Reconditioning center for shelf-ready secondary packaging
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2025-02-05
- Publication Date
- 2026-08-13
Smart Images
Figure EP2025052922_13082026_PF_FP_ABST
Abstract
Description
[0001] 40262 / 4361 / PTWO 5 February 2025
[0002] 1
[0003] Reconditioning center for shelf-ready secondary packaging
[0004] Field of the Invention
[0005] The present invention relates to a reconditioning center in a primary circuit for the reuse of shelf-ready secondary packaging for the appropriate presentation and delivery of primary packaging containing goods. The primary circuit extends across a multitude of separate and spatially distinct buildings including the reconditioning center, between which the shelf-ready secondary packaging is transported by vehicles. Furthermore, the invention relates to a system comprising such reconditioning center and to a method for operating such reconditioning center.
[0006] Background of the Invention
[0007] Cardboard displays, also known as cardboard stands or POS (Point of Sale) displays, are a common means of product presentation in discount stores and other retail outlets. It is estimated that 6 to 8 billion such cardboard displays are used annually in retail in Germany, for example, in grocery retail or drugstore retail. For Europe, the estimated number is around 30 billion cardboard displays.
[0008] Cardboard displays are commonly made of cardboard (paper), which is inherently a recyclable material. After use, the displays are typically disassembled and placed in recyclable wastepaper disposal to reduce the amount of non-recyclable waste generated by used cardboard displays. The wastepaper is then processed in recycling facilities into new paper products. However, in many cases, the cardboard displays are directly disposed of in non-recyclable residual waste due to contamination.
[0009] Existing recycling systems offer better environmental protection than single-use cardboard boxes; however, they remain energy and resource-intensive. Given the vast quantity of such cardboard packaging and displays, it would be desirable to generally reduce the amount of cardboard displays to be recycled, and especially reduce the amount of displays that cannot be recycled.
[0010] Moreover, systems in the state of the art are already so advanced that selective changes in individual steps of the system do not lead to any significant increase in40262 / 4361 / PTWO 5 February 2025
[0011] 2
[0012] the system's efficiency. Therefore, it would be desirable to have an alternative recycling system parallel to the current state of the art that meets the same requirements but operates in a much more energy- and resource-efficient way.
[0013] Summary of the Invention
[0014] The objective of the invention is therefore to provide a system that reduces the vast amount of cardboard packaging and cardboard displays, while simultaneously replacing them with a suitable shelf-ready secondary packaging in conjunction with an effective and resource-efficient return system.
[0015] This is solved by a reconditioning center in at least one primary circuit, the primary circuit extending over a plurality of separate and spatially separated buildings for the reuse of shelf-ready secondary packaging for transportation and suitable presentation and dispending of goods-filled primary packaging, wherein the shelfready secondary packaging is designed in two parts with a one-piece foldable base and a separate one-piece foldable lid each comprise at least one identification element for uniquely identifying at least the types of base and lid and determining their positions, comprising:
[0016] a sorting unit for classification of the bases and lids of the returned shelf-ready secondary packaging according to condition, quality and degree of soiling and type-based sorting of bases and lids according to the made classification, preferably the bases and lids are supplied from an entry point of the reconditioning center to the sorting means either continuously by suitable conveying means or in batches from one or more input containers;
[0017] a cleaning unit intended to clean and / or process the bases and lids handed over by the sorting unit, for which purpose the cleaning unit comprises one or more cleaning lines with respective one or more processing stations arranged in series, which are passed by the bases and lids on a conveyor belt, preferably the individual cleaning lines and their processing stations are specifically intended either only for bases or only for lids for their cleaning and / or processing;
[0018] a packing unit for type-based sorting for bases and lids, where bases and lids, which have passed the cleaning unit, are packed in separate transport boxes40262 / 4361 / PTWO 5 February 2025
[0019] 3
[0020] for a separate transportation in vehicles to the further buildings along the primary circuit and back to the reconditioning center, where the transport box comprises a bottom of the box and side walls of the box surrounding the bottom of the box;
[0021] a plurality of data exchange units distributed over the units of the reconditioning center to at least readout the identification elements of bases and lids for uniquely identifying at least the types of bases and lids and determining their positions within the reconditioning center;
[0022] a control unit intended to control the units of the reconditioning center to execute sorting, cleaning and / or preparation, and providing of the shelf-ready secondary packaging based on data readout by the data exchange units, wherein the base and the lid of the shelf-ready secondary packaging each consisting of more than 50% by weight of a corrugated plastic material, wherein the one-piece foldable base consisting at least of a bottom and side walls surrounding the bottom comprising a display side, wherein the lid and the base can be reversibly converted multiple times from a flat form to an erected form and back by folding along preformed fold lines, wherein the erected form of the base is intended for filling with primary packaging containing goods, and the erected form of the lid is intended to be suitably assembled with the base to enclose the primary packaging as filled shelfready secondary packaging.
[0023] The “primary packaging” is the first level of packaging that comes into direct contact with the goods or product and encloses it. Its primary purpose is to protect the goods from external influences such as moisture, light, air, and mechanical damage. Additionally, primary packaging plays an important role in maintaining the quality and shelf life of the goods.
[0024] “Shelf-ready secondary packaging” is packaging specifically designed to present the primary packaging directly on the sales shelf without the need for unpacking or repacking. This type of packaging offers both practical and aesthetic benefits for retailers and consumers. These secondary packages are typically strategically placed in stores with the display side (front) facing the customer attracting attention and promoting sales. They are often designed to be visually appealing and to draw customers' attention. They may include striking colors, graphics, and brand logos to40262 / 4361 / PTWO 5 February 2025
[0025] 4
[0026] highlight the products and spark customer interest. These shelf-ready secondary packages provide a structured and organized way to accept goods from the manufacturer as retail and / or to present products.
[0027] The term "primary circuit" refers to an intelligent circuit, which can also be called a "smart loop system," referring to an intelligent return system used in the distribution of goods to improve efficiency and sustainability. The inventive system offers an advanced solution that optimizes the entire logistics circuit of a shelf-ready secondary package from provisioning through product stocking to customer presentation and back. The system integrates various technologies to maximize efficiency and sustainability at every stage of the process and through the synergy of the overall system. Components of such a smart loop system can include supply depot, manufacturer, retail and sale, re-conditioning center, and the transport mechanisms between the individual components. The various components of the system consist in reality of individual or multiple separate and spatially separated buildings, or the components are housed in different building shells. A cycle can be the passing through of all components of the circuit.
[0028] Here, the reconditioning center (also denoted as first building) may be located in one or more buildings or building shells and may include one or more supply depots. In the inventive re-conditioning center the shelf-ready secondary packaging or their bases and lids are provided and / or at least part of the returned used bases and lids from retail are sorted, cleaned, and / or refurbished as reusable shelf-ready secondary packaging. Newly produced bases and lids can also be provided and / or labeled in the supply depot, as there can always be some inventory losses in the circuit process, for example, due to bases and lids that are no longer reusable. In the re-conditioning center, already used bases and lids can be refurbished (sorted, cleaned, and / or reconditioned). The labeling of the reusable bases and lids can also be handled by the re-conditioning center. The term "first building" is used for simplicity, even if it involves multiple first buildings and “first buildings” can also refer to only one building.
[0029] One or more "second buildings" or building shells can be the manufacturers of goods, to which the bases and lids are delivered separately from the first building in a flat40262 / 4361 / PTWO 5 February 2025
[0030] 5
[0031] state. The bases and lids are erected in the second building and filled with primary packaging containing goods. In the second building, bases and lids are assembled into the shelf-ready secondary packaging filled with primary packaging. The term "second building" is used for simplicity, even if it involves multiple second buildings and “second buildings” can also refer to only one building.
[0032] One or more "third buildings" or building shells can house supermarkets, markets, or retail in general. The erected product displays with goods are delivered from the second building to the third building by vehicles and leave the third building again in a flat, compact state without goods, as the goods are offered for sale in the third building. The term "third building" is used for simplicity, even if it involves multiple third buildings and “third buildings” can also refer to only one building.
[0033] The term "vehicles" here refers to all conventional means of transport such as cars, trucks, trains, airplanes, ships, which transport loads from one place to another. These means of transport can have suitable transport boxes that enable the transport of used product displays in a flat form from retail to the re-conditioning system. The vehicles or means of transport, as well as transport boxes, are also suitable for transporting the bases and lids prepared for reuse in the re-conditioning system to be stocked with primary packaging containing goods for retail. The bottom of the transport box and the side walls of the transport box surrounding the bottom define a transport volume for transporting the bases and lids.
[0034] The inventive shelf-ready secondary packaging can be brought into a flat form to save transport volume in the primary circuit with empty bases and lids. In flat form, the dead volume in the transport box is reduced. The dead volume is the volume in the transport box that is not filled by the transported bases or lids. Transport in flat form is also referred to as compressed transport. Only when they are filled with primary packaging containing goods (second building) is the intended three-dimensional form (erected form) created. This has the advantage that both during delivery and during the collection of the shelf-ready secondary packaging, a spacesaving and compressing transport box can be used as a collection container for the unfolded, empty bases and lids for the retail branch (third building) to increase transport efficiency and protect the environment. The bases and lids can have40262 / 4361 / PTWO 5 February 2025
[0035] 6
[0036] different shapes and sizes to accommodate different types of products (primary packaging), from small items like cosmetics to larger products like electronics. They can be variously foldable to make transport space- and timesaving. Providing the shelf-ready secondary packaging in a two-part form with (a) base and (b) lid allows for a clever dimensioning of the lids to reduce the number of types of bases. Also, only the non-reusable part (base or lid) needs to be sorted out, while the other part, if reusable, can continue to be used. The additional lid also allows for stacking the secondary packaging filled with primary packaging. This allows optimal use of limited space, including its vertical dimension, for providing the filled secondary packaging. The available space can be used without compromising the stability of the stacked secondary packaging and the primary packaging containing goods within them.
[0037] Shelf-ready secondary packaging in the state of the art are mostly made of cardboard, which is not intended for direct reuse. At best, indirect reuse is possible through a recycling step. However, many cardboard displays become unusable due to contamination, such as from food or liquids from a leaking shampoo bottle and must be disposed of directly in the residual waste. In contrast, the product display of the present invention is reusable, which is achieved and controlled by the inventive system. The inventive shelf-ready secondary packaging also meets the criteria of lightness, stability, and sustainability through the selected material (predominantly or even entirely made of corrugated plastic material) as well as the ability to attract customers' attention to highlight the products. The side walls of the base are as designable as existing product displays.
[0038] The term "corrugated plastic material" refers to a type of structured material, here plastic material, that consists of a fluted or ridged layer sandwiched between two flat linerboards. This design creates a series of parallel ridges and grooves, which significantly enhances the material's strength and rigidity while keeping it lightweight. The fluted layer provides cushioning and protection for the contents inside. The versatility and cost-effectiveness of corrugated materials make them an advantageous choice for the base and lid of the shelf-ready secondary packaging. The plastic material can be at least partially, preferably completely, made from a synthetic or semi-synthetic polymer, preferably polypropylene, a bio-based polymer,40262 / 4361 / PTWO 5 February 2025
[0039] 7
[0040] a sugar-based plastic, preferably from ethanol, or a combination thereof. Bases and lids, as structures made predominantly from material and plastic as the material for the corrugated structure, offer specific advantages in terms of stability, weight, and material savings, allowing the shelf-ready secondary packaging to meet various requirements. Due to the material used, the shelf-ready secondary packaging is designed to remain stable and securely hold the goods even when exposed to moisture or mechanical stress. This minimizes the risk of damage or loss of goods.
