Dish-Shaped Package Forming with Movable Secondary Moulds
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Solution Overview
Problem
Existing methods for producing dish-shaped foodstuff packages using fixed moulds result in film wastage, increased costs, and reduced efficiency due to the need for separate handling and processing of individual blanks, which also leads to higher carbon footprints and opportunities for errors.
Innovation Solution
An apparatus and method utilizing a forming station with secondary and primary moulds that allow for the simultaneous formation of multiple product packages from grouped blanks, with a control system and film track for efficient inner lining application, enabling the use of moving secondary moulds to minimize film wastage and improve processing speed and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fixed moulds are used for forming product packages, then the forming process is simple, but film wastage increases and productivity decreases
Solution Approach 1:
The patent employs movable moulds that can move relative to each other, transitioning from a fixed position to a movable position. This allows the moulds to accommodate multiple blanks simultaneously and facilitates efficient film application, thereby increasing productivity while maintaining manufacturing simplicity.
Solution Approach 2:
The patent combines multiple blanks into a single group blank that is processed together by the movable moulds. This merging approach allows simultaneous forming of multiple product packages and efficient film application across all packages in one operation, significantly improving productivity.
2Reliability
If individual blanks are processed separately, then each package can be formed independently, but handling time increases and errors occur
Solution Approach 1:
Multiple individual blanks are merged into a group blank structure that is processed as a single unit. The movable moulds form all packages simultaneously, and the film is applied to all packages in one operation, eliminating repeated handling and reducing errors while maintaining processing accuracy.
Solution Approach 2:
The group blank processing enables continuous forming and film application operations without interruption. All packages are formed and lined in a single continuous process cycle, eliminating the start-stop nature of individual blank processing and reducing total handling time.
3Manufacturing precision
If separate handling of blanks is required, then each blank can be positioned precisely, but costs increase and efficiency decreases
Solution Approach 1:
The group blank structure combines multiple blanks with predetermined positioning relationships. The movable moulds are designed to accommodate the entire group, maintaining precise positioning for each blank while using a single handling system rather than multiple separate tools, thereby reducing device complexity and costs.
4Productivity
If more moulds are used to increase production capacity, then productivity improves, but film wastage increases
Solution Approach 1:
The movable moulds can adjust their positions and configurations to accommodate different numbers and arrangements of blanks. This dynamic adaptability allows optimal film utilization across multiple packages formed simultaneously, reducing film wastage while maintaining high production capacity.
Solution Approach 2:
Multiple packages are formed and filmed together in a single operation using the movable moulds. This combined processing approach allows the film to be efficiently distributed across all packages, minimizing waste compared to processing packages separately with individual film applications.
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 reduces film wastage, enhances production speed and accuracy, optimizes the use of materials, and simplifies logistics, while also reducing the carbon footprint by allowing for larger batches and minimizing the need for separate handling of individual blanks, thus improving overall supply chain efficiency.
Implementation Method 1
In connection with the second moulds are means for producing negative pressure, with which negative pressure the inner surfaces of the formed product packages are provided with food-grade film
Implementation Method 2
In connection with the second moulds is a heating element for bonding the film to the inner surfaces of the formed product packages
Data Source
AI summary
The object of the invention is an apparatus and a method for producing dish-shaped product packages, which apparatus comprises a forming station (10) for product packages, in connection with which forming station is a secondary tool (20) with secondary moulds (21), a heating station and a primary tool (18) with primary moulds (19) for feeding the sheet-like, fiber-based blanks to be formed into product packages into the forming of product packages. The apparatus also comprises a control system for controlling the functions of the apparatus, and in connection with the apparatus is a film track (12) for providing a formed product package with a film functioning as an inner lining. Preferably, the primary tool (18) comprises two or more primary moulds (19) side by side.