Modified Atmosphere Packaging with In-Line Bag Making and Ribs

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Solution Overview

Problem

Existing modified atmosphere packaging systems face inefficiencies due to slow air and gas flow rates, bag collapse risks, and high costs associated with preformed bag webs and trimming processes.

Innovation Solution

The system incorporates an in-line bag-making process with a pneumatically operated unwind mechanism, a snorkel with longitudinal ribs for increased flow area, and a control system for precise gas filling and sealing, along with a tear-off mechanism for efficient pouch separation, reducing waste and improving cycle times.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a flattened cross-section snorkel is used to prevent undesired gas flow, then sealing effectiveness is improved, but volumetric draw out and refilling rate decreases

Engineering Contradiction:

Improvesealing effectivenessVSAvoidvolumetric draw out and refilling rate

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The snorkel transitions from a flattened cross-section to a circular cross-section, changing the dimensional geometry to maximize volumetric flow while maintaining sealing through the belt compression mechanism rather than relying on the snorkel shape alone

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Productivity

If flow velocity is increased to improve draw out and refilling rate, then productivity is improved, but bag collapse risk increases

Engineering Contradiction:

Improvedraw out and refilling rateVSAvoidbag collapse risk

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The circular cross-section of the snorkel provides superior aerodynamic characteristics compared to a flattened shape, allowing for optimized flow patterns that reduce turbulence and pressure fluctuations, thereby preventing bag collapse while maintaining high flow rates

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Ease of operation

If preformed bags are used to simplify packaging, then ease of operation is improved, but device complexity and cost increase

Engineering Contradiction:

Improvepackaging simplicityVSAvoidseparate bag-making apparatus

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The bag-making process is merged with the packaging process by integrating a bag-making station that forms bags from continuous web material directly within the packaging line, eliminating the need for separate preformed bag production equipment

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The packaging apparatus gains multi-functionality by incorporating both bag-making and packaging operations in a single integrated system, allowing the same equipment to perform multiple functions and eliminating the need for separate dedicated bag-making apparatus

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Manufacturing precision

If trimming equipment is used to remove unsealed edges, then manufacturing precision is improved, but device complexity and waste increase

Engineering Contradiction:

Improveedge trim accuracyVSAvoidspecial trimming equipment

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The sealing and cutting operations are merged into a single integrated station that performs both functions simultaneously, eliminating the need for separate trimming equipment and reducing overall device complexity while maintaining precision

Inventive Principle:

Principle #5Merging (Combining)

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 enhances volumetric flow rates, reduces bag collapse risks, and lowers costs by eliminating the need for preformed bags and trimming, resulting in faster, more cost-efficient packaging with consistent gas filling and sealing.

Implementation Method 1

a snorkel with longitudinal ribs for increased flow area, enhancing volumetric flow rates

Methodology Applied

Scientific EffectFluid flow:

Implementation Method 2

the plastic bag is heat sealed to form a gas-tight seal

Methodology Applied

Scientific EffectHeat sealing: Heating

Implementation Method 3

air is drawn out of the bag

Methodology Applied

Scientific EffectVacuum: Vacuum

Implementation Method 4

a gas is injected into the bag

Methodology Applied

Scientific EffectGas injection: Pressure Gradient

Data Source

PatentUS10633127B2Modified atmosphere packaging apparatus and method with automated bag production

Publication Date: 2020.04.28 CVP SYSTEMS LLC

AI summary

An automatic packaging apparatus is provided, having a conveyor, a continuous longitudinally folded web, cutting and sealing mechanisms for forming flexible pouches from the web. The apparatus also includes processing stations for loading the pouches, transferring fluids (typically gases) into and out of the pouches, and sealing the pouches. Various alternative methods and devices are provided for separating each sealed pouch from the web by either making a continuous cut across a connecting strip of web material downline of the processing stations or pre-perforating the connecting strip upline of the processing stations. When the connecting strip is pre-perforated, a sealed pouch of sufficient weight may be separated from the web passively by a takeaway conveyor, and a lighter sealed pouch may be separated from the web by a tear-off mechanism that grips and pulls the web.