High-Speed Poucher Using Chain Conveyance to Prevent Web Slippage
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Solution Overview
Problem
Existing pouching machines for producing smokeless tobacco products like snus are limited by low production rates and inconsistency in pouch length and volume due to slippage during the drawing action, leading to variations in mouth feel and taste.
Innovation Solution
An innovative high-speed poucher system that forms an endless hollow tube with a longitudinal seam, cuts it into individual pouches, and uses a series of drums to maintain seam orientation and consistency, followed by crimping and filling with tobacco or other content, achieving production rates of up to 1,700 pouches per minute.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional pouching machines operate at low speeds with one-at-a-time construction, then pouch consistency can be maintained, but production rate is limited to 150-350 pouches per minute
Solution Approach 1:
The machine divides the pouch construction process into separate functional sections: web processing section, filling section, and sealing section. Each section handles specific operations independently, allowing high-speed continuous production while maintaining control over pouch consistency. The web is processed continuously through these segmented sections rather than constructing pouches one-at-a-time.
Solution Approach 2:
The web is pre-formed and pre-positioned in the web processing section before reaching the filling and sealing sections. This preliminary preparation allows subsequent operations to proceed at high speed without compromising pouch consistency, as the base structure is already in place and properly oriented.
2Manufacturing precision
If drawing action is used to form pouches, then pouch formation is simplified, but slippage occurs causing variation in pouch length and volume
Solution Approach 1:
The problematic drawing action that causes slippage is completely removed from the system. Instead, the web is conveyed through the machine using a chain-driven mechanism that positively engages the web material, eliminating slippage and ensuring consistent pouch length and volume while maintaining ease of manufacture through the continuous web process.
Solution Approach 2:
A chain-driven conveying mechanism is introduced as an intermediary between the web source and the sealing section. This intermediary provides positive engagement and controlled movement of the web, preventing slippage and ensuring precise pouch dimensions without complicating the overall manufacturing process.
3Productivity
If high speed production is implemented, then productivity increases to thousands of pouches per hour, but maintaining seam orientation and pouch consistency becomes more difficult
Solution Approach 1:
The machine uses a rotating drum mechanism with chains that dynamically adjust to maintain proper web tension and orientation at high speeds. The rotating drums provide continuous positive engagement with the web, ensuring consistent seam orientation and pouch dimensions even during high-speed operation producing thousands of pouches per hour.
Solution Approach 2:
The system incorporates monitoring and control mechanisms that detect variations in web position and tension, automatically adjusting the conveying and sealing operations to maintain consistent seam orientation and pouch quality at high production speeds.
Data Source
AI summary
An apparatus and methods for producing at extremely high production speeds small pouches filled with tobacco or other granular, powdered or solid content is provided. An endless web substrate, with or without flavor film thereon, is formed into a tubular shape with a longitudinal seam. The tube is cut to individual lengths, and a procession of tubes is crimp-closed at one end, filled and crimp-closed at the other end to complete pouch production. During production, the seams formed at the crimped ends of the pouch are parallel to one another and the longitudinal seam of the pouch is midway between the sides of the pouch and orthogonal to the seams formed at the crimped ends of the pouch.