Apparatus for making unit dose product
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing water soluble products with particles face challenges such as interference with substrate formation, limited particle types and sizes, uncontrolled particle distribution, and difficulties in economic and flexible production, particularly in achieving precise and uniform particle delivery onto moving substrates.
Innovation Solution
The development of a travelling mask process that discretizes a continuous feed of particles into individual doses using a feeding system and a discretizing unit with moveable pockets, allowing for precise control of particle deposition onto substrates, accommodating various particle types, and maintaining manufacturing flexibility and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If particles are loaded onto substrates during substrate formation, then particle distribution can be controlled, but substrate formation is interfered with and manufacturing complexity increases
Solution Approach 1:
The manufacturing process is segmented into separate operations: substrate formation is completed first, then particles are loaded in a subsequent discrete step. This separation eliminates interference with substrate formation while maintaining particle distribution control through the particle loading apparatus.
Solution Approach 2:
The substrate is fully formed before particle loading begins. This preliminary completion of substrate formation ensures that the substrate structure is stable and ready to receive particles without interference to the formation process itself.
2Strength
If multi-ply articles are bonded together, then cohesive product is formed, but bonding and cutting becomes difficult when caliper varies across the surface
Solution Approach 1:
Particles are loaded onto the substrate before the multi-ply bonding and cutting operations. This preliminary particle loading ensures that particles are securely positioned on the substrate surface before subsequent processing, preventing particle loss or misalignment during bonding and cutting operations.
3Productivity
If continuous flow of particles is used, then manufacturing efficiency is improved, but precise discretization into individual doses becomes challenging
Solution Approach 1:
A particle loading apparatus acts as an intermediary between the continuous particle source and the substrate. This apparatus receives continuous particle flow and systematically dispenses precise discrete doses onto substrate positions, converting continuous flow into controlled discretization while maintaining high manufacturing efficiency.
Solution Approach 2:
The system replaces manual or mechanical discretization methods with an automated particle loading apparatus that uses controlled dispensing mechanisms to achieve precise dose discretization from continuous particle flow, improving both precision and efficiency.
4Adaptability or versatility
If floppy substrates are used, then product flexibility is maintained, but handleability and consumer experience deteriorate
Solution Approach 1:
Particles are loaded onto the substrate before final product completion. This preliminary action ensures proper particle positioning and adhesion, which can contribute to improved product structure and handleability while maintaining the inherent flexibility of the substrate material.
Data Source
AI summary
Included herein are manufacturing methods relating to water soluble substrates with particles and an apparatus to place the particles on the water soluble substrate.