Modular Packaging Facility for Vacuum Skin and Modified Atmosphere
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Solution Overview
Problem
Existing packaging technologies are complex, costly, and inflexible, requiring large spaces and skilled maintenance, and struggle to efficiently adapt to different product geometries and production batch sizes, especially for vacuum skin packaging and modified atmosphere packaging.
Innovation Solution
A modular packaging facility with independent packaging units that can handle various support geometries and sizes, using perforating tools and nozzles to create vacuum or controlled atmosphere packages, and a control system to optimize packaging cycles and adapt to different support types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sophisticated automated packaging machines are used, then productivity is improved, but device complexity and capital investment increase
Solution Approach 1:
The packaging machine is divided into multiple independent working stations (film feeding station, heating station, vacuum station, sealing station, etc.), each performing a specific function. This segmentation allows the system to achieve high productivity through parallel processing while keeping each station relatively simple and maintainable.
Solution Approach 2:
The machine is designed with universal components that can handle different packaging requirements. The heating station, vacuum station, and sealing station can accommodate various film types and packaging formats, reducing the need for multiple specialized machines and simplifying the overall system complexity.
2Productivity
If fully automated packaging machines are used, then productivity is improved, but ease of operation and adaptability to small batches deteriorate
Solution Approach 1:
The machine incorporates adjustable and reconfigurable components that allow dynamic adaptation to different production needs. The film feeding mechanism, heating elements, and sealing parameters can be adjusted for different batch sizes and packaging types, enabling the system to transition smoothly between small batches and large-scale production.
Solution Approach 2:
The machine allows changing of operational parameters (heating temperature, vacuum level, sealing pressure, film feed rate) to optimize performance for different batch sizes and packaging requirements. This parameter adjustability provides flexibility without compromising productivity.
3Productivity
If big size automated packaging machines are used, then productivity is improved, but space requirement and capital investment increase
Solution Approach 1:
The machine is designed with a compact vertical arrangement of working stations, utilizing the vertical dimension to accommodate multiple functions in a limited horizontal footprint. The film feeding, heating, vacuum, and sealing stations are arranged vertically or in a compact linear sequence, reducing the overall space requirement while maintaining high productivity.
4Productivity
If sophisticated automated packaging machines are used, then productivity is improved, but reliability and ease of repair worsen due to component sensitivity
Solution Approach 1:
The machine incorporates self-diagnostic and self-adjusting features that reduce dependence on highly skilled technical personnel for maintenance. The system can automatically detect and compensate for minor deviations, and the modular design allows easy replacement of worn components without requiring complex disassembly or specialized knowledge.
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
Enables efficient, flexible, and cost-effective packaging of diverse products with reduced human intervention and machine downtime, allowing for simultaneous execution of multiple packaging cycles and adaptation to different production needs.
Implementation Method 1
a film of thermoplastic material, held above the product placed on the support, is heated and softened
Implementation Method 2
natural atmosphere is evacuated from the space between the support and the plastic film
Implementation Method 3
the space between the support and the film is injected with gas at a controlled composition
Data Source
AI summary
A modular packaging facility has independent packaging units configured to receive one or more product loaded supports. The upper tool and the lower tool of each unit are relatively movable the one with respect to the other between at least a first position, allowing placement of the supports in the respective seats of the lower tool, and a second position, allowing coupling of a film portion of said film to said one or more product loaded supports received by the lower tool. Each unit has a vacuum arrangement and/or a controlled atmosphere arrangement and is configured to execute a packaging cycle wherein gas is removed and/or injected via holes in the supports and/or via nozzles placed between the support and the respective film portion. The process and the infrastructure may be used to contemporaneously process and pack supports of different types.