[0041] The auto-identification of the bases and lids in the primary circuit (Smart Loop System) according to the invention brings various advantages. The system according to the invention integrates modem technology at least in the primary circuit to significantly improve the efficiency, accuracy, and transparency of the entire supply chain compared to the state of the art (e.g., recycling system for cardboard displays). The auto-ID technology enables real-time tracking of displays and their contents. Each display can be equipped with a unique identification element that contains information such as type and location. This allows for precise inventory management and helps avoid bottlenecks, overstock, or even theft. Various techniques for contactless reading of an identification element are known to the expert. For example, barcodes or QR codes can be read as non-rewritable optically readable codes by corresponding reading devices as data exchange units. Such identification elements can be cost-effectively applied to the shelf-ready secondary packaging but require direct sight of the reading devices on these codes for reading. In the case of RF-based identification elements such as RFID transponders or NFC transponders, these can also be read without a direct line of sight from the reading device to the identification element, but such RF-based identification elements are more expensive than barcodes, etc. In this case RF readers adapted to the corresponding RF-based identification elements are used as data exchange units. Data exchange in the system according to the invention takes place between the identification element and the data exchange units distributed throughout the primary circuit as readers. The data exchange units are preferably arranged at all logistical branching points and critical process locations so that the system control can receive the data important for controlling the system to the shelfready secondary packaging.40262 / 4361 / PTWO 5 February 2025
[0042] 8
[0043] The sorting unit can be any suitable sorting unit that enables the shelf-ready secondary packaging to be sorted according to a classification of the bases and lids by condition, quality and degree of soiling. For this purpose, the sorting unit comprises suitable sensors with which the actual condition of the returned shelfready secondary packaging can be measured and evaluated, resulting in a classification of the bases and goods of the shelf-ready secondary packaging based on the measurement and evaluation. Depending on the application of the shelfready secondary packaging and the primary packaging to be transported and presented in the shelf-ready secondary packaging there are different types of bases and lids. The sorting within the sorting unit distinguishes between different types of bases and lids and collected as type-based sorting the bases or lids of different types separate from each other. The bases and lids might be supplied from an entry point of the reconditioning center to sorting means of the sorting unit either continuously by suitable conveying means (e.g. a conveying belt) or in batches by means of input containers both enabling an efficient feeding of the bases and lids to the sorting means speeding up and optimizing the entire sorting process. Continuous or batch feeding improves the material flow, avoiding bottlenecks and increasing productivity. Batch processes are advantageous where the individual process steps are significantly slower than those before or after. In this way, many product displays can be processed simultaneously in one slow process step without affecting the material flow through the processing system, in this case the sorting unit. The batch process also makes it possible to keep individual processing sections of the processing system compact. Continuous processes, on the other hand, facilitate the logistics of operating the processing system, for example. This applies in principle to both the sorting unit and the cleaning unit with its cleaning lines.
[0044] The cleaning unit for cleaning and / or reprocessing the bases and lids handed over from the sorting unit refers to a unit comprising one or more components for cleaning and / or reprocessing the bases and lids. The cleaning unit can comprise several parallel cleaning lines, which in turn comprise several processing stations arranged one behind the other per cleaning line to clean and disinfect the bases and lids. The individual processing stations in the respective cleaning line can be designed40262 / 4361 / PTWO 5 February 2025
[0045] 9
[0046] differently depending on the purpose and type of bases or lids and use different techniques for cleaning and disinfecting. This ensures that the bases and lids to be reused are in perfect hygienic condition, which is particularly important in sectors such as the food and pharmaceutical industries. The processing stations may be one or more of a first, a second, a third, a fourth and / or a fifth processing station, where the terms “first”, “second”, “third”, “fourth”, “fifth” etc. only denotes the processing units to distinguish a particular processing unit from other processing units und does not prescribe a specific sequence in the arrangement of the processing units in a cleaning line of the cleaning unit. In some embodiments there might be even more processing stations as part of the cleaning unit. By integrating the cleaning unit into the reconditioning center, the entire cleaning and disinfection process is automated and efficient, resulting in improved quality assurance and a reduction in manual cleaning work. In an embodiment the individual cleaning lines and their processing stations are specifically intended either only for bases or only for lids for their cleaning and / or processing. In another embodiment, the individual cleaning lines differ by the kind of implemented cleaning process, e.g. dry cleaning or wet cleaning. Hereby, it does not necessarily matter if the input is a base or a lid. The cleaning lines may be set to allow a throughput of at least 1500 bases or lids per hour, preferably a throughput of at least 1750 bases or lids per hour, particularly preferably a throughput of at least 2000 bases or lids per hour.
[0047] The packing unit for sorting and providing the bases and lids enables the typespecific sorting of the bases and lids to be transported in a space-saving manner in suitable transport boxes for transportation along the primary circuit to the other participants in the primary circuit. The transport boxes for transporting the bases or lids are transported by vehicles to other buildings in the primary circuit and back to the first building. Depending on the application and logistical requirements and route length, the vehicles used for this can be vehicles of all kinds, for example trucks, train wagons, airplanes, ships, etc.
[0048] For effective operation of the processing system and its components, the processing system comprises a control unit that controls the units of the processing system for carrying out sorting, cleaning and / or preparation and sorting and provision. For this purpose, the control unit is connected to the respective units and the sensors used40262 / 4361 / PTWO 5 February 2025
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[0050] for data transmission of the measured values and operating parameters via a suitable data line. In addition to one or more processors, the control unit comprises suitable data memories for storing and accessing the required data. Suitable control programs are executed on the processors of the control unit, which monitor and control the interaction of the individual components and the processing chain for the goods presenters. This also requires individual identification of the individual shelfready secondary packaging, which includes at least one identification element to uniquely identify its type and determine its position, at least in the primary circuit. Accordingly, a large number of data exchange units are distributed in the primary circuit, via which the identification elements of the bases and lids of the shelf-ready secondary packaging can be read out at all necessary points and, if necessary, written with data. Reuse saves enormous resources, as the mass production of new displays can be avoided. In addition, the cleaning processes are fast and effective, so that market participants can be supplied quickly and reliably with the required shelf-ready secondary packaging. By reusing each base and lids of the shelf-ready secondary packaging, any higher costs for the one-off production of the reusable merchandise display can be easily compensated for, reducing the overall costs of the system and protecting the environment at the same time.
[0051] According to the principle "return is cheaper than remake," the present invention has the advantage over the existing system with cardboard or paper-based shelfready secondary packaging that is significantly more environmentally friendly and cost-efficient. In numerical terms, the implementation of the inventive system can save 3.6 million tons of CO2, 36 million cubic meters of water, and 4 million tons of paper waste annually in Germany alone. Additionally, the present invention offers a range of individual advantages that synergize within the overall system. The invention is explained in more detail below.
[0052] The reconditioning center according to the present invention in a primary circuit for the reuse of shelf-ready secondary packaging for the transport and suitable presentation and dispensing of goods-filled primary packaging enables implementation of a system that can fulfill the same requirements for the presentation of goods, but works in a significantly more energy and resource-40262 / 4361 / PTWO 5 February 2025
[0053] 11
[0054] efficient manner than existing state-of-the-art systems by replacing a significant amount of one-use packaging.
[0055] In an embodiment the control unit is configured to exclude used bases and / or lids that cannot be reused due to damage or contamination from the primary circuit, preferably the sorting unit is configured to perform a sensor-based incoming inspection for the base and lids and to remove bases and / or lids from further processing that has been classified as non-reusable by the control unit due to e.g. condition, quality, and degree of contamination from the primary circuit. This means that only fully functional, cleaned and disinfected bases and lids displays are ever reused as shelf-ready secondary packaging in the primary circuit for loading with new goods. The incoming inspection prevents further processing of bases or lids, which cannot be reused, in the reconditioning center and therefore prevents wasted processing effort.
[0056] In another embodiment a software executed by the control unit uses machine learning and artificial intelligence through appropriate algorithms to support data analysis and process control in the sorting, cleaning and / or preparation, and providing of the shelf-ready secondary packaging, including a classification of the bases and lids according to parameters, e.g. condition, quality, and degree of contamination based on the recorded conditions, qualities, and degrees of contamination on the bases and lids. Here, machine learning might be supervised learning using classifications and / or regression. This has the advantage of significantly improving the efficiency, accuracy, and sustainability of these processes. Machine learning enables the automation and optimization of control processes for the shelf-ready secondary packaging by continuously collecting and analyzing data to recognize patterns and anomalies. Based on these insights, the reconditioning center can automatically adjust to maximize the efficiency of the shelf-ready secondary packaging, reducing the need for manual interventions and minimizing human errors. Another advantage is the prediction of maintenance needs. By analyzing historical data and recognizing patterns, the software can detect signs of wear or potential failures early and schedule maintenance work in a timely manner. This prevents unplanned downtimes and extends the lifespan of the bases and lids. Additionally, machine learning can optimize the cleaning processes40262 / 4361 / PTWO 5 February 2025
[0057] 12
[0058] of bases and lids by identifying the best cleaning methods and times based on the specific requirements and degree of contamination of the bases or lids. The software can adjust the cleaning cycles to ensure that the bases and lids are thoroughly cleaned without wasting unnecessary resources, leading to more efficient use of water, cleaning agents, and energy.
[0059] Machine learning also monitors the quality of the preparation of the shelf-ready secondary packaging and ensures that all bases and lids meet the required standards. The software can analyze images and sensor data to detect errors or irregularities that may occur during preparation, allowing for quick identification and correction of problems. Furthermore, machine learning enables software to continuously adapt to new conditions and requirements. The algorithms can learn from the collected data and improve their performance over time, leading to a continuous optimization of the control, cleaning, and preparation processes. By optimizing the cleaning and preparation processes, machine learning contributes to resource efficiency and sustainability. The software can minimize the consumption of water, energy, and cleaning agents by precisely controlling the processes within the reconditioning center and avoiding unnecessary waste, reducing environmental impact and lowering operating costs. Machine learning can also be seamlessly integrated into existing ERP (Enterprise Resource Planning) and WMS (Warehouse Management System) systems, allowing for centralized management and analysis of all data related to the control, cleaning, and preparation of the shelf-ready secondary packaging.
[0060] The use of machine learning for the control, cleaning, and preparation of bases and lids requires carefully selected and extensive training data as well as well-defined training procedures. The necessary training data can include sensor data such as temperature, humidity, pressure, vibrations, and fill level, which helps monitor the environmental conditions and the state of the bases and lids. Image and video data are also important to assess the quality of cleaning and detect defects or wear. Historical maintenance data, including maintenance logs and failure history, provide valuable insights into past maintenance work and its outcomes. Process data such as cleaning cycles, chemical consumption, and energy consumption, as well as operational data on the usage duration and load of the bases and lids, are also40262 / 4361 / PTWO 5 February 2025
[0061] 13
[0062] crucial. The training procedures for machine learning begin with data preparation, where the data is cleaned, enriched, and normalized. The data is then split into training, validation, and test datasets. Model training involves selecting appropriate ML algorithms (e.g., decision trees, neural networks, support vector machines), hyperparameter tuning, and cross-validation (k-fold cross-validation) to ensure the robustness of the model. Model evaluation is performed using performance metrics such as accuracy, precision, recall, F1 -score, and ROC-AUC, as well as error analysis to identify areas for improvement. After training, the model is integrated into the real-time system and continuously monitored and maintained. The required amount of data for visual inspection and error detection can include thousands to tens of thousands of images or videos to train a robust model. The data split can be as follows:
[0063] Training data 70% -80%: the majority of the data is used fortraining the model. This data is used to learn the model parameters and recognize the underlying patterns in the data.
[0064] Validation data 10% - 15%: a portion of the data is used for validation. This data helps optimize the model's hyperparameters and monitor performance during training. The validation data is not used fortraining the model but serves to evaluate the model's generalization ability and avoid overfitting.
[0065] Test data 10% - 15%: a separate portion of the data is used for the final evaluation of the model. This data is used only after training and hyperparameter optimization to measure the model's final performance. The test data provides an objective assessment of the model's generalization ability on unknown data.
[0066] An example of the data set structure could be as follows:
[0067]
[0068] 40262 / 4361 / PTWO 5 February 2025
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[0070] Here, the following data is measured and included as a dataset:
[0071] • Identification Element ID: Unique identification number of the bases and lids (base-ID or lid-ID).
[0072] • Temperature (°C): Measured temperature in the bases and lids.
[0073] • Humidity (%): Measured humidity of the bases and lids.
[0074] • Vibration (Hz): Measured vibrations of the bases and lids.
[0075] • Cleaning Cycle (min): Duration of the cleaning cycle in minutes.
[0076] • Chemical Consumption (ml): Amount of cleaning agents used in milliliters.
[0077] • Energy Consumption (kWh): Energy consumption during the cleaning cycle in kilowatt-hours.
[0078] • Maintenance Date: Date of the last maintenance of the bases and lids.
[0079] • Image URL: URL to an image of the bases and lids for visual inspection.
[0080] • Quality Rating: Assessment of the quality of the bases and lids after cleaning (e.g., good, very good, satisfactory).
[0081] In another embodiment, the Al can learn based on boundary patterns. The use of machine learning for sorting contaminated bases and lids based on boundary patterns also requires careful planning and execution. First, image data of bases and lids in various states of contamination must be collected. These images should be taken from different angles and under different lighting conditions. The images need to be manually annotated by marking the contaminated areas and classifying the types and severity of contamination. After data cleaning and augmentation, the data is split into training, validation, and test datasets.
[0082] For the model architecture, a suitable model for image processing and object detection is selected, such as Convolutional Neural Networks (CNNs) or specialized models like YOLO (You Only Look Once) or Faster R-CNN. The model architecture is adapted to the specific requirements of the task. Training the model involves hyperparameter tuning, the training process with techniques like backpropagation and Stochastic Gradient Descent (SGD), and validation with the validation dataset. Model evaluation is performed using performance metrics and error analysis.
[0083] After training, the model is integrated into the real-time system for sorting contaminated bases and lids. Continuous monitoring and maintenance of the model40262 / 4361 / PTWO 5 February 2025
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[0085] ensure that performance remains high in real-time operation. An example of a training dataset could include the following fields: Image ID, Image URL, Type of Contamination, Severity, and Bounding Box (x1, y1, x2, y2). The data and software can be stored and processed in the cloud.
