Multi-pack Packaging System for Beverage Variety Packs
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Solution Overview
Problem
Existing methods for repackaging multiple varieties of beverages into variety packs are inefficient and require costly automation systems.
Innovation Solution
A conveyor-based system with linear actuators that selectively remove and reconfigure rows of bottles from single-flavor cases to create multi-variety cases, allowing for the automatic creation of variety packs with different numbers of rows in each case, enabling the efficient combination of multiple beverage varieties into a single package.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual repackaging methods are used to create variety packs, then flexibility in creating different pack configurations is maintained, but labor intensity and time consumption increase significantly
Solution Approach 1:
The system segments the repackaging process into distinct functional modules: conveyor-based case positioning, row-specific actuator selection, bottle group extraction, and targeted deposition. Each actuator handles specific rows independently, allowing parallel processing of multiple cases simultaneously, thereby reducing overall time consumption while maintaining operational flexibility.
Solution Approach 2:
The system employs dynamically controllable actuators that can be selectively activated based on the specific variety pack configuration required. The conveyor speed, actuator activation timing, and bottle transfer timing are all dynamically adjusted to optimize both speed and flexibility for different repackaging scenarios.
2Productivity
If automated repackaging systems are implemented, then productivity and speed increase, but device complexity and cost increase
Solution Approach 1:
The system employs universal actuators that can handle multiple rows and serve multiple cases simultaneously. Each actuator is designed to be multi-functional, capable of extracting bottles from any position and depositing them into any target case, thereby reducing the total number of actuators needed and simplifying the overall system while maintaining high productivity.
Solution Approach 2:
The system uses the existing case structure and bottle arrangement on the conveyor as part of the sorting mechanism. Cases are self-positioned on the conveyor, and bottles are self-sorted based on their row position and target case requirements, reducing the need for additional complex sorting mechanisms.
3Adaptability or versatility
If rows of bottles are selectively removed and reconfigured, then variety pack customization is enabled, but manufacturing complexity increases
Solution Approach 1:
Cases are pre-positioned on the conveyor in a standardized sequence before the repackaging process begins. The system pre-identifies which rows need to be transferred to which cases based on the desired variety pack configuration, allowing for simplified real-time execution of the repackaging operation without complex on-the-fly decision-making.
Data Source
AI summary
Methods and apparatus for combining units from among a plurality of packages are disclosed. In some embodiments, units are combined from a plurality of single-variety packages to provide one or more variety packs. For example, a plurality of single-variety packages arranged in repeating order of variety can be provided. The single-variety packages being so arranged can define at least two lanes extending among the plurality of single-variety packages. At least one single-variety group of units can be selected from at least one of the plurality of single-variety packages. Each of the selected at least one single-variety group of units can be positioned in one of the lanes. The selected at least one single-variety group of units can be repositioned to another package and within the one of the lanes.