the operation of the machine ( s ) and keeping it prevented until a predefined latency time has elapsed after the control unit determines that there are no residues in the inspection area .

[0023] According to a further aspect , the method for identifying a residue comprises , once the stoppage of the machine ( s ) is determined, iteratively carrying out the steps of acquiring the visual information, determining the presence or absence of residues , and determining a detected residue signal ; and further keeping the operation of the machine ( s ) prevented until a predefined latency time has elapsed, which starts after the control unit determines the fulfilment of a set of conditions , which include at least that there are no residues in the predefined area or that a human or robotic operator sends a signal to the control unit that the predefined area is clean .

[0024] According to another aspect , the step of determining the presence of residues in the inspection area comprises the following operations :

[0025] - storing information on the position of atleast one camera in a storage unit ( 20 ' ) of the control unit ( 20 ) ;

[0026] - by means of the control unit ( 20 ) , comparing previously acquired visual information of the at least one camera when the machine is clean with current visual information of the machine, acquired by the at least one camera .

[0027] According to another aspect , the method for identifying a residue comprises the step of acquiring the visual information with one or more machines , preferably all the machines , in a state other than their normal operating state, for example in a maintenance state or in a cleaning state .

[0028] According to another aspect , the method for cleaning a product packaging line from possible residues of a batch of product previously processed in a product packaging line comprises the steps of the method for identifying a residue according to any of the embodiments described in this document , wherein, prior to step b) , the step of discharging and removing all products of the preceding production batch is carried out , and wherein the step of removing any product residues detected in step c) is also provided, so as to clean the machines of the product packaging line .

[0029] According to a further aspect , a system foridentifying a residue from a batch of product previously processed in a product packaging line composed of one or more machines comprises at least two machines arranged so that a second machine of said machines receives products output from a first machine, wherein at least one or each of said machines comprises one or more respective inspection areas ; furthermore, the system comprises cameras installed inside at least one or each machine, wherein each of said cameras is configured to acquire visual information associated with one of said one or more inspection areas ; furthermore, a control unit is connected to the cameras and is configured to determine, from the visual information acquired, the presence or absence of residues in each inspection area and, once the presence of residues is determined, the control unit is configured to determine a detected residue signal .

[0030] According to another aspect, the at least two machines comprise a labelling machine and a case packer .

[0031] According to another aspect, the at least two machines comprise a case packer and a cartoner .

[0032] According to a further aspect , the system further comprises a visual indicator connected to the control unit , wherein said visual indicator is configured to provide certain information to a user, andwherein said certain information comprises one or more of the following information : an instantaneous result of the detection of the presence of residues carried out by the control unit in each inspection area; a current state of each camera installed in the machine ( s ) based on the instantaneous result of the detection of the presence of residues carried out by the control unit .

[0033] According to another aspect , a computer product comprises computer program code configured to perform the method for identifying a residue in accordance with any of the embodiments described in this document , when said program code is executed on a computer, a digital signal processor, a field gate array, an application-specific integrated circuit , a microprocessor, a microcontroller or any other form of programmable hardware .Description of the drawings

[0034] The characteristics and advantages of the method for identifying a residue from a batch of product previously processed in a machine for a product packaging line, of the method for cleaning a product packaging line and of the system for identifying a residue according to the present invention will nevertheless become apparent from the description provided below of some preferred embodiments , given by way of example andnot limitation, with reference to the attached figures , in which :Figure 1 shows a schematic diagram of a product packaging line equipped with a system for identifying a residue, in accordance with an embodiment of the present invention, in particular in which a loading station, a labelling machine, a case packer and a cartoner are present ;Figure 2 shows a labelling machine equipped with cameras for the identification of a residue, in accordance with an embodiment of the present invention, in which, for greater clarity, the machine protection casing has been partially removed fictitiously;Figure 3 shows the labelling machine of figure 1 in which the casing is visible, but some internal components of the machine have been fictitiously removed so that the positions of the camera supports that hold the cameras are more clearly visible .Figure 4 shows the labelling machine of figure 3 in which the doors of the machine protection casing are visible in the open position for inspection;Figure 5 shows a case packer equipped with cameras for the identification of a residue, in accordance with an embodiment of the present invention, in which the casing is visible, but some internal components of themachine have been fictitiously removed so that the positions of the camera supports that hold the cameras are more clearly visible ;Figure 5a shows the case packer of figure 5 in which the doors of the machine protection casing are visible in the open position for inspection;Figure 6 shows a cartoner equipped with cameras for the identification of a residue, in accordance with an embodiment of the present invention, in which the casing is visible, but some internal components of the machine have been fictitiously removed so that the positions of the camera supports that hold the cameras are more clearly visible ;Figure 6a shows the cartoner of figure 6 in which the doors of the machine protection casing are visible in the open position for inspection .Detailed description

[0035] Although the present invention is described below with reference to preferred embodiments illustrated in the accompanying drawings , the present invention is not limited to the embodiments described below and shown in the drawings . On the contrary, the embodiments described and illustrated clarify certain aspects of the present invention .