[0086]
[0087] Another application of Al is the more precise forecasting of demand for the new production of reusable secondary packaging. The variety of different users of the secondary packaging, their diverse processes and conditions, and uncontrollable additional factors such as weather, result in traditional forecasting methods providing only inadequate results regarding the expected return of secondary packaging within specific time periods. To avoid resource-wasting overstock or holding costs, Al is used to determine the optimal forecasting model for each subarea based on the product, secondary packaging type, and customer structure. By aggregating the individual results, a significantly better overall outcome can be achieved.
[0088] In another embodiment the sorting unit comprises at least first sensors, preferably an RFID reader, for reading the identification element, preferably an RFID transponder, of the base and / or lid of the shelf-ready secondary packaging to determine and classify the respective type of base and lid, and at least second sensors, preferably optical sensors, for recording the condition and / or quality and / or degree of contamination of the base or lid, where first and second sensors are connected to the control unit. The described sorting unit for bases and lids offers a variety of advantages, particularly regarding the efficiency and accuracy of sorting. By precisely determining and classifying the bases and lids using the first sensors,40262 / 4361 / PTWO 5 February 2025
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[0090] which identify the type of base or lid, correct assignment and treatment of each base and lid is ensured. The integrated RFID reader reads the RFID transponders of the bases and lids, enabling quick and reliable identification, as the transponders contain specific information that can be captured automatically and without manual intervention. Additionally, second sensors assess the condition and quality of the bases and lids. This automatic assessment is crucial to ensure that only bases and lids in good condition are reused or sold. Early detection and sorting out defective or damaged bases and lids improve the overall quality of the products. The sensors detect the degree of contamination of the display stands, which is particularly important in industries where hygiene and cleanliness play a significant role, such as the food or pharmaceutical industry. Based on the data from these sensors, bases and lids that require cleaning can be automatically identified and treated accordingly. The integration of these sensors into the sorting unit allows for extensive automation of the sorting process, reducing manual effort and minimizing human errors. The automated capture and classification of the bases and lids accelerate the sorting process, leading to a higher throughput rate. This results in cost savings, as the automation of the sorting process can reduce personnel costs and require fewer manual interventions. Additionally, the precise condition and quality assessment reduce scrap and rework, lowering overall costs. The second sensors can be optical sensors connected to an evaluation unit, on which recognition software for detecting and classifying the condition, quality, and degree of contamination of the respective base or lid is executed, with the recognition software using artificial intelligence through appropriate machine learning algorithms. Optical sensors can perform precise and contactless measurements. This can be particularly advantageous in environments where physical contact with the object to be measured is difficult, such as in a fully automated processing plant. Optical sensors can provide accurate measurements of distances, positions, dimensions, and other physical quantities, leading to higher accuracy and reliability of the data. Another advantage of optical sensors is their high sensitivity and fast response time. They can detect the smallest changes in the parameters to be measured and respond immediately. Optical sensors are also very versatile and can be used in a variety of environments. They are insensitive to electromagnetic interference, making them ideal for use in industrial environments where40262 / 4361 / PTWO 5 February 2025
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[0092] electromagnetic fields are common. Furthermore, optical sensors can operate reliably in extreme temperature ranges and under challenging conditions such as dust, moisture, or vibrations. Another advantage is the possibility of miniaturizing optical sensors. Thanks to their compact design, they can be used in confined spaces and in applications where space is at a premium. This enables flexible integration into existing systems and installations without the need for extensive modifications.
[0093] In another embodiment the sorting unit is configured to record parameters e.g. the condition, quality, and degree of contamination on both sides of the base and lids fully spread out in one plane, whereas the base and / or lids spread out in this way are preferably classified on a detection substrate, whereas it is particularly preferred, that a transparent detection substrate is to be able to determine the condition, quality, and degree of contamination of both sides of the base and lids simultaneously. The described embodiment of the sorting unit offers significant advantages for the classification of bases and lids by performing the detection of condition, quality, and degree of contamination on the fully spread-out base or lid on both sides. This allows for a comprehensive and precise assessment, as both sides of the base or lid can be examined simultaneously. The use of a transparent detection substrate is particularly advantageous as it allows for the simultaneous determination of the relevant parameters on both sides of the base or lid. This measure increases the accuracy of the classification and ensures that no defects or contaminations are overlooked, leading to improved quality assurance and time efficiency in the sorting process.
[0094] In another embodiment the sorting unit comprises a plurality of collection containers and one or more sorting means, preferably gripping robots, which are designed to enable a type-based sorting of the respective bases and lids into the collection containers accessible to the sorting means based on parameters e.g. the classified condition, quality, and degree of contamination of the respective base or lid, with each collection container being assigned to different types and classifications of e.g. condition, quality, and degree of contamination. The gripping means can be designed differently. For example, gripping robots enable precise sorting of the bases and lids into collection containers, each assigned to the different40262 / 4361 / PTWO 5 February 2025
[0095] 18
[0096] classifications of condition, quality, and degree of contamination. Type-based means that only a specific type of base or lid is sorted into each collection container. Therefore, an appropriate number of collection containers is arranged around the sorting means. The automated and classified condition-based sorting significantly increases the efficiency of the sorting process. This leads to a reduction in manual interventions and minimizes human errors, resulting in improved quality assurance and optimized management of the primary circuit. The collection containers may have any suitable shape and may be made of any suitable material. The collection containers only represent an intermediate storage volume for bases and lids in the reconditioning center at the processing stations. The collection container will not be transported outside the reconditioning center. Therefore, the boundaries of a transport volume provided by using light weight material and compact size for transportation along the primary circuit do not necessarily apply to the collection containers in the reconditioning center, if the reconditioning center provides sufficient space to place the collection containers.
[0097] In another embodiment at least a second collecting container and / or a third collecting container are present within an arrangement of the collecting containers for certain classifications, which can be loaded with bases or lids by the respective sorting means, accessible to the same sorting means, wherein the second collecting container is provided as a temporary buffer container for full and exchangeable collecting containers for certain classifications, and the third collecting container is provided as an intermediate storage for goods displays with incorrect spatial orientation. This has several advantages. First, the second collection container as a temporary buffer container allows efficient use of space, as full and exchangeable collection containers for specific classifications can be temporarily stored. This prevents bottlenecks in the sorting process and ensures smoother handling. Furthermore, the system offers high flexibility and adaptability by allowing bases and lids of all classifications to be stored in the second collection container. This is particularly useful in dynamic environments where classifications and quantities can vary. The arrangement of the collection containers and the possibility of intermediate storage of bases and lids with incorrect spatial orientation contribute to optimizing the material flow. This leads to smoother and more efficient processing of the bases40262 / 4361 / PTWO 5 February 2025
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[0099] and lids. Another advantage is the improved sorting accuracy, which is achieved by the third collection container as an intermediate storage area for bases or lids with an incorrect spatial orientation. This makes it possible to correct the orientation before the bases and lids are processed further, which increases the efficiency of the sorting process. In addition, the use of a temporary buffer bin helps to reduce downtime, as full bins and bins that need to be replaced can be handled quickly and efficiently without interrupting the sorting process. This increases the overall productivity of the system. The arrangement of the collection bins and the ability to temporarily store bases and lids with incorrect spatial orientation help to optimize the material flow. This leads to smoother and more efficient processing of the bases and lids. Finally, the provision of additional collection containers (second and third collection containers) increases the overall capacity of the system, enabling the handling of larger quantities of bases and lids and improving the scalability of the system. Depending on the application there might be more than one second collecting container and / or more than one third collecting container, where the particular number of second and third collection containers may vary also over time.
[0100] In another embodiment the sorting unit comprises at least two arrangements of collecting containers and sorting means as separate sorting cells arranged one behind the other to enable cascading fine sorting of the bases and lids in a cascaded sorting process. Preferably the separate sorting cells are set up to suitably transfer collecting containers of one sorting cell to the subsequent sorting cells for cascading fine sorting of the bases and lids. Cascaded sorting of this kind reduces the space required and the logistics for the individual cascades but may extend the sorting distance. In order to further finely sort the coarse sorting in the first sorting cell by the second sorting cell, the second sorting cell comprises more collection containers than the first sorting cell or there are several second sorting cells as a second level of sorting cells, all of which are supplied by the first sorting cell with bases and lids to be further sorted, whereby the assignment of certain coarsely sorted bases and lids to certain second sorting cells already represents a part of the fine sorting. This cascade of sorting cells can also comprise more than just two sorting cells or more than two levels of sorting cells, depending on the requirements and scope of the fine sorting. The term “level” refers to all sorting cells that are supplied with pre-sorted40262 / 4361 / PTWO 5 February 2025
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[0102] bases and lids in parallel by the preceding sorting cell or preceding level of sorting cells. The sorting process, where only one sorting cell is arranged in each sorting level is a linear sorting process. In case of sorting levels comprising two or more sorting cells, the sorting process is a branched sorting process.
[0103] In another embodiment a first processing station of the cleaning line is set up to detect labels at least on the bases, that do not serve as identification elements and to remove them before cleaning the bases. This ensures that unnecessary and disruptive labels for the reuse process are removed. This improves the efficiency and quality of the cleaning process by avoiding potential contamination from label residues. De-labeling is an important part of the primary circuit for the "reconditioning" of display stands. The removal of labels can preferably be carried out by blowing them off, provided the labels and / or the base are prepared for this. For example, the adhesive layer of the label can be omitted in the edge area of the label, so that the edge of the label slightly protrudes, where compressed air can attack to blow the label away. The alignment of the blowing device is predetermined by the known orientation and shape of the base in this processing unit. A first processing station can mean more than one station. This also applies to other stations.
[0104] In another embodiment a second processing station of the cleaning line carries out the cleaning process of the base and / or the lid by means of wet cleaning, preferably by spraying with a cleaning fluid, and / or by means of dry cleaning, preferably by mechanical brushing or air pressure cleaning, and at least a third processing station of the cleaning line for drying the bases and / or lids cleaned with the preceding wet cleaning, preferably by means of a gas blower, heat radiation, or a spinning process. This versatility allows for thorough and flexible cleaning, tailored to the specific requirements of the bases and lids. Additionally, another processing station of the cleaning line ensures that the cleaned bases and lids are dried after wet cleaning, for example, using a gas blower, thermal radiation, or a spinning process. This ensures that the display stands are completely dry and ready for use after cleaning, increasing the efficiency and quality of the entire cleaning process. The drying process prevents, for example, the sticking together of bases (or lids) stacked on top of each other in transport boxes due to remaining residual moisture.40262 / 4361 / PTWO 5 February 2025
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[0106] In another embodiment an inspection station as a sixth processing station is arranged behind the third processing station, where the inspection station is designed to detect any remaining residual liquid on the bases or lids after drying and, in the event of detecting residual liquid, to subject the base or lid to a renewed drying, preferably by reintroducing the base or lid onto the conveyer belt passing through the third processing station for drying in front of the third processing station. The terms “behind” and “in front of” refer to the direction of the process flow, where e.g. “behind” denotes a position passed by the bases or lids later that the referred position. This measure ensures that the bases and lids are completely dry and ready for use after the cleaning process, increasing the efficiency and quality of the entire drying process. Dry bases and lids, for example, cannot stick together in transport boxes, which would be possible with residual moisture on the bases and lids.
[0107] In another embodiment a fourth processing station of the cleaning line is intended for disinfecting the bases and / or lids, preferably by irradiation with suitable UV light. This measure ensures effective and thorough disinfection, which is particularly important for maintaining high hygiene standards. Preferably the processing stations for disinfecting are arranged along the conveyor belt behind the third processing station for drying in the case of a preceding wet cleaning. This arrangement behind the processing station for drying is particularly advantageous, because it ensures that the bases and lids are immediately disinfected after drying, thereby increasing the efficiency and quality of the entire cleaning and disinfection process.
[0108] In another embodiment a fifth processing station of the cleaning line is intended for labeling at least the bases after cleaning, wherein at least one base label is applied to a prepared application surface on at least one of the side walls of the base, preferably on the side wall opposite the display side, which comprises the application surface, particularly preferably the base label completely covers the application surface. The base label is applied in the cleaning unit after the cleaning processes are completed. The base label provides a surface dedicated for additional information labels as over-label to be applied at a later point in time on top of the base label, e.g. by operators of the second buildings to assign specific information about the primary packaging (such as type of goods, manufacturing date, place of40262 / 4361 / PTWO 5 February 2025
[0109] 22
[0110] manufacture, etc.) that are packed into the bases in the second buildings to the bases, without the operators of the second buildings being restricted in terms of the application technique of their information. The goods packer can further stick (with the goods packer's over-label in the second building) or print on the existing base label on the base, but the sticking or printing must not go beyond the area of the base label to ensure that the base label can still be easily removed in the first building. The application means for applying the base label can be supported by sensors that enable precise detection and localization of the application surface. This fifth processing station as a labeling station ensures that the bases are immediately provided with a new, clean base label after cleaning and disinfection, which enables the operator of the second house to further improve the traceability and identification of the bases in the primary circuit with their own over-label in the second building. The application surface for applying the base label specifically reduces the adhesion of the base label on the application surface to achieve sufficient adhesion of the base label during a cycle in the primary circuit and to enable easy removal of the base label in the cleaning unit by blowing off. The application surface can be adapted and coordinated to the process requirements in the cleaning line (removal of the base label) and in the other primary circuit (sufficient adhesion of the base label on the application surface). Thus, a specific adhesion provided by the application surface in conjunction with the adhesive side of the base label can fulfill both requirements. As an example, the application surface may consist of a silicon layer applied on top of the corrugated material of the base (and eventually also on the lid) at a suitable position on the outside surface of the base.
