Integrated Capsule Forming Machine Inverted Shearing
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Solution Overview
Problem
Current methods for producing coffee capsules involve separate machines for thermoforming and packaging, leading to inefficiencies such as high material waste, complex and expensive transfer systems, and significant rejection rates due to weight tolerance issues, resulting in bulky and costly plants with labor-intensive operations.
Innovation Solution
A machine that integrates thermoforming, precise weight control, and filling of capsules in a single compact unit, using an "inverted" shearing method to separate and transport capsules on the plastic sheet, allowing for accurate dosing and recycling of materials while eliminating the need for intermediate packaging and complex transfer systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate thermoforming and packaging machines are used, then each machine can be optimized for its specific function, but the plant becomes bulky, expensive, and labor-intensive with complex transfer systems
Solution Approach 1:
The patent combines the thermoforming machine and packaging machine into a single integrated machine. The thermoforming unit forms capsules from plastic sheets, and the packaging unit immediately follows to fill and seal them, eliminating the need for separate machines and complex transfer systems between them.
Solution Approach 2:
The integrated machine performs multiple functions within a single device: it thermoforms plastic sheets into capsules, transports them on the same sheets, fills them with product, seals them with covers, and weighs them. This multi-functionality eliminates the need for separate specialized machines.
2Measurement precision
If capsules are weighed after closing and detaching from the sheet, then weight control can be performed, but many capsules must be rejected due to out-of-tolerance weights, reducing productivity
Solution Approach 1:
The weighing station is positioned immediately after the filling station, allowing weight measurement to occur before the capsule undergoes subsequent processing steps. This enables early detection of out-of-tolerance capsules, limiting rejection to only those specific capsules rather than requiring rejection of all capsules processed since the filling station.
Solution Approach 2:
The weighing system provides feedback on capsule weights immediately after filling, allowing for real-time identification and rejection of out-of-tolerance capsules. This feedback mechanism prevents the propagation of weight errors through subsequent processing stages.
3Ease of manufacture
If the plastic sheet is sheared to separate capsules after applying the covering element, then capsules can be separated for packaging, but mixed scrap of plastic and metal is formed that requires separation for recycling
Solution Approach 1:
The covering element is applied to the capsule before the capsule is separated from the plastic sheet by shearing. This extraction of the metal cover from the mixed waste stream allows the plastic sheet scraps to be separated and recycled independently, eliminating the contamination problem of mixed plastic-metal waste.
Solution Approach 2:
The covering element is applied in advance to the capsule while it is still attached to the plastic sheet, before the shearing operation separates them. This preliminary application ensures that the metal cover does not become mixed with the plastic waste during the separation process.
4Reliability
If intermediate packaging is used to transfer capsules from forming to packaging machine, then capsule integrity is maintained, but the process becomes more complex and time-consuming
Solution Approach 1:
The plastic sheet itself serves as the intermediary carrier that transports the formed capsule from the thermoforming station to the packaging station. The sheet acts as a natural conveyor that maintains capsule integrity during transfer without requiring additional intermediate packaging or complex transfer mechanisms.
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 integrated solution reduces material waste, enhances productivity, and simplifies operations by enabling precise weight control and recycling of plastic materials, minimizing capsule rejection and the need for separate machines, resulting in a more efficient and cost-effective production process.
Implementation Method 1
In the heating station the plastic sheet is prepared for the subsequent forming operation or rather is heated up to a predefined softening temperature, so as to enhance the plasticity and deformability of the plastic sheet
Implementation Method 2
The forming station comprises a forming mold in which one or more punches push the sheet into respective cavities of a die so as to carrying out the casings
Implementation Method 3
In the shearing station a shearing element separates the casings that are formed on the plastic material sheet, by shearing said plastic material sheet according to predefined cutting contours
Implementation Method 4
the weight control is executed after closing and detaching the capsules from the sheet... the capsules have to be separated from the plastic sheet and inserted separated and singularized in a suitable transport or convey system, such as a belt with seats
Data Source
AI summary
A machine for making capsules containing a product includes a forming station for forming in a sheet of thermoformable plastic material at least a casing of a capsule having a cavity, a shearing station with a punch and a die for cutting the sheet so as to separate the capsule along a respective edge, and a filling station for dosing the product into the cavity. During the cutting, the punch moves to cut the sheet with the die and then lift and detach the capsule from the sheet. The punch and the die are movable away from each other for placing the capsule on the sheet, and a through opening is created in the sheet by separating the capsule. The through opening has a passage section smaller than external dimensions of the edge to allow the sheet to support and move the capsule along an advancing direction.