[0036] With reference to the above-mentioned figuresreference number 10 overall designates a system for identifying a residue from a batch of product previously processed in a product packaging line 100. Such product packaging line 100 may be implemented with a variety of machines, in particular packaging machines, such as loading stations 1, labelling machines 2, case packers 3, cartoners 4, each equipped with cameras installed on camera supports 22, 23, 24, 25, 26, 27, 28, 29, 29', 29' ' inside the machine protection casing 210, 310, 410. These cameras are strategically positioned to cover predefined inspection areas 220, 230, 280 wherein residues of a previous product batch are likely to remain, that is, a batch of product previously processed in the same line with respect to the batch of product that is to be processed immediately afterwards.

[0037] It is clear that the term "residue" or "residues" refers to at least a portion of a product from the batch previously processed with respect to the batch that is to be processed in a subsequent step, after completing the method for identifying a residue according to the present invention, which therefore allows cleaning of the line.

[0038] For example, a residue may be a label, or a bottle, or a carton, or a leaflet, or a part of each of these .

[0039] According to further examples , the expression "residue of a batch of product previously processed" may therefore refer to a discrete and macroscopic element , a component of the finished product or of its packaging, which has improperly remained inside the machine .

[0040] In accordance with one embodiment , such definition of residue therefore excludes microscopic contamination, powders , or liquid / chemical residues deriving from the product contents . The present invention is preferably directed to avoiding the risk of cross-contamination by physical components (mix-up) , i . e . , that a component of a batch "A" (e . g . , a label or a leaflet ) ends up in the packaging of a batch "B" .

[0041] Preferably, the cameras may be of different types , including high-resolution digital cameras , infrared cameras or 3D vision systems , depending on the specific requirements of the inspection task .

[0042] According to one embodiment , a control unit 20 processes the visual information acquired by the cameras and may be configured with advanced image-processing algorithms to accurately detect residues , for example with machine learning algorithms .

[0043] Preferably, the control unit 20 is a computer . Preferably, the control unit 20 is a computer located remotely with respect to the machines 1 , 2 , 3 , 4 butcapable of communicating with each machine 1, 2, 3, 4, for example by communicating with a respective electronic processing unit 50 of each machine 1, 2, 3, 4.

[0044] In accordance with one embodiment, the control unit 20 is associated with a respective machine of the machines 1, 2, 3, 4 or is integrated into the electronic processing unit 50 of each machine 1, 2, 3, 4. In other words, each machine comprises a respective control unit 20.

[0045] In one embodiment, the system may include additional sensors, such as ultrasonic or laser sensors, to supplement visual inspection and improve the accuracy of residue detection.

[0046] Preferably, the control unit 20 is programmed to communicate with the electronic processing units 50 of the machines 1, 2, 3, 4, instructing them to perform specific movements, such as rotation, tilting, or vibration of certain parts, to ensure a complete inspection of all potential residue areas. This dynamic interaction may be further enhanced by incorporating machine-learning algorithms that allow the system to adapt to different types of products and packaging configurations, improving efficiency and reliability over time.

[0047] According to one embodiment , the control unit 20 is configured to acquire visual information from one or more cameras when the machine ( s ) are completely clean . Such visual information is then stored in a storage unit 20 ' of the control unit so that the visual information can be compared by the control unit with current visual information from the cameras during the residue identification operation or the line-cleaning operation .

[0048] Moreover, in accordance with one embodiment , the system is designed to operate in various states , such as maintenance states or cleaning states or a state between two different product-packaging batches , and is preferably designed not to operate during the normal operation of the packaging line, that is , for example during the normal packaging process of products , for instance during carton filling or product labelling . The same applies to the method for identifying a residue or for the line-cleaning method .

[0049] Preferably, one or more of the machines 1 , 2 , 3 , 4 comprise one or more visual indicators 51 , 52 connected to the control unit 20 , which are configured to provide real-time feedback to human or robotic operators , ensuring prompt action when residues are detected .