[0111] In another embodiment the fifth processing station is further configured
[0112] to apply a presentation label in the form of the display side for further designation of the product-filled primary packaging to the display side, and / or
[0113] to connect a reversibly attachable and removable cover with the display side of the base by use of fixing means of the cover fitting to corresponding means of the display side, preferably the fixing means of the display side is realized40262 / 4361 / PTWO 5 February 2025
[0114] 23
[0115] as one or more suitably dimensioned slots and the corresponding fastening means of the cover is realized as one or more suitably shaped tabs.
[0116] A "presentation label" is understood to mean a marking that is used as a flexible decoration principle to enable advertising and attention generation for the primary packaging in the third building towards the customer. The presentation labeling is an important part of product advertising, as the shelf-ready secondary packaging usually represents an advertising unit that should be appropriately labeled. This requirement must be implemented within the technical framework of reusing the shelf-ready secondary packaging for any participants in the primary circuit and the associated cleaning with suitable technical means. The reversibly attachable and removable cover serves the same purpose as the presentation label, but here the base does not need to be prepared with any application surfaces, but only needs to include generally adapted fastening means that can be used as needed when such a cover is to be attached. The shape of the cover corresponds to the display side of the base. When the cover is used, no additional label is required. Instead, the cover (either single-use or reusable) is inserted by a robot after cleaning, thereby branding the standard secondary packaging. When the secondary packaging is returned from the retail store (third building) to the reconditioning center, the panel is then removed by a robot. In the case of a single-use cover, it is disposed of, while in the case of a reusable cover, it is stored by type.
[0117] In another embodiment the base label and / or the presentation label each comprise at least one lateral side area designed so that the lateral side area does not adhere to the base or the application surface or comprises a pull tab to prepare for the successful removal of the base label and / or the presentation label during reuse of the respective base in the first processing station. With a non-adhesive edge area, the base labels and presentation labels can be easily blown off with compressed air in the first building as a first cleaning step. Alternatively, one or both labels can include a pull tab, which can either be the attack point of the compressed air for blowing off or a corresponding gripping mechanism grips the pull tab and pulls off the base label and / or the presentation label. The pull tab does not adhere to the base but stands suitably off the surface of the base label. The size and shape of the40262 / 4361 / PTWO 5 February 2025
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[0119] pull tab can be adapted by the specialist to the size and shape required for the gripping mechanism.
[0120] In another embodiment, these labels (base label, the presentation label) can alternatively also be water-soluble and thus washable. Such labels can be applied to unprepared areas of the shelf-ready secondary packaging and still be easily removed for reuse in a cleaning cycle. Water-soluble labels thus provide users with a flexible option for applying labels.
[0121] In another embodiment the cleaning line comprises a conveyor belt passing the bases and lids through the respective cleaning line in such a way that they lie completely spread out on the conveyor belt or hang on the conveyor belt, preferably the processing stations in the case of a lying transport each comprise a turning station for the bases and lids to enable cleaning and disinfection of both sides of the bases and lids. This positioning allows for even and thorough cleaning and disinfection. In the case of lying transport the turning stations enable bilateral cleaning and disinfection of the bases and lids, which further improves hygiene and quality. In the case of hanging transport, the cleaning is simplified by apparatus, but hanging transport cannot define the position of the bases and lids as precisely as lying transport. Especially in cleaning processes with applied fluids, the bases and lids could start to swing in the hanging state, making the process less defined. The conveyor belt can be a continuous conveyor belt or arranged from sections of conveyor belts placed one after the other.
[0122] In another embodiment the cleaning unit is set up to carry out a sensor-based final inspection of the respective bases and lids after passing through the cleaning unit and to exclude the bases and lids classified as non-reusable from the primary circuit in case of being classified as non-reusable by the control unit. This ensures that only bases and lids in perfect condition are reused, which increases the quality and efficiency of the entire primary circuit process. The ongoing results of the final inspection can be fed back into the self-learning process control as feedback data, which continuously improves the process success.
[0123] In another embodiment the cleaning unit comprises one or more data exchange units which store the respective processes carried out for the individual bases and40262 / 4361 / PTWO 5 February 2025
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[0125] lids in the cleaning unit digitally in the identification element as a rewritable identification element of the bases and lids. By recording the history, defects that only occur later can also be fed back into the process control and causes of errors can be eliminated.
[0126] In another embodiment the packing unit is adapted to place the bases and the lids, which have passed the cleaning unit, as individual stacks by folding or flapping the bases or the lids in a flat state into one or more compartments of the transport box. The packing unit includes suitable gripping means to grasp the bases and lids from a delivery means, such as a conveyor belt, and place them into the transport boxes. These gripping means are, for example, gripping robots. The bases and lids can be brought into the folded flat form on the conveyor belt or in a folding device connected to or following the conveyor belt before being grasped. Alternatively, the folded flat form could be achieved when placing the bases and lids into the transport boxes, for example, by the side boundaries (walls) of the compartments folding the bases and lids along the fold lines when inserting them into the compartments, with the areas of the bases and lids being folded that protrude beyond the side boundaries (walls) of the compartments. This would make folding and placing into the transport boxes a combined process. The term “compartment” denotes the transport volume, where lids or bases are placed into. The size of the compartment might be equal to the size of the transport box or smaller.
[0127] In another embodiment the packing unit is intended to insert one or more partition walls into the transport box to divide the transport box into several suitable compartments. Insertable partition walls allow flexible design of different compartments. Here, the transport boxes could be retrofitted to the respective need for transporting bases or lids. Also, a folded transport of empty transport boxes is facilitated if partition walls can be removed before empty transport to facilitate flat laying of the transport box for volume-reduced transport. These are then reinserted into the erected transport boxes in the packing unit. In the easiest case, a flat wall is inserted into the transport volume of the transport box to divide the transport volume into two compartments separated from each other by the partition wall.40262 / 4361 / PTWO 5 February 2025
[0128] 26
[0129] In another embodiment the packing unit is intended to store data for the unique identification of the bases and lids transported with the transport box in a machine-readable data storage of the transport box. This allows the transport of bases and lids from the first to the second building to be effectively monitored and the provision of the required number of bases and lids to be precisely controlled, as the position and content of the transport boxes can be matched and tracked with the target values. The machine-readable data storage of the transport box might be an RFID chip.
[0130] In another embodiment the packing unit is adapted to close the transport box with a cover lid, preferably the transport boxes and / or the cover lids are made of a dirt-tight material. The cover lid and the used dirt-tight material is suited to maintain the cleaned and disinfected status of bases and lids during transport.
[0131] The present invention further relates to a system comprising a reconditioning center according to the present invention in a primary circuit and a recycling unit in a secondary circuit, wherein the recycling unit is arranged in a separate and spatially remote building from the reconditioning center, wherein the secondary circuit is logistically linked to the primary circuit in the reconditioning center, in order to granulate the non-reusable bases or lids of the shelf-ready secondary packaging excluded from the primary circuit by the reconditioning center and to feed them to a recovery or other use, wherein the system comprises a plurality of data exchange units distributed over the primary and secondary circuits to determine actual positions of bases and lids in the primary and secondary circuits and a system controller which is connected to the data exchange units and to the control unit of the reconditioning center for transmitting data, where the a system controller controls the individual bases and lids of the shelf-ready secondary packaging in the system with their unique identification, their type, their positions in the system and stores data on the bases and lids of the shelf-ready secondary packaging and, by knowing the data on bases and lids, controls the primary circuit and the secondary circuit for the reuse of shelf-ready secondary packaging on the basis of the condition, quality and degree of soiling of the respective shelf-ready secondary packaging.40262 / 4361 / PTWO 5 February 2025
[0132] 27
[0133] The secondary circuit ensures that non-reusable bases and lids are also efficiently and environmentally friendly recycled to enable the sustainability of the entire system. The secondary circuit can also be called the "Smart Recycling System," which can meet the primary circuit "Smart Loops System" at various touchpoints. Components of the secondary circuit can be buildings or building shells for production, granulation, supply storage, and newly manufactured bases and lids. The inventive system can include a fourth building for production, a fifth building for granulation, and a sixth building for supply storage.
[0134] The reconditioning center is well suited as a link point to connect primary and secondary circuit logistically, as the provision of the bases and lids for further processing through the primary circuit takes place in the reconditioning center, and the recovered bases and lids can be assigned to the quantitative and local needs in the second buildings. This feeding can be done by delivery to the entrance area of the reconditioning center with subsequent sorting and cleaning. In this case, the recovered bases and lids can be delivered type-pure by the recycling unit but can also be delivered in a mixed transport of different types, as sorting takes place in the sorting unit of the reconditioning center. The recovered bases and lids can be delivered by the recycling unit in the same transport boxes as in the rest of the primary circuit. Alternatively, in the case of type-pure transport, the bases and lids can also be delivered to the packing unit of the reconditioning center or directly to the second building for equipping with primary packaging, provided the recovery process does not require cleaning of the recovered bases and lids for later use. If the recovered bases and lids are delivered to the packing unit, the packing unit additionally includes an entrance area for recovered bases and lids, to which the packing station uses suitable transfer means (e.g., gripping robots) to remove the bases and lids from the transport boxes and place them into the transport boxes intended for providing the bases and lids for the second building.
[0135] The recycling unit may equip the manufactured bases and lids with the identification element for the unique identification of the bases and lids and their types and determine their positions in the system by means of data exchange units, wherein the date of new manufacture, preferably also the date of first use of the original material, is stored in the identification element. Thus, precise traceability and40262 / 4361 / PTWO 5 February 2025
[0136] 28
[0137] management of the bases and lids can be ensured from the time of recovery to increase reliability and transparency throughout the system, including the secondary circuit. The identification elements can be glued to the bases and lids from the outside, for example. Alternatively, these can be embedded in the material of the bases and lids during the manufacturing process of the bases and lids.
[0138] The system controller refers to a central element in the technical and organizational system that enables the monitoring, control, and coordination of various processes and components. It ensures the efficiency and effectiveness of the entire system by collecting, analyzing data, and making decisions based on it. The system controller continuously monitors the condition and performance of the various components of the system. This can be done through sensors, cameras, or other data collection devices that provide real-time information. The collected data is analyzed and processed to assess the current state of the system. This can include anomaly detection, performance evaluation, or prediction of future states. Based on the data analyzed, the system controller makes decisions and sends control commands to the various components of the system. This can include adjusting parameters, turning devices on or off, or changing operating modes. The system controller coordinates the interactions between the various components of the system to ensure that they work efficiently and harmoniously together. This is particularly important in complex systems with many interdependent processes. All actions and state changes are documented by system control. This enables traceability and helps with error diagnosis and troubleshooting.
[0139] In a circuit system for the reuse of shelf-ready secondary packaging, the system controller plays a central role. It monitors the shelf-ready secondary packaging transported between different buildings and ensures that they are in a suitable condition for reuse. The system controller collects data on each base and lid of the shelf-ready secondary packaging, such as identification, type, position, condition, and degree of contamination. Based on this data, it decides whether a display should be reused. These decisions are documented to ensure seamless traceability. System control is thus an indispensable tool for monitoring, controlling, and coordinating processes in technical and organizational systems. It collects and40262 / 4361 / PTWO 5 February 2025
[0140] 29
[0141] analyzes data, makes decisions based on it, and documents all actions to maximize the efficiency and effectiveness of the system.
[0142] The system controller comprises one or more databases, preferably a central database. This database can include, among other things, the locations of the individual bases and lids along the primary circuit. This allows a deposit system to be integrated into the system according to the invention to ensure that the displays are returned. As a basis for a deposit system, this technical system can track the position data of the bases and lids as well as their return, for example, in the first building, which makes a deposit system possible in the first place.
[0143] The system according to the invention can help reduce losses and theft by continuously monitoring the secondary packaging and thus the goods. If an item is unexpectedly moved or removed from the designated area, the system can immediately trigger an alarm and take appropriate measures. This increases security in the warehouse and protects the inventory. The system offers seamless traceability of secondary packaging along the entire supply chain. This means that companies always know where a particular base and / or lid is located and what its status is. This transparency is particularly important for compliance with regulations and for traceability in the event of product recalls. The system also offers the possibility of applying any labeling or customization to the bases and lids in various ways through the appropriate choice of materials and surface structure.
