Automated Modified Atmosphere Bagging for Perishable Pallets
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Solution Overview
Problem
Current systems for preserving perishables using modified atmosphere technologies require manual labor and are not automated, leading to inefficiencies in production rate and consistency.
Innovation Solution
An automated system that automatically inserts and positions a plastic sheet on a pallet of perishables, applies a plastic bag, and delivers gases to create a modified atmosphere, eliminating the need for manual manipulation and staples, and adjusts the bag's permeability based on the type and weight of the perishables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual manipulation of bags and plastic sheets is used, then ease of operation is maintained, but productivity is low and consistency is poor
Solution Approach 1:
The system uses self-aligning features where the plastic sheet automatically positions itself on the pallet through gravity and geometric constraints, and the bag automatically seals itself around the perishables without manual intervention. The margins of the plastic sheet extend beyond the pallet edges to automatically align with sealing surfaces, eliminating the need for manual positioning and achieving high-speed automated operation.
2Manufacturing precision
If automated systems are implemented, then productivity increases and consistency improves, but device complexity increases
Solution Approach 1:
The automated system is divided into distinct functional modules: a plastic sheet feeding and positioning module, a bagging module, and a sealing module. Each module performs a specific function independently, which simplifies the control logic and reduces overall system complexity while maintaining high precision and consistency in bag sealing.
Solution Approach 2:
The plastic sheet acts as an intermediary element between the pallet and the bag. It provides a stable, pre-positioned surface that facilitates automatic bag alignment and sealing, reducing the complexity of direct bag-to-pallet sealing while ensuring consistent sealing quality.
3Reliability
If staples are used to hold plastic materials, then reliability of plastic sheet positioning is improved, but ease of manufacture decreases and productivity is reduced
Solution Approach 1:
The system replaces the mechanical stapling process with a friction-based and geometry-based positioning system. The plastic sheet margins extend beyond the pallet edges and are held in place by friction against the pallet surface and geometric constraints during the bagging process, eliminating the need for staples and simplifying the overall system while maintaining reliable positioning.
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
The system significantly increases production efficiency by producing finished pallets every 30 seconds with fewer operators, ensuring consistent modified atmosphere preservation of perishables while reducing manual labor and errors.
Implementation Method 1
Because the bag has been stretched, the elasticity of the bag pulls tight against, and holds the sheet margins in place
Data Source
AI summary
Methods and apparatus for enclosing a palletized container of fresh containers of perishables inside a modified atmosphere-containing plastic bag/enclosure stretched over the containers and over upwardly-folded and sealed margins of a plastic sheet placed between the pallet and the containers to seal the containers of perishables inside the bag/enclosure and to facilitate forming and maintaining a modified atmosphere inside the bag/enclosure.