Automated Bulk Bin Liner Sealing for Airtight Modified Atmosphere
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Solution Overview
Problem
Current methods for sealing bulk bins used in perishable product packaging are inefficient, leading to delays, labor-intensive manual handling, potential contamination, and inadequate sealing, which can result in product deterioration and increased costs.
Innovation Solution
A method involving automated or robotic systems to seal bulk bin liners using clips, robotic arms, or fingers, combined with heat sealers, to create a sealed enclosure, and infuse nitrogen and sanitizers, reducing manual handling and ensuring airtight seals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual sealing methods are used for bulk bin liners, then labor flexibility is maintained, but handling time increases and labor costs increase
Solution Approach 1:
The system enables self-service automation where the sealing apparatus automatically performs sealing operations on bulk bin liners without requiring manual intervention. The apparatus moves along the conveyor and seals liners as they pass through, allowing the system to service itself rather than requiring continuous human operation.
Solution Approach 2:
The patent replaces manual mechanical sealing operations with an automated mechanical sealing apparatus. The system uses mechanical conveyors, heating elements, and sealing mechanisms to automatically seal liners, substituting human labor with automated mechanical systems that operate continuously at high speed.
2Reliability
If inadequate sealing is used, then sealing time is reduced, but product deterioration occurs and contamination risk increases
Solution Approach 1:
The system performs preliminary positioning and preparation of the liner edges before the actual sealing process. The apparatus aligns and prepares the liner material in advance, ensuring that when sealing occurs, it is quick and effective. This preliminary action prevents the need for repeated sealing attempts, thus maintaining high reliability without increasing time loss.
Solution Approach 2:
The sealing apparatus controls sealing parameters such as temperature, pressure, and dwell time to optimize the sealing process. By precisely adjusting these parameters, the system achieves reliable seals quickly, preventing both product deterioration and unnecessary time loss. The controlled parameter changes ensure consistent seal quality while maintaining high processing speed.
3Productivity
If automated sealing systems are implemented, then handling efficiency increases, but system complexity increases
Solution Approach 1:
The sealing apparatus is designed as a multi-functional system that combines conveying, positioning, sealing, and cutting operations in a single integrated unit. This universal design allows the system to perform multiple functions without requiring separate devices for each operation, thereby increasing productivity while managing overall system complexity through consolidation.
Solution Approach 2:
The automated sealing system is divided into modular segments that can be independently maintained and adjusted. Each module performs a specific function (conveying, heating, sealing, cutting), allowing for easier maintenance and reduced complexity in terms of troubleshooting and repair. This segmentation enables high processing speed while keeping the system manageable through modular architecture.
4Object-affected harmful factors
If manual liner handling is used, then equipment cost is reduced, but contamination risk increases
Solution Approach 1:
The automated sealing apparatus acts as an intermediary between the liner material and the final sealed product. By introducing this controlled mechanical system, the patent eliminates direct manual contact with the liners, thereby reducing contamination risk from human handling. The intermediary apparatus maintains a controlled environment that prevents harmful factors while managing the sealing process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces handling time, minimizes labor costs, and ensures airtight seals, maintaining product quality by preventing contamination and deterioration, thus enhancing the efficiency and safety of perishable product handling.
Implementation Method 1
sealing the liner together with a heated band sealer
Implementation Method 2
sealing the liner together with a heated band sealer, a wide or double seal impulse sealer, a heat sealer
Data Source
AI summary
A system for sealing a bin includes a movable conveyor for moving one or more bins, a protective racking system for stacking one or more bins into the movable shuttle or conveyor, and a vacuum cooling tube. The one or more bins have an open top or vented bin lid configured to cool a product within the bin and protect the product from falling debris and cross contamination during vacuum cooling, gas flushing, substance treatments, further handling, or the covering, closing, and/or sealing of the bins.