[0144] The present invention further relates to a method to operate a reconditioning center according to the present invention in at least one primary circuit, the primary circuit extending over a plurality of separate and spatially separated buildings for the reuse of shelf-ready secondary packaging for transportation and suitable presentation and dispending of goods-filled primary packaging, wherein the shelf-ready secondary packaging is designed in two parts with a one-piece foldable base and a separate one-piece foldable lid each comprise at least one identification element for uniquely identifying at least the types of base and lid and determining their positions and each consisting of more than 50% by weight of a corrugated plastic material, wherein the base consists at least of a bottom and side walls surrounding the bottom comprising a display side, wherein the lid and the base can be reversibly converted multiple40262 / 4361 / PTWO 5 February 2025
[0145] 30
[0146] times from a flat form to an erected form and back by folding along pre-formed fold lines, wherein the erected form of the base is intended for filling with primary packaging containing goods, and the erected form of the lid is intended to be suitably assembled with the base to enclose the primary packaging as filled shelf-ready secondary packaging, comprising following steps:
[0147] receiving the used bases and lids of the shelf-ready secondary packaging in transport boxes in a compact or other state in the reconditioning center by means of one or more vehicles;
[0148] uniquely identifying types and position of the received bases and lids by a plurality of data exchange units distributed over the for subsequent processes carried out in the reconditioning center, which at least reading out the identification elements of bases and lids;
[0149] type-based sorting of bases and lids in a sorting unit of the reconditioning center according to a classification of bases and lids executed in the sorting unit with respect to condition, quality and degree of soiling;
[0150] cleaning and / or processing the bases and lids handed over by the sorting unit in a cleaning unit of the reconditioning center, for which purpose the cleaning unit comprises one or more cleaning lines with respective one or more processing stations arranged in series, which are passed through the respective cleaning line on a conveyor belt by the bases and lids;
[0151] type-based packing of bases and lids, which have passed the cleaning unit as reusable bases and lids, into separate transport boxes in a packing unit of the reconditioning center for a separate transport of the bases and lids to the further buildings in the primary circuit for the future reuse and back transport to the reconditioning center after use; and
[0152] controlling the units of the reconditioning center to execute sorting, cleaning and / or preparation, and packing of the shelf-ready secondary packaging based on data provided by the data exchange units.
[0153] The method to operate the reconditioning center according to the present invention in a primary circuit for the reuse of shelf-ready secondary packaging for the transport and suitable presentation and dispensing of goods-filled primary packaging provides the same advantages as already described for the reconditioning.40262 / 4361 / PTWO 5 February 2025
[0154] 31
[0155] In an embodiment the step of type-based sorting is executed as cascaded fine sorting of the bases and lids, where the sorting unit comprises at least two separate sorting cells arranged one behind the other in a branching linear sorting process, where each sorting cell comprises an arrangements of collecting containers and sorting means, preferably the separate sorting cells are set up to suitably transfer collecting containers of one sorting cell to the subsequent sorting cells for further fine sorting.
[0156] In another embodiment the method comprises the further steps of:
[0157] detecting and removing labels that do not serve as identification elements at least from the bases before cleaning the bases, preferably by blowing them off, in a first processing station of the cleaning line, and
[0158] labeling at least the bases after cleaning, wherein at least one base label is applied to a prepared application surface on at least one of the side walls of the base, preferably on the side wall opposite the display side, which comprises the application surface, in a fifth processing station of the cleaning line, particularly preferably the base label completely covers the application surface.
[0159] In another embodiment the step of labeling at least the bases after cleaning comprises the further steps of:
[0160] applying a presentation label in the form of the display side for further designation of the product-filled primary packaging to the display side of the base in the fifth processing station; and / or
[0161] connecting a reversibly attachable and removable cover with the display side of the base in the fifth processing station by use of fixing means of the cover fitting to corresponding means of the display side, preferably the fixing means of the display side is realized as one or more suitably dimensioned slots and the corresponding fastening means of the cover is realized as one or more suitably shaped tabs.
[0162] The term "a," "an," or "one" here does not denote a specific number of the components referred to but explicitly includes the possibility that the claimed subject matter may also comprise one or more of these components in addition to the one40262 / 4361 / PTWO 5 February 2025
[0163] 32
[0164] component. Thus, the term is also to be understood as "one or more." If the number of specified components is meant to be exactly 1 , this is indicated with "exactly one”.
[0165] The above-described embodiments can be used individually or in any combination with each other, even in deviation from the back references of the dependent claims to each other stated in the claims.
[0166] Brief description of the drawings
[0167] These and other aspects of the invention are illustrated in detail in the following drawings:
[0168] Fig.1 : a schematic view of an embodiment of the reconditioning center according to the present invention;
[0169] Fig.2: a detailed view of an embodiment the reconditioning center of fig.1 ;
[0170] Fig.3: a detailed view of an alternative embodiment the reconditioning center of fig.1;
[0171] Fig.4: a schematic view of a detection substrate in the sorting unit of the reconditioning center according to the present invention;
[0172] Fig.5: a schematic view of an inspection station within the cleaning line of the reconditioning center according to the present invention;
[0173] Fig.6: a schematic view of preparing the transport box for transportation of bases or lids in the packaging unit of the reconditioning center according to the present invention;
[0174] Fig.7: a schematic view of (a) applying a base label in the labeling station and (b) removing a base label from the base in the de-labeling station of the reconditioning center according to the present invention;
[0175] Fig.8: a schematic view of (a) applying a presentation label and (b) attaching a removable cover, both to the display side of the base in the labeling station of the reconditioning center according to the present invention;
[0176] Fig.9: a schematic view of an embodiment of the system according to the invention (a) as a circuit, and (b) with a system control; and
[0177] Fig.10: an embodiment of the method according to the present invention to operate the reconditioning center of fig.1.40262 / 4361 / PTWO 5 February 2025
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[0179] Detailed description of embodiments
[0180] The embodiments shown here are only examples of the present invention and must therefore not be understood as restrictive. Alternative embodiments considered by skilled people are equally covered by the scope of protection of the present invention.
[0181] Fig.1 shows a schematic view of an embodiment of the reconditioning center 20 in at least one primary circuit 1a according to the present invention. The primary circuit 1a extends over a plurality of separate and spatially separated buildings 20, 70, 80 for the reuse of shelf-ready secondary packaging 10, 15 for transportation and suitable presentation and dispending of goods-filled primary packaging 50. The shelf-ready secondary packaging 10, 15 is designed in two parts with a one-piece foldable base 10 and a separate one-piece foldable lid 15 each comprising at least one identification element 13 for uniquely identifying at least the types of bases 10 and lids 15 and determining their positions. For more details regarding the bases and lids, see figure 2, 3, 7 and 8. The reconditioning center 20 comprises a sorting unit 21 for the classification of the bases 10 and lids 15 of the returned shelf-ready secondary packaging 10, 15 according to parameters, e.g. condition, quality and degree of soiling and type-based sorting S of bases 10 and lids 15 based on the made classifications. It further comprises a cleaning unit 31 intended to clean and / or process RA the bases 10 and lids 15 handed over by the sorting unit 21 , for which purpose the cleaning unit 31 comprises one or more cleaning lines 31a, 31b with respective one or more processing stations 32a - f arranged in series, which are passed by the bases 10 and lids 15 on a conveyor belt 33. The individual cleaning lines 31a, 31b and their processing stations 32a - f might be specifically intended for different cleaning methods RA based on the degree of contamination of the bases 10 or the lids 15. For example, the cleaning line 31 a can be for dry cleaning RT and the cleaning line 31 b for wet cleaning RF or vice versa. It further comprises a packing unit 41 for type-based sorting for bases 10 and lids 15, where bases 10 and lids 15, which have passed the cleaning unit 31, are packed in separate transport boxes 61 for separate transportation in vehicles 60 to the other buildings 70, 80 along the primary circuit 1a and back to the reconditioning center 20. The transport box 61 comprises a bottom of the box 61 and side walls of the box 61 around the bottom of the box 61 (for more details on transport boxes see fig. 6 and40262 / 4361 / PTWO 5 February 2025
[0182] 34
[0183] description). It further comprises a plurality of data exchange units 6 distributed over the units 21, 31, 41 of the reconditioning center 20 to at least readout the identification elements 13 of bases 10 and lids 15 for uniquely identifying at least the types of bases 10 and lids 15 and determining their positions within the reconditioning center 20. It further comprises a control unit 20s intended to control the units 21 , 31, 41 of the reconditioning center 20 to execute sorting S, cleaning and / or preparation RA, and providing B of the shelf-ready secondary packaging 10, 15 based on data readout by the data exchange units 6. In this embodiment, the control unit 20s is configured to exclude used bases 10 and / or lids 15 that cannot be reused due to damage or contamination from the primary circuit 1a. Therefore, the sorting unit 21 is configured to perform a sensor-based incoming inspection for the bases 10 and lids 15 and to remove bases 10 and / or lids 15 from further processing that has been classified as non-reusable by the control unit 20s due to e.g. condition, quality, and degree of contamination from the primary circuit 1a. Here, the excluded bases 10 and lids 15 enter a secondary circuit 1b as further described in fig.9. The cleaning unit 31 is set up to carry out a sensor-based final inspection of the respective bases 10 and lids 15 after passing through the cleaning unit 31 and to exclude the bases 10 and lids 15 classified as non-reusable from the primary circuit 1 a in case of being classified as non-reusable by the control unit. The same applies to the packaging unit in case some bases 10 or lids 15 are not suitable to be packed into the transport boxes for delivery to the subsequent buildings 70, 80. A software SW is executed by the control unit 20s that may use machine learning and artificial intelligence through appropriate algorithms to support data analysis and process control in the sorting S, cleaning and / or preparation RA, and providing B of the shelf-ready secondary packaging 10, 15, including a classification of the bases 10 and lids 15 according to parameters, e.g. condition, quality, and degree of contamination based on the recorded conditions, qualities, and degrees of contamination on the bases 10 and lids 15, preferably, the machine learning is supervised learning using classifications and / or regression.
[0184] Fig.2 shows a detailed view of an embodiment of the reconditioning center 20 of fig.1. The bases 10 and lids 15 processed in the reconditioning center 20 are supplied from an entry point of the reconditioning center 20 to the sorting means 2240262 / 4361 / PTWO 5 February 2025
[0185] 35
[0186] of the first unit, the sorting unit 21 , either continuously by suitable conveying means 24 or in batches from one or more input containers 23c. The sorting unit 21 comprises an RFID reader as a first sensor(s) 21a for reading an RFID transponder as the identification element 13 of the base 10 and the lid 15 of the shelf-ready secondary packaging 10, 15 to determine and classify the respective type of base 10 and lid 15, and one or more optical sensors as second sensors 21b for recording the condition and / or quality and / or degree of contamination of the base 10 or lid 15, where first and second sensors 21a, 21b are connected to the control unit 20s. The sorting unit 21 comprises a plurality of collection containers 23 and one or more sorting means 22, shown as gripping robots 22 here , which are designed to enable a type-based sorting of the respective bases 10 and lids 15 into the collection containers 23 accessible to the gripping robots 22 based on parameters e.g. the classified condition, quality, and degree of contamination of the respective base 10 or lid 15. Each collection container 23 is assigned to different types and classifications of e.g. condition, quality, and degree of contamination. At least a second collecting container 23a and / or a third collecting container 23b are present within an arrangement of the collecting containers 23 for certain classifications, which can be loaded with bases 10 or lids 15 by the respective gripping robots 22 accessible to the same gripping robots 22. Hereby, the second collecting container 23a is provided as a temporary buffer container for full and exchangeable collecting containers 23 for certain classifications, and the third collecting container 23b is provided as an intermediate storage for goods displays with incorrect spatial orientation. There are two separate cleaning lines 31 a, 31 b, where a first processing station 32a of the cleaning lines 31a, 31b is set up to detect labels 14a, 14b (shown in fig. 7 and 8) at least on the bases 10, that do not serve as identification elements 13 and to remove them before cleaning the bases 10, preferably by blowing them off. For more details on de-labeling see fig.7b. A second processing station 32b of the cleaning lines 31a, 31b carries out the cleaning process of the base 10 and / or the lid 15 by means of wet cleaning RF, e.g. by spraying with a cleaning fluid, and / or by means of dry cleaning RT, e.g. by mechanical brushing or air pressure cleaning, and at least a third processing station 32c of the cleaning line 31a (lower line) for drying the bases 10 and / or lids 15 cleaned with the preceding wet cleaning RF, e.g. by means of a gas blower, heat radiation, or a spinning process. To execute the40262 / 4361 / PTWO 5 February 2025
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[0188] spinning process, a gripper may hold the bases 10 and lids 15 in their flat spread out form 10e (see fig. 4) from both side at a location close to the center of gravity of base 10 and lid 15 and rotates the gripped base 10 or lid 15 around a gripping axis, which is perpendicular to the surface of the gripped part of the base 10 and lid 15. A fourth processing station 32d of the cleaning lines 31a, 31b is intended for disinfecting the bases 10 and / or lids 15, preferably by irradiation with suitable UV light. Particularly preferable hereby is the arrangement of the processing stations 32a - f for disinfecting along the conveyor belt 33 behind the third processing station 32c for drying in the case of a preceding wet cleaning FT. A fifth processing station 32e of the cleaning lines 31a, 31b is intended for labeling at least the bases 10 after cleaning, wherein at least one base label 14a is applied to a prepared application surface 18 on at least one of the side walls 12 of the base 10, preferably on the side wall 12b opposite the display side 12a, which comprises the application surface 18, particularly preferably the base label completely covers the application surface 18. For more details regarding the labeling see fig. 7a, 8. The cleaning lines 31a, 31b comprise a conveyor belt 33 where the bases 10 and lids 15 pass through the respective cleaning lines 31a, 31b in a completely spread out 10e way or hanging on the conveyor belt 33. The cleaning unit 31 comprises one or more data exchange units 6 which stores the respective processes carried out for the individual bases 10 and lids 15 in the cleaning unit 31 digitally in the identification element 13. Whereas the identification element 13 of the bases 10 and lids 15 is rewritable. The packing unit 41 is adapted to place bases 10 and lids 15, which have passed the cleaning unit, as individual stacks by folding or flapping the bases 10 or the lids 15 in a flat state 10k into one or more compartments 61 b of the transport box 61. By integrating the content (goods) with the unique identification element 13 of the shelf-ready secondary packaging 10, 15, information about the goods can be associated with the shelf-ready secondary packaging 10, 15. Additionally, events affecting the goods during distribution can be recorded on the identification element 13. The information can then deleted in the reconditioning center 20.
