Modular Packaging Plant for Sterile Confectionary Adaptation
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Solution Overview
Problem
Current packaging plants for confectionary products in sterile containers are rigid and dedicated to specific container formats, making it difficult and costly to adapt to different container types, resulting in significant downtime, waste, and increased production costs due to the need for entire plant replacements.
Innovation Solution
A modular packaging plant with independent operating modules that can be easily coupled and decoupled, allowing for quick adaptation to different container formats and sizes, using interchangeable modules and adjustable half-shells to accommodate varying strip widths and maintain a sterile environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dedicated packaging plant is used for a specific container format, then packaging reliability and sterility are ensured, but adaptability to different container formats is lost and requires complete plant replacement
Solution Approach 1:
The packaging plant is divided into independent modular units (sterilization module, heating module, forming module, sealing module, cutting module) that can be independently configured and repositioned along the packaging path, allowing the same plant to accommodate different container formats by rearranging modules rather than complete replacement
Solution Approach 2:
The plant employs adjustable and movable components including repositionable forming modules, adjustable half-shells for strip width accommodation, and flexible module coupling mechanisms that enable dynamic adaptation to different container dimensions and formats while maintaining sterile conditions
2Manufacturing precision
If a dedicated packaging plant is designed for a specific container format, then manufacturing precision for that format is optimized, but loss of time for adaptation and downtime increase significantly
Solution Approach 1:
By segmenting the plant into independent modules with standardized interfaces, the system allows rapid reconfiguration through module repositioning rather than complete plant replacement, significantly reducing adaptation time while maintaining manufacturing precision through standardized positioning mechanisms
Solution Approach 2:
The plant is designed with pre-configurable modules and adjustable components that can be quickly repositioned or reconfigured before production changes are needed, allowing preparation for different container formats in advance without requiring complete plant replacement and minimizing downtime
3Productivity
If the packaging plant is dedicated to a specific container format, then production efficiency for that format is maximized, but waste of strips increases due to inability to use different strip widths
Solution Approach 1:
The plant employs adjustable half-shells and movable forming modules that can adapt to different strip widths, allowing the same packaging plant to efficiently produce different container formats without wasting strips, thereby maintaining high productivity across various container types
Solution Approach 2:
The modular plant design with adjustable components creates a universal system that can handle multiple container formats and strip widths with a single configuration, eliminating the need for dedicated plants for each format and reducing strip waste through versatile utilization of packaging materials
4Adaptability or versatility
If strips of different width are used on existing plants, then adaptability to different formats is improved, but device complexity increases due to need for modifications of mechanical components
Solution Approach 1:
The plant is divided into modular units with standardized coupling mechanisms, allowing different width strips to be accommodated by repositioning or reconfiguring modules rather than modifying individual mechanical components, thereby maintaining adaptability while minimizing device complexity
Solution Approach 2:
The plant employs adjustable half-shells and movable forming modules that can dynamically adapt to different strip widths through simple repositioning operations, avoiding the need for complex mechanical modifications and maintaining relatively simple device architecture while achieving versatility
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 fast and cost-effective transformation of packaging plants to accommodate different container types with minimal downtime and waste reduction, while maintaining production efficiency and reliability by allowing for the use of different strip widths and precise module positioning.
Implementation Method 1
a sterile duct extending along said packaging path and designed to contain a sterile gas, said duct being common to said assemblies and being delimited at least partially by said strips
Implementation Method 2
a welding sealing assembly for connecting together said strips and closing said confectionary product within said housing compartment
Implementation Method 3
at least one first assembly for sterilization and heating of a first thermoformable strip
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A plant (1) for packaging confectionary products comprises: at least one first assembly (3a) (6a) for preparation of a first thermoformable strip (4); a 'forming assembly (7a)" for making on the first strip (4) at least one compartment for housing confectionary products; an assembly (9a) for supplying/dispensing a confectionary product in the aforesaid compartment; a second assembly (10a) for preparation of a second closing strip (11); a welding assembly (13a) for connecting together the first strip (4) and the second strip (11) and closing the confectionary product within the housing compartment; and a cutting assembly (14a) for cutting the strips (4) (11) and making at least one container; each assembly (3a) (6a) (7a) (9a) (10a) (13a) (14a) forming part of a respective operating module (3) (6) (7) (9) (10) (13) (14) that is independent of the other modules and coupled to the adjacent modules in a releasable way.