[0050] Making now specific reference to figure 1 , theproduct packaging line 100 includes a loading station 1, a labelling machine 2, a case packer 3 and a cartoner 4. Each of these machines is equipped with cameras installed on camera supports 22, 23, 24, 25, 26, 27, 28, 29, 29', 29' ', 32, 42 inside the casing 210, 310, 410 of at least one of the machines 1, 2, 3, 4 to detect residues of a previous product batch in the product packaging line 100 in a predefined inspection area 220, 230, 280, 320, 420 of the machine.

[0051] The loading station 1 serves as the initial point in the product packaging line 100. Products are introduced into the product packaging line 100 at this station. The loading station 1 ensures that the products are correctly positioned and oriented for subsequent processing by the labelling machine 2. The loading station 1 interacts with the labelling machine 2 by feeding the products into the labelling machine 2, ensuring a continuous flow of items for labelling. The labelling machine 2 applies self-adhesive labels to the products, such as labels on bottles, vials, containers made of glass, plastic or metal, of various shapes and sizes, preferably related to pharmaceutical products.

[0052] Preferably, the labelling machine 2 is equipped with self-learning systems and onboard data storage for the labels, improving flexibility andintegration with robotic systems . The labelling machine 2 is equipped with cameras installed on camera supports 22 , 23 , 24 , 25 , 26, 27 , 28 , 29, 29 ' , 29 ' ' inside the casing 210 to detect residues of a previous product batch in the product packaging line 100 in a predefined inspection area 220 , 230 , 280 of the machine . The cameras acquire visual information associated with the inspection area 220 , 230 , 280 , which is then processed by the control unit 20 to determine the presence or absence of residues . The labelling machine 2 preferably also comprises a machine protection casing 210 with a first door of the casing 211 and a second door of the casing 212 , which may be opened during the inspection process . Therefore, with the casing door open, the machine is not in its normal operating state, but in a state specifically intended for line cleaning or maintenance, to facilitate the acquisition of visual information or to operate specific parts or robots of the machine .

[0053] The case packer 3 is designed to insert one or more products , together with the leaflet , into a carton . The case packer 3 may operate in continuous or intermittent mode, wherein the conveyor belt moves without interruption or with a series of advance-and- stop phases to ensure correct positioning of the itemsinside the carton .

[0054] The case packer 3 receives products from the labelling machine 2 , for example pharmaceutical bottles , and inserts them into the cartons . The case packer 3 is equipped with cameras installed on camera supports 32 inside the casing 310 to detect residues of a previous product batch in the product packaging line 100 in a predefined inspection area 320 of the machine . The cameras acquire visual information associated with the predefined inspection area 320 , which is then processed by the control unit 20 to determine the presence or absence of residues .

[0055] The case packer 3 preferably also comprises a machine protection casing 310 with a first door of the casing 311 and a second door of the casing 312 , which may be opened during the inspection process . Therefore, with the casing door open, the machine is not in its normal operating state, but in a state specifically intended for line cleaning or maintenance, to facilitate the acquisition of visual information or to operate specific parts or robots of the machine .

[0056] Preferably moreover, the case packer 3 also includes a fourth door of the casing 313 and a fifth door of the casing 314 , which may be opened during the inspection process , that is , during the execution of themethod for identifying the residue of the previously processed batch .

[0057] The case packer 3 includes various subcomponents , such as the bottle transport screw ( screw conveyor) 31 , the carton feeding device 34 and the carton transport device 33 . Residues from previous batches may remain in these components .

[0058] The cartoner 4 is designed to receive single or grouped products on a f illed-carton feeding device 41 ( for example an infeed conveyor) , to group them, insert them into a carton taken from a magazine and formed inside the machine, seal it with non-overwrapping adhesive tape and discharge the closed carton . The cartoner 4 is equipped with cameras installed on camera supports 42 inside the casing 410 to detect residues of a previous product batch in the product packaging line 100 in a predefined inspection area 420 of the machine . The cameras acquire visual information associated with the predefined inspection area 420 , which is then processed by the control unit 20 to determine the presence or absence of residues . The f illed-carton feeding device 41 is responsible for feeding the filled cartons to the cartoner 4 for final sealing and discharge .

[0059] The cartoner 4 preferably also comprises amachine protection casing 410 with a first door of the casing 411 and a second door of the casing 412 , which may be opened during the inspection process . Therefore, with the casing door open, the machine is not in its normal operating state, but in a state specifically intended for line cleaning or maintenance, to facilitate the acquisition of visual information or to operate specific parts or robots of the machine .