[0189] The bases 10 and lids 15 of the shelf-ready secondary packaging 10, 15 processed in the reconditioning center 20 each consisting of more than 50% by weight of a corrugated plastic material, wherein the one-piece foldable base 10 consisting at40262 / 4361 / PTWO 5 February 2025
[0190] 37
[0191] least of a bottom 11 and side walls 12 surrounding the bottom 11 comprising a display side 12a, wherein the lid 15 and the base 10 can be reversibly converted multiple times from a flat form 10k to an erected form 10h and back by folding along pre-formed fold lines, wherein the erected form 10h of the base 10 is intended for filling with primary packaging 50 containing goods, and the erected form of the lid 15 is intended to be suitably assembled with the base 10 to enclose the primary packaging 50 as filled shelf-ready secondary packaging 10, 15, see also fig. 4, 7, 8. The application surface 18 on the bases 15 (and eventually also on the lids 15) for applying the base label 14a specifically reduces the adhesion of the base label 14a on the application surface 18 to achieve sufficient adhesion of the base label 14a during a cycle in the primary circuit 1a and to enable easy removal of the base label 14a in the cleaning unit 31 by blowing off. The application surface 18 can be adapted and coordinated to the process requirements in the cleaning lines 31 a, 31 b (removal of the base label) and in the other primary circuit 1 a (sufficient adhesion of the base label on the application surface). Thus, a specific adhesion provided by the application surface 18 in conjunction with the adhesive side of the base label 14b can fulfill both requirements. This also applies to the labeling of a representation label 14b as shown in fig.8a.
[0192] Fig.3 shows a detailed view of an alternative embodiment of the reconditioning center 20 of fig.1. In contrast to fig.2, the sorting unit 21 here comprises two arrangements of collecting containers 23, 23a, 23b, 23c and gripping robots 22 as respective separate sorting cells 211, 212 arranged behind each other in order to enable cascading fine sorting of the bases 10 and lids 15 in a cascaded sorting process. Here, the sorting cells 211, 212 are arranged as levels 211 and 212 comprising three sorting cells per level 211, 212. Therefore, the sorting process shown here is a branched sorting process. The separate sorting cells or levels 211 , 212 are set up to transfer collecting containers from the first sorting cell 211 to the second sorting cell 212 for cascading fine sorting of the bases 10 and lids 15 by gripping robots 22. Fig.2 and its description is referred to for all other details of fig.
[0193] 3.
[0194] Fig.4 shows a schematic view of a detection substrate 25 in the sorting unit 21 of the reconditioning center 20 according to the present invention. Since the sorting40262 / 4361 / PTWO 5 February 2025
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[0196] unit 21 has to determine parameters e.g. the condition, quality, and degree of contamination on both sides of the base 10 and lids 15, bases 10 and lids 15 are present fully spread out in one plane on the detection substrate 25, shown in an example for a base 10, where bottom 11 and side walls 12 are spread out in one plane from a formally flat form 10k. The readout of the RFID tag as identification element 13 is contactless by an RFID reader as sensor 21b, while the other parameters are detected by one or more optical sensor 21a. The data readout or determined are transferred to the control unit 20s via data connections, either via data cables or cableless via a LAN connection. The spread out base 10 and / or lids 15 are classified on a transparent detection substrate 25 allowing the determination of the parameters e.g. the condition, quality, and degree of contamination of both sides of the base 10 and lids 15 simultaneously on both sides. In this embodiment, it has the advantage that there is no need for a turning mechanism to assess the parameters of bases 10 and lids 15 on both sides.
[0197] Fig.5 shows a schematic view of an inspection station 32f within the cleaning line 31a of the reconditioning center 20 according to the present invention. The inspection station 32f as a sixth processing station 32f of the cleaning line 31a is arranged behind the third processing station 32c, where the inspection station 32f is designed to detect any remaining residual liquid on the bases 10 and lids 15 after drying and, in the event of detecting residual liquid, to subject the base 10 or lid 15 to a renewed drying, preferably by reintroducing the base 10 or lid 15 onto the conveyer belt 33 passing through the processing station 32c for drying in front of the third processing station. The detection of residual humidity or liquid might be done by optical detection, where a suitable detection software analyses a taken picture and recognizes residual humidity or liquid according to characteristic patterns on the picture. The bases 10 and lids 15 pass through the respective cleaning line 31a in a completely spread out 10e form on the conveyor belt 33 (shown here) or hanging on the conveyor belt 33 (not shown here). In case of the spread out transport shown here, the third processing station 32c comprises a turning station 32w for the bases 10 and lids 15 to drying of both sides, one before turning, the other side after turning.
[0198] Fig.6 shows a schematic view of preparing the transport box 61 for transportation of the bases 10 or the lids 15 in the packaging unit 41 of the reconditioning center 2040262 / 4361 / PTWO 5 February 2025
[0199] 39
[0200] according to the present invention. The packing unit 41 is adapted to place the bases 10 and the lids 15, which have passed the cleaning unit 31, as individual stacks by folding or flapping the bases 10 or the lids 15 in a flat state 10k into one or more compartments 61 b of the transport box 61. If requested, the packing unit 41 inserts one or more partition walls 61a into the transport box 61 to divide the transport box 61 into several suitable compartments 61b. The partition wall 61a might be pushed into corresponding guiding rails or grooves of the transport box 61 to ensure a defined position of the inserted partition wall 61a. In any case the packing unit 41 is intended to store data for the unique identification of the bases 10 and lids 15 transported with the transport box 61 in a machine-readable data storage 62 of the transport box 61. The packing unit 41 may close the transport box 61 with a cover lid 63. Preferably, the transport boxes 61 and / or the cover lids 63 are made of a dirt-tight material. In case the transport boxes 61 are provided to the packing unit 41 in a folded or flattened form, the packing unit 41 is adapted to erect the transport boxes 61 , eventually attaching a bottom part and side walls of the transport box 61 together to provide the storage volume inside the transport box 61.
[0201] Fig.7 shows a schematic view of (a) applying a base label 14a to a base 10 in the labeling station 32e and (b) removing a base label 14a from the base 10 in the delabeling station 32a of the reconditioning center 20 according to the present invention. The fifth processing station 32e as the labeling station of the cleaning line 31a, 31b is intended for labeling at least the bases 10 after cleaning, wherein at least one base label 14a is applied to a prepared application surface 18 on at least one of the side walls 12 of the base 10. Preferably, this side wall 12 is the side wall 12b opposite the display side 12a, which comprises the application surface 18. Here, the base label may partly or completely cover the application surface 18. The base label 14a here comprises two lateral side area 14c (black areas) designed so that the two lateral side areas do not adhere to the base 10 or the application surface 18 or comprises a pull tab 14d to prepare for the successful removal of the base label 14a and / or the presentation label 14b during reuse of the respective base 10 in the first processing station 32a. Furthermore, a first processing station 32a as delabeling station 32a of the cleaning line 31a, 31b is set up to detect labels (base labels 14a, representation labels 14b at least on the bases 10, that do not serve as40262 / 4361 / PTWO 5 February 2025
[0202] 40
[0203] identification elements 13 and to remove them before cleaning the bases 10. The attached base labels 14a can be blown off by blowing below one of the non-adhering lateral side areas 14c or the pull tab 14d. Labels with pull tabs 14d might be removed mechanically alternatively by suitable pulling means, such as pulling grippers (not shown here).
[0204] Fig.8 shows a schematic view of (a) applying a presentation label 14b and (b) attaching a removable cover 17, both to the display side 12a of the base 10 in the labeling station 32e of the reconditioning center 20 according to the present invention. The fifth processing station 32e as the labeling station 32e of the cleaning line 31 a, 31 b for labeling at least the bases 10 after cleaning is further configured to apply a presentation label 14b in the form of the display side 12a for further designation of the product-filled primary packaging 50 to the display side 12a. The presentation label 14b comprises at least one lateral side area 14c designed so that the lateral side area 14c does not adhere to the base 10 or the application surface 18 or the lateral side area 14b comprises a pull tab 14d to prepare for the successful removal of the base label 14a and / or the presentation label 14b during reuse of the respective base 10 in the first processing station 32a. Alternatively or in combination, the fifth processing station 32e is configured to connect a reversibly attachable and removable cover 17 on the display side 12a of the base 10 by use of fixing means 172 of the cover 17 fitting to corresponding means 173 of the display side 12a. Here, the fixing means 173 of the display side 12a is realized as one or more suitably dimensioned slots 173 and the corresponding fastening means 172 of the cover 17 is realized as one or more suitably shaped tabs 172.
[0205] Fig.9 shows a schematic view of an embodiment of the system 1 according to the invention (a) as a circuit, and (b) with a system control 7. The system 1 comprises a reconditioning center 20 according to the present invention in a primary circuit 1a and a recycling unit 5 in a secondary circuit 1b, wherein the recycling unit 5 is arranged in a separate and spatially remote building from the reconditioning center 20, wherein the secondary circuit 1b is logistically linked to the primary circuit 1a in the reconditioning center 20 in order to granulate the non-reusable bases 10 or lids 15 of the shelf-ready secondary packaging 10, 15 excluded from the primary circuit 1a by the reconditioning center 20 and to feed them to a recovery or other use. The40262 / 4361 / PTWO 5 February 2025
[0206] 41
[0207] system 1 comprises a plurality of data exchange units 6 distributed over the primary and secondary circuits 1a, 1b to determine actual positions of bases 10 and lids 15 in the primary and secondary circuits 1a, 1b and a system controller 7 which is connected to the data exchange units 6 and to the control unit 20s of the reconditioning center 20 for transmitting data, where the system controller 7 controls the individual bases 10 and lids 15 of the shelf-ready secondary packaging 10, 15 in the system 1 with their unique identification, their type, their positions in the system 1 and stores data on the bases 10 and lids 15 of the shelf-ready secondary packaging 10, 15. By knowing the data on bases 10 and lids 15, the controller 7 controls the primary circuit 1a and the secondary circuit 1b for the reuse of shelfready secondary packaging 10, 15 on the basis of e.g. the condition, quality and degree of soiling of the respective shelf-ready secondary packaging 10, 15.
