Bag Filling with Volume Reduction to Prevent Material Loss

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Solution Overview

Problem

Conventional methods for filling flexible packages with loose materials, such as bags, often result in significant material loss and contamination due to excess pressure during the filling process, leading to increased operating costs and reduced bagging capacity.

Innovation Solution

A method and apparatus that involve a filling process comprising a filling stage, a settling stage with a squeezing device to reduce the package volume and vent excess pressure, and a discharge stage, where the package volume is expanded to rapidly reduce internal pressure, allowing for efficient discharge without material loss.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the bag is pulled off the filling element immediately after filling, then the filling speed is high, but material escapes through the valve causing weight loss and contamination

Engineering Contradiction:

Improvefilling speedVSAvoidmaterial loss

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The patent applies preliminary action by reducing the bag volume before discharge to lower the internal pressure. The volume reduction is performed in advance during the filling process, so that when the bag is discharged, the pressure is already reduced and material does not escape. This resolves the contradiction by preparing the bag in advance to enable both high filling speed and prevent material loss.

Inventive Principle:

Principle #10Preliminary action

2Loss of substance

If the pressure in the bag is allowed to drop naturally through the walls, then material loss is reduced, but the waiting time increases dramatically reducing bagging capacity

Engineering Contradiction:

Improvematerial lossVSAvoidbagging capacity

Core Design Contradiction:

Loss of substanceVSProductivity

Solution Approach 1:

The patent replaces the passive mechanical process of natural pressure drop through bag walls with an active volume reduction mechanism. By mechanically reducing the bag volume, the pressure drops rapidly and controllably without requiring long waiting periods. This substitution resolves the contradiction between preventing material loss and maintaining high productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If a bypass is used to release excess pressure quickly, then bagging capacity is maintained, but material escapes through the bypass causing weight fluctuations

Engineering Contradiction:

Improvebagging capacityVSAvoidmaterial loss

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The patent applies local quality by creating a localized volume reduction zone within the bag rather than using a bypass system. The volume reduction is applied locally to the bag contents through mechanical compression, which lowers pressure without creating an escape path for material. This resolves the contradiction by maintaining bagging capacity while preventing material loss through targeted local action.

Inventive Principle:

Principle #3Local quality

4Productivity

If the volume available to the package is reduced during filling, then pressure is maintained for efficient filling, but the settling time is extended

Engineering Contradiction:

Improvefilling rateVSAvoidsettling time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent applies dynamics by making the bag volume dynamic and adjustable during the filling process. The volume is reduced during filling to maintain pressure and filling rate, then can be expanded if needed during settling. This dynamic adjustment resolves the contradiction by enabling both efficient filling and adequate settling time through flexible volume control.

Inventive Principle:

Principle #15Dynamics

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 material loss and contamination, shortens the filling process, and enhances the bagging capacity by ensuring rapid venting and precise weight control, resulting in improved operational efficiency and reduced costs.

Implementation Method 1

at least in the settling phase at least one squeezing device applies a squeezing pressure to the package for venting the package and reducing the volume available to the package

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

the volume available to the package is expanded so as to reduce the pressure prevailing in the package

Methodology Applied

Scientific EffectPressure gradient: Pressure Gradient

Data Source

PatentUS8720494B2Method and device for filling a package

Publication Date: 2014.05.13 HAVER & BOECKER OHG

AI summary

Method and apparatus for filling bags with loose materials, wherein a package to be filled is filled by means of a filling element in a filling process. The filling process comprises a filling stage, a settling stage, and a discharge stage wherein during the filling stage, loose material is filled into the bag while admitting air and in the settling stage, a settling phase is provided for the pressure to drop and in the discharge stage, the bag is discharged from the filling element. In the settling phase, the squeezing device applies a squeezing pressure to the package so as to vent the package and to reduce the volume available to the package, until a predetermined reduction of the volume available to the package is reached, whereupon the squeezing pressure of the squeezing device on the package is reduced and the package is discharged from the filling element.