Modular Packaging Units for Flexible Vacuum and MAP Tray Sealing
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Solution Overview
Problem
Existing packaging technologies are complex, large, and costly, requiring significant space and skilled maintenance, and are inflexible for small production batches or varied product geometries, with a lack of efficient solutions for vacuum skin packaging and modified atmosphere packaging that do not rely on huge investments or sophisticated machinery.
Innovation Solution
A modular packaging facility with independent packaging units that use perforating tools and nozzles to create holes in supports for efficient gas removal and controlled atmosphere injection, allowing for flexible adaptation to different product geometries and production sizes, and optimizing human and machine time without requiring extensive investments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sophisticated automated packaging machines are used to achieve high productivity, then packaging speed and efficiency are improved, but device complexity and capital investment increase significantly
Solution Approach 1:
The packaging system is divided into multiple independent packaging units (5) that can operate simultaneously. Each unit is a simplified module with basic components (lower tool 7, upper tool 11, film supply 9, vacuum arrangement 15) rather than one complex automated machine. This segmentation allows parallel operation to achieve high productivity while keeping individual units simple and affordable.
Solution Approach 2:
The system uses simple manual loading of supports (4) into the packaging units, eliminating the need for complex automated feeding mechanisms. The basic automated functions (vacuum evacuation, film heating, sealing) are inherent to each simple packaging unit, reducing overall system complexity while maintaining productivity.
2Productivity
If large fully automated packaging machines are used to achieve high productivity, then packaging output is improved, but adaptability to different production batches and product geometries deteriorates
Solution Approach 1:
Multiple independent packaging units (5) allow different configurations for different products. Each unit can be independently adjusted or removed, enabling flexible adaptation to various production batches and support geometries while maintaining overall high productivity through parallel operation.
Solution Approach 2:
The system allows dynamic reconfiguration by adding or removing packaging units based on production requirements. Supports of different geometries can be manually loaded into appropriate units, providing versatility without requiring a completely different machine for each product type.
3Productivity
If sophisticated automated machines with high degree of automation are used, then packaging efficiency is improved, but reliability deteriorates due to sensitivity to component malfunctions
Solution Approach 1:
Each packaging unit is designed with simple, robust components that perform basic functions reliably. The manual loading process eliminates sensitivity to automated feeding component failures. The system's modular nature means a malfunction in one unit does not affect others, improving overall reliability while maintaining efficiency.
Solution Approach 2:
The packaging units use simple, easily replaceable components rather than expensive, complex automated mechanisms. If a component fails, it can be quickly replaced without requiring highly qualified technical personnel, improving reliability through ease of maintenance.
4Productivity
If big size fully automated packaging machines are used to achieve high productivity, then packaging output is improved, but ease of operation and maintenance deteriorates due to need for skilled technical personnel
Solution Approach 1:
The system consists of multiple simple, identical packaging units that can be operated and maintained independently. This segmentation allows basic operators to service individual units without needing specialized knowledge of complex automated systems, improving ease of operation and maintenance while achieving high output through parallel processing.
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
The modular system enables efficient and flexible packaging of various products with reduced capital investment, improved reliability, and adaptability to different production sizes, while maintaining high packaging quality and productivity.
Implementation Method 1
removing gas from a volume between each support received by the lower tool and the respective film portion
Implementation Method 2
an upper tool provided with a heater and configured for holding at least one film portion above the respective product loaded support
Implementation Method 3
a controlled atmosphere arrangement configured to inject a controlled gas composition in said volume
Data Source
Figure 1
Figure 2
Figure 2A
AI summary
The present invention relates to a modular packaging facility having independent packaging units configured to receive one or more product loaded supports, wherein 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.