[0208] Fig.10 shows an embodiment of the method 100 according to the present invention to operate the reconditioning center 20 of fig.1 according to the present invention in at least one primary circuit 1a. The primary circuit 1a extends over a plurality of separate and spatially separated buildings 20, 70, 80 for the reuse of shelf-ready secondary packaging 10, 15 for transportation and suitable presentation and dispending of goods-filled primary packaging 50. The shelf-ready secondary packaging 10, 15 is designed in two parts with a one-piece foldable base 10 and a separate one-piece foldable lid 15 each comprising at least one identification element 13 for uniquely identifying at least the types of base 10 and lid 15 and determining their positions, comprising the following steps: receiving 110 the used bases 10 and lids 15 of the shelf-ready secondary packaging 10, 15 in transport boxes 61 in a compact or other state 10k, 10e, 10h in the reconditioning center 20 by means of one or more vehicles 60; uniquely identifying 120 types and position of the received bases 10 and lids 15 by a plurality of data exchange units 6 distributed over the for subsequent processes carried out in the reconditioning center 20, which at least reading out the identification elements 13 of bases 10 and lids 15; typebased sorting 130 of bases 10 and lids 15 in a sorting unit 21 of the reconditioning center 20 according to a classification of bases 10 and lids 15 executed in the sorting unit 21 with respect to condition, quality and degree of soiling; cleaning and / or processing 140 the bases 10 and lids 15 handed over by the sorting unit 21 in a40262 / 4361 / PTWO 5 February 2025
[0209] 42
[0210] cleaning unit 31 of the reconditioning center 20, for which purpose the cleaning unit 31 comprises one or more cleaning lines 31a, 31b with respective one or more processing stations 32a - f arranged in series, which are passed through the respective cleaning line 31a, 31b on a conveyor belt 33 by the bases 10 and lids 15; type-based packing 150 of bases 10 and lids 15, which have passed the cleaning unit 31 as reusable bases 10 and lids 15, into separate transport boxes 61 in a packing unit 41 of the reconditioning center 20 for a separate transport of the bases 10 and lids 15 to the further buildings 70, 80 in the primary circuit 1a for the future reuse and back transport to the reconditioning center 20 after use; and controlling 160 the units 21, 31, 41 of the reconditioning center 20 to execute sorting 130, S, cleaning and / or preparation 140, RA, and packing 150, B of the shelf-ready secondary packaging 10, 15 based on data provided by the data exchange units 6. In an embodiment the type-based sorting 130 is executed as cascaded fine sorting of the bases 10 and lids 15, where the sorting unit 21 comprises at least two arrangements of collecting containers 23, 23a, 23b, 23c and sorting means 22 as separate sorting cells 211 , 212 arranged one behind the other in a branching linear sorting process, preferably, the separate sorting cells 211, 212 are set up to suitably transfer collecting containers of one sorting cell 211 , 212 to the subsequent sorting cells 211 , 212. In case the bases (and eventually also the lids) already have labels or will be having labels attached to them, the method comprises the further steps of detecting and removing 170 labels 14a, 14b that do not serve as identification elements 13 at least from the bases 10 before cleaning the bases 10, preferably by blowing them off, in a first processing station 32a of the cleaning line 31a, 31b, and labeling 180 at least the bases 10 after cleaning, wherein at least one base label 14a is applied to a prepared application surface 18 on at least one of the side walls 12 of the base 10, preferably on the side wall 12b opposite the display side 12a, which comprises the application surface 18, in a fifth processing station 32e of the cleaning line 31a, 31b, particularly preferably the base label completely covers the application surface 18. Eventually the lids 15 might be labeled in an analogous procedure applied to the lids in principally the same way. The same applies for eventually de-labeling the lids 15 in case of labels being present on the lids 15 of the lids 15 returned to the reconditioning center 20. In an embodiment, the step of labeling 180 at least the bases 10 after cleaning may comprises the further steps of40262 / 4361 / PTWO 5 February 2025
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[0212] applying 190 a presentation label 14b in the form of the display side 12a for further designation of the product-filled primary packaging 50 to the display side 12a of the base 10 in the fifth processing station 32e; and / or connecting 200 a reversibly attachable and removable cover 17 with the display side 12a of the base 10 in the fifth processing station 32e by use of fixing means 172 of the cover 17 fitting to corresponding means 173 of the display side 12a, preferably the fixing means 173 of the display side 12a is realized as one or more suitably dimensioned slots 173 and the corresponding fastening means 172 of the cover 17 is realized as one or more suitably shaped tabs 172. Therefore, step 140 may lead directly to step 150 or may comprise additionally step 180 or a combination of steps 170 and 180. Step 180 may only relate to the application of a base label 14a or may comprise additionally the steps 190 or 200, where the fifth processing station 32e of the cleaning line 31 a, 31 b as labeling station 32e may execute step 190 for some bases 10 and step 200 for other bases 10 in a mixed operational mode. However, for an individual base 10, only one of steps 190 or 200 is applied.40262 / 4361 / PTWO 5 February 2025
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[0214] List of reference numerals
[0215] 1 system according to the present invention
[0216] 1 a primary circuit of the inventive system
[0217] I b secondary circuit of the inventive system
[0218] 5 recycling unit
[0219] 6 data exchange unit
[0220] 7 system control
[0221] 10 base of shelf-ready secondary packaging
[0222] 10e completely spread out form of base and lid
[0223] 10h erected form of the base and / or lid intended for filling or already filled with primary packaging containing goods
[0224] 10k flat form of base or lid
[0225] I I bottom of the base
[0226] 12 side walls of the base
[0227] 12a display side of the base
[0228] 12b side wall opposite of the display side
[0229] 13 identification element of the base and / or the lid
[0230] 14a base label as one of the labels
[0231] 14b presentation label for further designation of the product-filled primary packaging as another one of the labels
[0232] 14c lateral side area of any label designed so that it does not adhere to the base
[0233] 14d pull tab
[0234] 15 lid of shelf-ready secondary packaging
[0235] 17 cover
[0236] 171 surface of the cover, for labeling
[0237] 172 fastening means
[0238] 173 fastening means adapted for the attachment of the cover to the cover 18 application surface of base or lid
[0239] 20 reconditioning center (as a first building)
[0240] 20s control unit of the reconditioning center40262 / 4361 / PTWO 5 February 2025
[0241] 45
[0242] 21 sorting unit
[0243] 21a first sensors of the sorting unit
[0244] 21b second sensors of the sorting unit
[0245] 211, 212 separate sorting cells, level of sorting cells
[0246] 22 sorting means, preferably gripping robots
[0247] 23 collection containers
[0248] 23a second collection containers
[0249] 23b third collection containers
[0250] 23c input containers
[0251] 24 conveying means
[0252] 25 detection substrate
[0253] 31 cleaning unit
[0254] 31a, 31b cleaning line
[0255] 32a first processing station (de-labeling) of the cleaning line 32b second processing station (cleaning) of the cleaning line 32c third processing station (drying) of the cleaning line 32d fourth processing station (disinfecting) of the cleaning line 32e fifth processing station (labeling) of the cleaning line 32f sixth processing station (inspection) of the cleaning line 32w turning station
[0256] 33 conveyer belt of the cleaning unit
[0257] 36 handling robot
[0258] 41 packing unit
[0259] 42 conveyer belt of the packing unit
[0260] 43 packing robot
[0261] 50 goods-filled primary packaging
[0262] 60 vehicles for the transport of the base and lids
[0263] 61 transport box for the bases and / or lids
[0264] 61a partition walls inside of the transport box
[0265] 61b compartments for receiving the bases and lids
[0266] 62 machine-readable data storage of the transport box 63 cover lid of the transport box40262 / 4361 / PTWO 5 February 2025
[0267] 46
[0268] 70 second building(s), e.g. manufacturer buildings for filling the bases with goods-filled primary packaging
[0269] 80 third building(s), e.g. supermarkets for selling goods
[0270] 100 method to operate a reconditioning center
[0271] 110 receiving the used bases and lids of the shelf-ready secondary packaging in the reconditioning center
[0272] 120 uniquely identifying the received bases and lids and their types
[0273] 130 type-based sorting of bases and lids in a sorting unit
[0274] 140 cleaning and / or processing the bases and lids in a cleaning unit 150 type-based packing of bases and lids into separate transport boxes in a packing unit
[0275] 160 controlling the units of the reconditioning center
[0276] 170 detecting and removing labels from bases before cleaning the bases 180 labeling at least the bases after cleaning,
[0277] 190 applying a presentation label to the display side of the base.
[0278] 200 connecting a reversibly attachable and removable cover with the display side of the base.
[0279] AB removing the base label, e.g. by blowing off
[0280] B providing
[0281] S sorting
[0282] SW software
[0283] RA cleaning and / or preparation
[0284] RF wet cleaning
[0285] RT dry cleaning
Claims
40262 / 4361 / PTWO 5 February 202547Claims1. A reconditioning center (20) in at least one primary circuit (1a), the primary circuit (1a) extending over a plurality of separate and spatially separated buildings (20, 70, 80) for the reuse of shelf-ready secondary packaging (10, 15) for transportation and suitable presentation and dispending of goods-filled primary packaging (50), wherein the shelf-ready secondary packaging (10, 15) is designed in two parts with a one-piece foldable base (10) and a separate one-piece foldable lid (15) each comprise at least one identification element (13) for uniquely identifying at least the types of base (10) and lid (15) and determining their positions, comprising:a sorting unit (21) for classification of the bases (10) and lids (15) of the returned shelf-ready secondary packaging (10, 15) according to condition, quality and degree of soiling and type-based sorting (S) of bases (10) and lids (15) according to the made classification, preferably the bases (10) and lids (15) are supplied from an entry point of the reconditioning center (20) to the sorting means (22) either continuously by suitable conveying means (24) or in batches from one or more input containers (23c);a cleaning unit (31 ) intended to clean and / or process (RA) the bases (10) and lids (15) handed over by the sorting unit (21), for which purpose the cleaning unit (31) comprises one or more cleaning lines (31a, 31b) with respective one or more processing stations (32a-f) arranged in series, which are passed by the bases (10) and lids (15) on a conveyor belt (33), preferably the individual cleaning lines (31a, 31b) and their processing stations (32a-f) are specifically intended either only for bases (10) or only for lids (15) for their cleaning and / or processing (RA);a packing unit (41) for type-based sorting for bases (10) and lids (15), where bases (10) and lids (15), which have passed the cleaning unit (31 ), are packed in separate transport boxes (61 ) for a separate transportation in vehicles (60) to the further buildings (70, 80) along the primary circuit (1a) and back to the reconditioning center (20), where the transport box40262 / 4361 / PTWO 5 February 202548(61) comprises a bottom of the box (61) and side walls of the box (61) around the bottom of the box (61);a plurality of data exchange units (6) distributed over the units (21, 31, 41) of the reconditioning center (20) to at least readout the identification elements (13) of bases (10) and lids (15) for uniquely identifying at least the types of bases (10) and lids (15) and determining their positions within the reconditioning center (20);a control unit (20s) intended to control the units (21, 31, 41) of the reconditioning center (2) to execute sorting (S), cleaning and / or preparation (RA), and providing (B) of the shelf-ready secondary packaging (10, 15) based on data readout by the data exchange units (6), wherein the base (10) and the lid (15) of the shelf-ready secondary packaging (10, 15) each consisting of more than 50% by weight of a corrugated plastic material, wherein the one-piece foldable base (10) consisting at least of a bottom (11) and side walls (12) surrounding the bottom (11) comprising a display side (12a), wherein the lid (15) and the base (10) can be reversibly converted multiple times from a flat form (10k) to an erected form (10h) and back by folding along pre-formed fold lines, wherein the erected form (10h) of the base (10) is intended for filling with primary packaging (50) containing goods, and the erected form of the lid (15) is intended to be suitably assembled with the base (10) to enclose the primary packaging (50) as filled shelf-ready secondary packaging (10, 15).
2. The reconditioning center (20) according to claim 1, wherein the control unit (20s) is configured to exclude used bases (10) and / or lids (15) that cannot be reused due to damage or contamination from the primary circuit (1a), preferably the sorting unit (21) is configured to perform a sensor-based incoming inspection for the base (10) and lids (15) and to remove bases (10) and / or lids (15) from further processing that has been classified as non- reusable by the control unit (20s) due to e.g. condition, quality, and degree of contamination from the primary circuit (1a).40262 / 4361 / PTWO 5 February 2025493. The reconditioning center (20) according to claim 1 or 2, wherein a software (SW) executed by the control unit (20s) uses machine learning and artificial intelligence through appropriate algorithms to support data analysis and process control in the sorting (S), cleaning and / or preparation (RA), and providing (B) of the shelf-ready secondary packaging (10, 15), including a classification of the bases (10) and lids (15) according to parameters, e.g. condition, quality, and degree of contamination based on the recorded conditions, qualities, and degrees of contamination on the bases (10) and lids (15), preferably, the machine learning is supervised learning using classifications and / or regression.
4. The reconditioning center (20) according to any of the preceding claims, wherein the sorting unit (21 ) comprises at least first sensors (21a), preferably an RFID reader, for reading the identification element (13), preferably an RFID transponder, of the base (10) and / or lid (15) of the shelf-ready secondary packaging (10, 15) to determine and classify the respective type of base (10) and lid (15), and at least second sensors (21b), preferably optical sensors, for recording the condition and / or quality and / or degree of contamination of the base (10) or lid (15), where first and second sensors (21a, 21b) are connected to the control unit (20s).
5. The reconditioning center (20) according to any of the preceding claims, wherein the sorting unit (21) is configured to record parameters e.g. the condition, quality, and degree of contamination on both sides of the base (10) and lids (15) fully spread out in one plane, whereas the base (10) and / or lids (15) spread out in this way are preferably classified on a detection substrate (25), whereas it is particularly preferred, that a transparent detection substrate (25) is to be able to determine the condition, quality, and degree of contamination of both sides of the base (10) and lids (15) simultaneously.
6. The reconditioning center (20) according to any of the preceding claims, wherein the sorting unit (21 ) comprises a plurality of collection containers (23) and one or more sorting means (22), preferably gripping robots (22), which are40262 / 4361 / PTWO 5 February 202550designed to enable a type-based sorting of the respective bases (10) and lids (15) into the collection containers (23) accessible to the sorting means (22) based on parameters e.g. the classified condition, quality, and degree of contamination of the respective base (10) or lid (15), with each collection container (23) being assigned to different types and classifications of e.g. condition, quality, and degree of contamination.
