Modular Food Packaging Line with Movable Processing Units
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Solution Overview
Problem
Current food products packaging plants are inflexible and require significant downtime and operator intervention for production diversification, maintenance, and product changes, leading to prolonged downtimes and increased operational costs.
Innovation Solution
An automatic packaging plant with movable processing units, sensors, and a central control unit that allows for rapid reconfiguration and autonomous operation, reducing the need for specialized operators and minimizing downtime for maintenance and product changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional fixed packaging lines are used for production diversification, then product variety can be achieved, but the time required for plant modification is prolonged and numerous specialized operators are required
Solution Approach 1:
The packaging line is divided into modular functional units (dosing unit, sealing unit, labeling unit, etc.) that can be independently moved along the conveying line. Each unit can be detached and replaced without affecting the entire system, enabling rapid reconfiguration for different products.
Solution Approach 2:
The functional units are designed to be movable rather than fixed, allowing them to be repositioned along the conveying line using automated handling systems. This dynamic reconfigurability enables quick adaptation to different production requirements without prolonged downtime.
2Adaptability or versatility
If traditional fixed packaging lines are used for production diversification, then product variety can be achieved, but numerous especially selected operators are required to intervene
Solution Approach 1:
The system incorporates automated recognition and handling mechanisms that enable functional units to be identified, grasped, and repositioned without manual intervention. Sensors and control systems automatically guide the reconfiguration process, eliminating the need for specialized operators.
Solution Approach 2:
Manual operations are replaced with automated robotic systems and computer-controlled mechanisms. The central control unit coordinates the movement and positioning of functional units, substituting human labor with automated mechanical and electronic systems.
3Ease of operation
If dosing means are washed in line with shower system, then cleaning is automated, but the washing cycle takes approximately one hour and requires effectiveness checks
Solution Approach 1:
The dosing unit is completely detached from the conveying line and removed to a dedicated washing station. This extraction allows for rapid cleaning in a specialized environment without the time constraints and complexity of in-line washing systems.
Solution Approach 2:
The dosing unit is designed with pre-arranged washing capabilities and quick-release connections that enable immediate removal and cleaning. The washing process is prepared in advance with dedicated washing stations that can quickly clean multiple units in sequence.
4Reliability
If operator safety protections are added to existing lines, then operator safety is improved, but the protections are expensive, occupy large surface area, and must be washed frequently
Solution Approach 1:
The system is designed to operate autonomously without human presence during production and cleaning operations. Automated units handle all tasks including dosing, sealing, labeling, and washing, eliminating the need for operator safety protections entirely.
Solution Approach 2:
This principle is not applicable to the safety protection aspect of the patent.
Data Source
Figure 1
AI summary
The invention relates to a food products (P) packaging automatic plant (1), comprising: at least a first food products (P) conveying line (2), comprising in turn a plurality of first connection areas (3). The plant (1) further comprises a plurality of operative units (4), each comprising: a movable base (40), that is able to move at the first connecting areas (3) of the first food products (P) conveying line (2); processing means (41), placed on the movable base (40) and connectable to the first conveying line (2) at the first connection areas (3); the processing means (41) being provided for processing the food products (P) conveyed on the first conveying line (2); a plurality of sensors; wireless communication means. The plant (1) further comprises: a maintenance station (5) of the operative units (4); a preparation station (6) of the operative units (4); and a control and managing central unit, comprising: wireless communication means, for sending and receiving information to and from the operative units (4); and an internal memory, wherein predetermined information is stored. The control and managing central unit commands the operative units (4) so that they move from and towards the first food products (P) conveying line (2) and from and towards the operative units (4) maintenance (5) and preparation (6) stations.