[0060] Furthermore, preferably, the cartoner 4 also includes a fourth door of the casing 413 and a fifth door of the casing 414 , which may be opened during the inspection process , that is , during the execution of the method for identifying the residue of the previously processed batch .

[0061] The control unit 20 plays an important role in the system for identifying a residue from a batch of product previously processed in a product packaging line . The control unit 20 is connected directly to the cameras or indirectly through each electronic processing unit 50 of the machines 1 , 2 , 3 , 4 and is configured to determine, from the visual information acquired, the presence or absence of residues in each inspection area 220 , 230 , 280 , 320 , 420 .

[0062] Once the presence of residues is determined, the control unit 20 determines a detected residue signal .The control unit 20 may communicate with an electronic processing unit 50 of at least one of the machines 1, 2, 3, 4 to instruct the machine to perform specific movements of the parts of the machine 1, 2, 3, 4, to verify that the machine 1, 2, 3, 4 is clean, that is, free of residues, while simultaneously acquiring visual information from the cameras. The control unit 20 may also stop the machine if the presence of at least one residue is detected in the inspection area 220, 230, 280, 320, 420, and display a visual indication on the machine's display if a residue of the previous batch is detected .

[0063] In accordance with one embodiment, the control unit 20 prevents the operation of the machine 1, 2, 3, 4 and keeps the operation prevented until a latency time has elapsed after determining that there are no residues in the inspection area 220, 230, 280.

[0064] For example, the control unit 20 iteratively performs the steps for verifying the cleanliness of the machine and keeps the operation of the machine prevented until a latency time has elapsed, which starts after determining the fulfilment of a set of conditions, which include at least that there are no residues in the predefined area or that a human or robotic operator sends a signal to the control unit 20 that the predefined areais clean .

[0065] In accordance with one embodiment , the control unit 20 stores information on the position of at least one camera in a storage unit 20 ' and compares the visual information acquired in order to determine, for each pixel, whether it belongs to a defined field of view for at least one camera and to which inspection area it belongs . Preferably, the electronic control unit 20 , based on a reference image of the defined field of view for at least one camera and stored position information, determines whether a residue is present in current visual information by processing said position information and said reference image .

[0066] In accordance with one embodiment , the system for identifying a residue from a batch of product previously processed in a product packaging line 100 is composed of machines 1 , 2 , 3 , 4 , including at least two machines 1 , 2 arranged so that a second machine of said machines 1 , 2 , 3 , 4 receives product s output from a first machine .

[0067] In accordance with one embodiment , the at least two machines comprise a labelling machine 2 and a case packer 3 .

[0068] In accordance with one embodiment , the at least two machines comprise a case packer 3 and acartoner 4 .

[0069] Preferably, the system for identifying a residue from a batch of product previously processed is composed, in order, of a loading station 1 , a labelling machine 2 , a case packer 3 and a cartoner 4 .

[0070] As mentioned, the control unit 20 is connected to the cameras and is configured to determine, from the visual information acquired, the presence or absence of residues in each inspection area 220 , 230 , 280 and, once the presence of residues is determined, to determine a detected residue signal .

[0071] According to one aspect of the present invention, a cleaning system comprises a system for identifying a residue from a batch of product previously processed and a system for removing the detected residue .

[0072] According to one embodiment , the labelling machine 2 comprises a product feeding drum 21 . During step b) of the method according to the present invention ( i . e . during the step of acquiring visual information associated with the inspection area, provided by at least one of the cameras ) the product feeding drum is rotated by at least 360 ° and preferably stopped, to ensure that no residues remain inside each housing of the drum .

[0073] In accordance with the present invention, a computer product comprises computer program codeconfigured to perform the method for identifying a residue from a batch of product previously processed in a machine for a product packaging line 100 as described in one of the preferred embodiments of the present description, when said program code is executed on a computer, a digital signal processor, a field gate array, an application-specific integrated circuit , a microprocessor, a microcontroller or any other form of programmable hardware .

[0074] It should be noted that , with regard to the computer product , the steps of the method that involve physical actions of supplying hardware ( such as the step of providing a line ) are intended as steps of configuring the control system to receive data from such pre-existing hardware, whereas the operational steps (acquisition, determination, movement control ) are carried out directly by the code of the computer product .

