Nested Product Pack Packaging System with Movable Compression Plates
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Solution Overview
Problem
Traditional packaging systems are inflexible and inefficient in handling non-traditional product groupings and sizes, such as 8 or 16 bottles, leading to slower production rates and limited configuration options, as they are often designed for specific package sizes.
Innovation Solution
A packaging system that includes an infeed area for product selection and grouping, with primary and secondary selectors to form nested or staggered product packs, and loading assemblies with movable compression plates to stabilize and guide products into cartons, allowing for a wide range of configurations from 2×3-6 packs to 4×8-32 packs, and enabling the use of various pusher face configurations to accommodate different pack sizes and shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional packaging systems are used for specific package sizes, then packaging speed is maintained, but flexibility and adaptability to different pack sizes are lost
Solution Approach 1:
The packaging system employs movable and adjustable components including selector mechanisms that can dynamically reconfigure product groupings, movable compression plates that adjust to different pack sizes, and variable pitch conveyor flights that adapt to various carton dimensions. This dynamic design enables the system to handle multiple pack sizes (6, 8, 12, 16, 20, 24 packs) without requiring complete system replacement, thereby improving adaptability while managing complexity through modular adjustability
Solution Approach 2:
The packaging system is designed with universal components that can perform multiple functions across different packaging configurations. The selector mechanism can create various product groupings, the compression plates can stabilize different pack sizes, and the loading assemblies can accommodate multiple carton types. This multi-functionality allows a single system to handle diverse packaging requirements, improving versatility without proportionally increasing overall system complexity
2Adaptability or versatility
If non-traditional size packages are created to meet consumer demand, then product variety is improved, but production rate decreases
Solution Approach 1:
The system performs preliminary grouping and nesting of products into desired configurations before the loading stage. Selector mechanisms pre-assemble product groups in nested or staggered arrangements, and compression plates pre-stabilize these groupings. This preliminary action ensures that when products are loaded into cartons, they are already in the correct configuration, eliminating time-consuming adjustments during loading and maintaining high production rates despite handling multiple pack sizes
Solution Approach 2:
The packaging system utilizes nested product groupings where smaller product packs are nested within larger carton structures. The selector mechanisms create nested arrangements of bottles or cans, and the movable compression plates help compact these nested groups efficiently. This nesting approach allows the system to handle various pack sizes (from 6 to 32 packs) in a streamlined manner, maintaining productivity by processing multiple configurations through a unified nesting and loading process
3Adaptability or versatility
If multiple selectors and loading assemblies are added to handle various configurations, then adaptability increases, but device complexity increases
Solution Approach 1:
The packaging system merges multiple functional components into integrated assemblies. The selector mechanisms are combined with product grouping functions, compression plates are integrated with loading assemblies, and conveyor flights are coordinated with carton positioning systems. This merging reduces the number of separate components and simplifies control, allowing the system to handle various configurations (2×3-6 packs to 4×8-32 packs) without proportionally increasing device complexity
Data Source
AI summary
A packaging system for the selection, grouping and loading of varying size and/or configuration product packs into cartons as provided. The packaging system includes a selection area having a primary selector for forming an initial product pack configuration, and a secondary selector adapted to select and direct an additional grouping of products into a nested arrangement against the initial product pack so as to form a nested product pack. The nested product packs thereafter can be engaged by loader arms of a pair of opposed loading assemblies, which move the nested product packs into a series of cartons moving through the packaging machine. Thereafter, the ends of the cartons can be closed and sealed to complete the packaging of the product packs therein.