Packaging Unit Production with Closed-Loop Strapping and Blanks
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing packaging methods for beverage containers, such as shrink film wrapping and strapping, are energy-intensive, costly, and require complex machinery, with strapping processes being time-consuming and complex due to the need for closed strapping connections.
Innovation Solution
A method and device that uses a strapping band and packaging blank to securely hold grouped articles together by encircling them laterally and applying a packaging blank on top, allowing for simultaneous application of both elements to form a packaging unit with reduced complexity and time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If strapping bundles are produced using closed strapping bands, then articles are held together stably, but additional process time is required to produce stable connections
Solution Approach 1:
The strapping band is pre-formed as a closed loop before application to the articles. This preliminary preparation eliminates the time-consuming connection step during the packaging process, as the band is already in its final stable configuration and simply needs to be positioned and tensioned around the articles.
Solution Approach 2:
The packaging process is segmented into separate functions: the strapping band is prepared independently as a closed loop, then applied separately to the articles. This segmentation allows the connection function to be pre-performed, improving overall process efficiency without compromising connection stability.
2Reliability
If closed strapping connections are produced, then stable packaging is achieved, but the complexity of the packaging process and tools increases
Solution Approach 1:
The complex connection function is performed in advance during strapping band manufacturing, creating a pre-formed closed loop. This transfers the complexity from the packaging machine to the strapping band production, simplifying the packaging process while maintaining connection stability.
Solution Approach 2:
The connection function is extracted from the packaging process and incorporated into the strapping band manufacturing process. This separation removes the complexity of connection mechanisms from the packaging machine, leaving only the simpler application and tensioning functions.
3Ease of manufacture
If shrink film wrapping is used to combine beverage containers, then bundles are formed effectively, but energy consumption and investment costs increase
Solution Approach 1:
The thermal shrinking process is replaced with a mechanical strapping system. Instead of using heat to shrink film around the bundle, a mechanical strapping band is tensioned and secured, eliminating the energy-intensive heating and shrinking steps while achieving effective bundling.
Solution Approach 2:
The bundling mechanism changes from thermal contraction (shrink film) to mechanical tension (strapping band). This parameter change from thermal to mechanical forces reduces energy consumption while maintaining or improving bundling effectiveness.
4Ease of manufacture
If shrink tunnel with hot air application is used, then shrink film is shrunk around bottles, but capital investment and energy costs increase
Solution Approach 1:
The hot air shrinking mechanism is replaced with mechanical strapping application. The shrink tunnel and hot air generation system are eliminated in favor of a mechanical strapping device that applies and tensions bands, dramatically reducing stationary energy consumption while achieving secure packaging.
Solution Approach 2:
The energy-intensive hot air shrinking function is extracted from the packaging line and replaced with a mechanical alternative. This removes the shrink tunnel infrastructure and its associated energy consumption from the packaging process.
Data Source
AI summary
The invention relates to methods and devices for producing packaging units. Each of the packaging units has at least two articles which are held together by at least one strapping band and by at least one packaging blank. The method includes: providing the articles in a handling area of an application head; inserting a closed strapping band and a prepared packaging blank into the application head; feeding the application head to the articles, with the grouped articles being at least slightly compressed; positioning the strapping band; securing the packaging blank to the articles; opening the application head while simultaneously releasing and separating the at least one strapping band from the fixed position of the strapping band within the application head; releasing and separating the at least one packaging blank; and removing the application head from the strapped article grouping combined by a packaging blank.