[0075] Innovatively, by equipping the machines with cameras installed on camera supports inside the machine protection casing, the system can detect residues of a previous product batch in predefined inspection areas . This arrangement ensures that the cameras have a clear and unobstructed view of the critical areas where residues are likely to remain, thus improving the accuracy of residue detection .

[0076] Acquiring visual information associated with the inspection area provided by the cameras enables realtime monitoring and analysis of the packaging line . This continuous acquisition of visual data ensures that any residues are promptly identified, reducing the risk of contamination and product mix-ups .

[0077] The ability of the control unit to determine the presence or absence of residues from the visual information acquired by the cameras automates the verification process , significantly reducing reliance on manual inspections . This automation minimises human error and ensures a higher level of accuracy and reliability in residue detection .

[0078] Once the presence of residues has been determined by the control unit , generating a detected residue signal allows immediate actions to be taken, such as stopping the machine or alerting the operator . This prompt response helps maintain the integrity of the packaging process and prevents continued operations with potential contaminants .

[0079] Thanks to the possibility of communicating with an electronic processing unit of each machine to instruct the machine to carry out specific movements of the machine parts , the system can dynamically verify that the machine is clean . This interaction ensures thatthe inspection process is complete and covers all potential areas where residues could be hidden, which may not be visible in a static state during manual inspection .

[0080] This dynamic verification process improves the accuracy of residue detection by allowing the cameras to acquire visual information from different angles and positions as the machine parts move . This reduces the likelihood that residues will be missed due to occlusions or blind spots , thereby improving the reliability of the automatic residue identification system on the line .

[0081] Furthermore, the ability to perform specific movements of the machine parts while simultaneously acquiring visual information enables a more complete inspection without requiring manual intervention . This reduces downtime and operating costs associated with manual inspections and increases the overall efficiency of the packaging process .

[0082] In the particularly advantageous embodiment in which the method provides for carrying out specific movements of the parts of the packaging machine ( s ) with at least one of the doors of the machine protection casing open, and therefore for acquiring visual information associated with the inspection area during such movements , this represents an overcoming of a long-standing technical pre judice in the automatic packaging sector . According to standard safety regulations and common practice, the opening of a protection casing or an interlock results in the immediate emergency stop or removal of driving torque from all moving parts to prevent injury to the operator . Consequently, in the known art , visual inspection (manual or automated) is carried out with the machine stopped and static, or with the casings closed . However, static inspection does not allow detection of residues hidden in shadow zones or blind spots created by the overlap of mechanical components (e . g . behind a screw conveyor or under a belt ) . In contrast , the present invention implements a redundant safety control logic that allows the machine to be instructed to perform specific movements (e . g . slow rotations , movement pulses or " jogging" , displacements of specific axes ) even when the casing is open (and preferably when the safety sensors detect that the casing is open) .

[0083] Furthermore, carrying out specific movements coordinated with the opening of the casing and visual acquisition makes it possible to overcome the limitations of human manual inspection . A human operator, being required to comply with safety procedures that impose machine stoppage upon opening thecasings , would have a static and limited view . The operator would be forced to close the casing again, move the machine in " jog" mode from the panel, reopen the casing, and inspect again, in a slow iterative process subject to human error . The system according to the present invention, on the other hand, verifies that the area is free of residues while the parts are moving, ensuring a deterministic and repeatable verification of line cleanliness (Line Clearance ) that is not influenced by operator fatigue or subjectivity . This guarantees a process quality and batch mix-up safety far superior to known standard procedures .

[0084] It is clear that a person skilled in the art , in order to meet contingent needs , may introduce modifications to the invention, all of which fall within the scope of protection as defined by the following claims .

Claims

CLAIMS1. A method for identifying a residue from a batch of previously processed product in a machine for a product packaging line (100) , the method comprising the following steps : a) providing a product packaging line (100) , comprising one or more machines (1, 2, 3, 4) equipped with cameras installed on camera supports (22, 23, 24, 25, 26, 27, 28, 29, 29', 29' ') inside a machine casing (210, 310, 410) of said one or more machines (1, 2, 3, 4) of the product packaging line (100) , for detecting residues of a batch of previously processed product in the product packaging line (100) in a predefined inspection area (220, 230, 280) of said one or more machines (1, 2, 3, 4) ; b) acquiring visual information associated with the inspection area (220, 230, 280) , provided by at least one of the cameras; c) determining, by means of a control unit (20) , from the visual information acquired, the presence or absence of residues in the inspection area (220, 230, 280) ; d) once the presence of residues in the inspection area (220, 230, 280) has been determined by the controlunit (20) , determining a detected residue signal in the control unit (20) .