7. The reconditioning center (20) according to claim 6, wherein at least a second collecting container (23a) and / or a third collecting container (23b) are present within an arrangement of the collecting containers (23) for certain classifications, which can be loaded with bases (10) or lids (15) by the respective sorting means (22), accessible to the same sorting means (22), wherein the second collecting container (23a) is provided as a temporary buffer container for full and exchangeable collecting containers (23) for certain classifications, and the third collecting container (23b) is provided as an intermediate storage for goods displays with incorrect spatial orientation.
8. The reconditioning center (20) according to claim 6 or 7, wherein the sorting unit (21 ) comprises at least two arrangements of collecting containers (23, 23a, 23b, 23c) and sorting means (22) as respective separate sorting cells (211 , 212) arranged one behind the other in order to enable cascading fine sorting of the bases (10) and lids (15) in a cascaded sorting process, preferably, the separate sorting cells (211, 212) are set up to suitably transfer collecting containers of one sorting cell (211 , 212) to the subsequent sorting cells (211 , 212) for cascading fine sorting of the bases (10) and lids (15).
9. The reconditioning center (20) according to any of the preceding claims, wherein a first processing station (32a) of the cleaning line (31a, 31b) is set up to detect labels (14a, 14b) at least on the bases (10), that do not serve as identification elements (13) and to remove them before cleaning the bases (10), preferably by blowing them off.40262 / 4361 / PTWO 5 February 20255110. The reconditioning center (20) according to any of the preceding claims, wherein a second processing station (32b) of the cleaning line (31a, 31b) carries out the cleaning process of the base (10) and / or the lid (15) by means of wet cleaning (RF), preferably by spraying with a cleaning fluid, and / or by means of dry cleaning (RT), preferably by mechanical brushing or air pressure cleaning, and at least a third processing station (32c) of the cleaning line (31a, 31b) for drying the bases (10) and / or lids (15) cleaned with the preceding wet cleaning (RF), preferably by means of a gas blower, heat radiation, or a spinning process.
11. The reconditioning center (20) according to claim 10, wherein an inspection station (32f) as a sixth processing station (32f) of the cleaning line (31a, 31b) is arranged behind the third processing station (32c), where the inspection station (32f) is designed to detect any remaining residual liquid on the bases (10) and lids (15) after drying and, in the event of detecting residual liquid, to subject the base (10) or lid (15) to a renewed drying, preferably by reintroducing the base (10) or lid (15) onto the conveyer belt (33) passing through the third processing station (32c) for drying in front of the third processing station.
12. The reconditioning center (20) according to any of the preceding claims, wherein a fourth processing station (32d) of the cleaning line (31a, 31b) is intended for disinfecting the bases (10) and / or lids (15), preferably by irradiation with suitable UV light, particularly preferably the processing stations (32a-f) for disinfecting are arranged along the conveyor belt (33) behind the third processing station (32c) for drying in the case of a preceding wet cleaning (FT).
13. The reconditioning center (20) according to any of the preceding claims, wherein a fifth processing station (32e) of the cleaning line (31a, 31b) is intended for labeling at least the bases (10) after cleaning, wherein at least one base label (14a) is applied to a prepared application surface (18) on at least one of the side walls (12) of the base (10), preferably on the side wall40262 / 4361 / PTWO 5 February 202552(12b) opposite the display side (12a), which comprises the application surface (18), particularly preferably the base label completely covers the application surface (18).
14. The reconditioning center (20) according to claim 13, wherein the fifth processing station (32e) is further configuredto apply a presentation label (14b) in the form of the display side (12a) for further designation of the product-filled primary packaging (50) to the display side (12a),and / or- to connect a reversibly attachable and removable cover (17) with the display side (12a) of the base (10) by use of fixing means (172) of the cover (17) fitting to corresponding means (173) of the display side (12a), preferably the fixing means (173) of the display side (12a) is realized as one or more suitably dimensioned slots (173) and the corresponding fastening means (172) of the cover (17) is realized as one or more suitably shaped tabs (172).
15. The reconditioning center (20) according to one of claims 13 or 14, wherein the base label (14a) and / or the presentation label (14b) each comprise at least one lateral side area (14c) designed so that lateral side area (14c) does not adhere to the base (10) or the application surface (18), or comprises a pull tab (14d) to prepare for the successful removal of the base label (14a) and / or the presentation label (14b) during reuse of the respective base (10) in the processing station (32a).
16. The reconditioning center (20) according to any of the preceding claims, wherein the cleaning line (31a, 31b) comprises a conveyor belt (33) passing the bases (10) and lids (15) pass through the respective cleaning line (31a, 31b) in such a way that they lie completely spread out (10e) on the conveyor belt (33) or hang on the conveyor belt (33), preferably the processing stations (32a-f) in the case of a lying transport each comprise a turning station40262 / 4361 / PTWO 5 February 202553(32w) for the bases (10) and lids (15) to enable cleaning and disinfection of both sides of the bases (10) and lids (15).
17. The reconditioning center (20) according to any of the preceding claims, wherein the cleaning unit (31) is set up to carry out a sensor-based final inspection of the respective bases (10) and lids (15) after passing through the cleaning unit (31) and to exclude the bases (10) and lids (15) classified as non-reusable from the primary circuit (1a) in case of being classified as non- reusable by the control unit.
18. The reconditioning center (20) according to any of the preceding claims, wherein the cleaning unit (31) comprises one or more data exchange units (6) which store the respective processes carried out for the individual bases (10) and lids (15) in the cleaning unit (31) digitally in the identification element (13) as a rewritable identification element (13) of the bases (10) and lids (15).
19. The reconditioning center (20) according to any of the preceding claims, wherein the packing unit (41) is adapted to place the bases (10) and the lids (15), which have passed the cleaning unit (31), as individual stacks by folding or flapping the bases (10) or the lids (15) in a flat state (10k) into one or more compartments (61 b) of the transport box (61 ).
20. The reconditioning center (20) according to any of the preceding claims, wherein the packing unit (41) is intended to insert one or more partition walls (61a) into the transport box (61) to divide the transport box (61) into several suitable compartments (61b).
21. The reconditioning center (20) according to any of the preceding claims, wherein the packing unit (41) is intended to store data for the unique identification of the bases (10) and lids (15) transported with the transport box (61 ) in a machine-readable data storage (62) of the transport box (61 ).40262 / 4361 / PTWO 5 February 20255422. The reconditioning center (20) according to any of the preceding claims, wherein the packing unit (41 ) is adapted to close the transport box (61 ) with a cover lid (63), preferably the transport boxes (61 ) and / or the cover lids (63) are made of a dirt-tight material.
23. A system (1) comprising a reconditioning center (20) according to one of the preceding claims in a primary circuit (1a) and a recycling unit (5) in a secondary circuit (1b), wherein the recycling unit (5) is arranged in a separate and spatially remote building from the reconditioning center (20), wherein the secondary circuit (1b) is logistically linked to the primary circuit (1a) in the reconditioning center (20) in order to granulate the (150) non-reusable bases (10) or lids (15) of the shelf-ready secondary packaging (10, 15) excluded from the primary circuit (1a) by the reconditioning center (20) and to feed them to a recovery or other use, wherein the system (1) comprises a plurality of data exchange units (6) distributed over the primary and secondary circuits (1a, 1b) to determine actual positions of bases (10) and lids (15) in the primary and secondary circuits (1a, 1b) and a system controller (7) which is connected to the data exchange units (6) and to the control unit (20s) of the reconditioning center (20) for transmitting data, where the system controller (7) controls the individual bases (10) and lids (15) of the shelf-ready secondary packaging (10, 15) in the system (1) with their unique identification, their type, their positions in the system (1) and stores data on the bases (10) and lids (15) of the shelfready secondary packaging (10, 15) and, by knowing the data on bases (10) and lids (15), controls the primary circuit (1a) and the secondary circuit (1b) for the reuse of shelf-ready secondary packaging (10, 15) on the basis of the condition, quality and degree of soiling of the respective shelf-ready secondary packaging (10, 15).
24. A method (100) to operate a reconditioning center (20) according to any of claims 1 to 22 in at least one primary circuit (1a), the primary circuit (1a) extending over a plurality of separate and spatially separated buildings (20, 70, 80) for the reuse of shelf-ready secondary packaging (10, 15) for transportation and suitable presentation and dispending of goods-filled primary packaging40262 / 4361 / PTWO 5 February 202555(50), wherein the shelf-ready secondary packaging (10, 15) is designed in two parts with a one-piece foldable base (10) and a separate one-piece foldable lid (15) each comprise at least one identification element (13) for uniquely identifying at least the types of base (10) and lid (15) and determining their positions and each consisting of more than 50% by weight of a corrugated plastic material, wherein the base (10) consists at least of a bottom (11) and side walls (12) surrounding the bottom (11) comprising a display side (12a), wherein the lid (15) and the base (10) can be reversibly converted multiple times from a flat form (10k) to an erected form (1 Oh) and back by folding along pre-formed fold lines, wherein the erected form (10h) of the base (10) is intended for filling with primary packaging (50) containing goods, and the erected form of the lid (15) is intended to be suitably assembled with the base (10) to enclose the primary packaging (60) as filled shelf-ready secondary packaging (10, 15), comprising following steps:receiving (110) the used bases (10) and lids (15) of the shelf-ready secondary packaging (10, 15) in transport boxes (61) in a compact or other state (10k, 10e, 10h) in the reconditioning center (20) by means of one or more vehicles (60);uniquely identifying (120) types and position of the received bases (10) and lids (15) by a plurality of data exchange units (6) distributed over the for subsequent processes carried out in the reconditioning center (20), which at least reading out the identification elements (13) of bases (10) and lids (15);type-based sorting (130) of bases (10) and lids (15) in a sorting unit (21 ) of the reconditioning center (20) according to a classification of bases (10) and lids (15) executed in the sorting unit (21) with respect to condition, quality and degree of soiling;cleaning and / or processing (140) the bases (10) and lids (15) handed over by the sorting unit (21) in a cleaning unit (31) of the reconditioning center (20), for which purpose the cleaning unit (31) comprises one or more cleaning lines (31a, 31b) with respective one or more processing stations (32a-f) arranged in series, which are passed through the40262 / 4361 / PTWO 5 February 202556respective cleaning line (31a, 31b) on a conveyor belt (33) by the bases (10) and lids (15);type-based packing (150) of bases (10) and lids (15), which have passed the cleaning unit (31) as reusable bases (10) and lids (15), into separate transport boxes (61) in a packing unit (41) of the reconditioning center (20) for a separate transport of the bases (10) and lids (15) to the further buildings (70, 80) in the primary circuit (1a) for the future reuse and back transport to the reconditioning center (20) after use; andcontrolling (160) the units (21 , 31 , 41 ) of the reconditioning center (20) to execute sorting (130, S), cleaning and / or preparation (140, RA), and packing (150, B) of the shelf-ready secondary packaging (10, 15) based on data provided by the data exchange units (6).
25. The method (100) according to claim 24, wherein the type-based sorting (130) is executed as cascaded fine sorting of the bases (10) and lids (15), where the sorting unit (21) comprises at least two arrangements of collecting containers (23, 23a, 23b, 23c) and sorting means (22) as separate sorting cells (211 , 212) arranged one behind the other in a branching linear sorting process, preferably, the separate sorting cells (211, 212) are set up to suitably transfer collecting containers of one sorting cell (211, 212) to the subsequent sorting cells (211, 212).
26. The method (100) according to claim 24 or 25, comprising the further steps of:detecting and removing (170) labels (14a, 14b) that do not serve as identification elements (13) at least from the bases (10) before cleaning the bases (10), preferably by blowing them off, in a first processing station (32a) of the cleaning line (31 a, 31 b), andlabeling (180) at least the bases (10) after cleaning, wherein at least one base label (14a) is applied to a prepared application surface (18) on at least one of the side walls (12) of the base (10), preferably on the side wall (12b) opposite the display side (12a), which comprises the application surface (18), in a fifth processing station (32e) of the cleaning40262 / 4361 / PTWO 5 February 202557line (31a, 31b), particularly preferably the base label completely covers the application surface (18).
27. The method (100) according to claim 26, wherein the step of labeling (180) at least the bases (10) after cleaning comprises the further steps of:applying (190) a presentation label (14b) in the form of the display side (12a) for further designation of the product-filled primary packaging (50) to the display side (12a) of the base (10) in the fifth processing station (32e); and / or- connecting (200) a reversibly attachable and removable cover (17) with the display side (12a) of the base (10) in the fifth processing station (32e) by use of fixing means (172) of the cover (17) fitting to corresponding means (173) of the display side (12a), preferably the fixing means (173) of the display side (12a) is realized as one or more suitably dimensioned slots (173) and the corresponding fastening means (172) of the cover (17) is realized as one or more suitably shaped tabs (172).