2. Method according to claim 1, further comprising: bl) during step b) , communicating with an electronic processing unit (50) of said one or more machines (1,2, 3, 4) to instruct said one or more machines (1, 2,3, 4) to carry out specific movements of the parts of the machine (s) (1, 2, 3, 4) to verify that the machine (s) is / are free of residues while simultaneously acquiring visual information from the cameras .

3. Method according to claim 2, wherein step bl) is carried out with at least one of the doors (211, 212) of the machine protection casing (210, 310, 410) open.

4. Method according to any one of claims 2 to 3, comprising the step of stopping said one or more machines (1, 2, 3, 4) if the presence of at least one residue is detected by the control unit (20) in the inspection area (220, 230, 280) .

5. Method according to any one of the preceding claims, comprising the step of displaying a visual indication on a display of the machine (s) (1, 2, 3, 4) if a residue of the previous batch is detected by thecontrol unit (20) .

6. Method according to any one of the preceding claims, comprising the step of preventing the operation of the machine (s) (1, 2, 3, 4) and keeping it prevented until a predefined latency time elapses after the control unit (20) determines in step c) that there are no residues in the inspection area (220, 230, 280) .

7. Method according to any one of claims 3 to 6, wherein once the downtime of the machine is determined, the method also comprises the steps of:- iteratively carrying out steps b) to d) ;- keeping the operation of the machine (s) (1, 2, 3, 4) prevented until a latency time has elapsed, which starts after the control unit (20) determines the fulfilment of a set of conditions, including at least that there are no residues in the predefined zone or that a human or robotic operator sends a signal to the control unit (20) that the predefined zone is clean, i.e., free of residues.

8. Method according to any one of the preceding claims, wherein determining the presence of residues in the inspection area (220, 230, 280) comprises: storing information on the position of at least onecamera in a storage unit (20' ) of the control unit (20) ;- by means of the control unit (20) , comparing previously acquired visual information of the at least one camera when the machine (1, 2, 3, 4) is clean with current visual information of the machine (1, 2, 3, 4) , acquired by the at least one camera.

9. Method according to any one of the preceding claims, wherein step b) is carried out with the one or more machines (1, 2, 3, 4) , preferably all the machines (1, 2, 3, 4) , in a state other than the normal operating state thereof, for example in a maintenance state or a cleaning state.

10. A method of cleaning a product packaging line (100) from residues of batches of previously processed product in said product packaging line (100) comprising the steps of the method according to any one of claims 1 to 9, wherein prior to step b) , the step of discharging and removing all products of the preceding production batch is carried out, and further comprising the step of removing any product residues detected in step c) .

11. A system for identifying a residue from a batch of previously processed product in a product packagingline (100) composed of several machines (1, 2, 3, 4) comprising :- at least two machines (1, 2, 3, 4) arranged so that a second machine (2) of the two machines (1, 2, 3, 4) receives products output from a first machine (1) of the two machines (1, 2) , wherein at least one of the two machines (1, 2) comprises one or more respective inspection areas (220, 230, 280) or wherein both machines (1, 2, ) comprise one or more respective inspection areas (220, 230, 280) ;- cameras installed inside said at least one of the two machines (1, 2) or inside said two machines (1, 2) , wherein each of the cameras is configured to acquire visual information associated with one of the aforesaid one or more inspection areas (220, 230, 280) ;- a control unit (20) connected to the cameras, configured to determine, from visual information acquired by the cameras, the presence or absence of residues in each inspection area (220, 230, 280) , and once the presence of residues is determined, determine a detected residue signal.

12. System according to claim 11, wherein the at least two machines comprise a labelling machine (2) and a case packer (3) .

13. System according to any one of claims 10 to 12, further comprising a visual indicator connected to the control unit (20) , wherein said visual indicator (51) (52) is configured to provide certain information to a user, said certain information comprising one or more of the following information:- an instantaneous result of the detection of the presence of residues carried out by the control unit (20) in each inspection area (220, 230, 280) ;- a current state of each camera installed in the at least two machines (1, 2) based on the instantaneous result of the detection of the presence of residues carried out by the control unit (20) .

14. A computer product comprising computer program code, configured to perform the steps from b) to d) of the method according to any one of claims 1 to 9 when said program code is executed on a computer, or a digital signal processor, or a programmable field gate array, or an application-specific integrated circuit, or a microprocessor, or a microcontroller or any other form of programmable hardware.

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