Packaging Film Cutting and Positioning for Reduced Waste
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Solution Overview
Problem
Existing packaging technologies, such as vacuum skin packaging and induction sealing, face inefficiencies due to complex machinery, excess plastic waste, and mis-positioning issues, particularly when using continuous film rolls and requiring precise cutting and positioning of film sheets during the packaging process.
Innovation Solution
A packaging apparatus and process that includes a film cutting assembly outside the packaging chamber, a transfer device for positioning cut film sheets, and a control unit to synchronize operations, allowing for flexible use of heat-shrinkable or non-heat-shrinkable films, reducing plastic consumption, and improving productivity by minimizing mis-positioning and waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If continuous film rolls are used for packaging, then productivity is improved, but manufacturing precision deteriorates due to mis-positioning issues
Solution Approach 1:
The continuous film roll is divided into individual film sheets of precise dimensions through a cutting assembly. This segmentation allows each sheet to be positioned accurately on the support, eliminating mis-positioning issues while maintaining the productivity benefits of using continuous film rolls.
Solution Approach 2:
Film sheets are cut to the exact required size and shape before being transferred to the packaging chamber. This preliminary cutting action ensures that when the film is later applied to the support, it fits precisely without requiring complex real-time positioning adjustments during the packaging process.
2Manufacturing precision
If complex cutting and positioning mechanisms are added to achieve precise film positioning, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The film sheet itself serves as the positioning reference through its pre-cut dimensions and shape. The cutting assembly creates film sheets with exact boundaries that naturally align with the support contours, eliminating the need for additional complex positioning mechanisms, sensors, or adjustment devices.
Solution Approach 2:
The cutting function is extracted as a separate, dedicated assembly that operates independently from the packaging chamber. This allows the cutting mechanism to be optimized for precision without adding complexity to the packaging process itself, as the pre-cut sheets are simply transferred and applied.
3Reliability
If excess film is used to ensure proper coverage, then reliability is improved, but loss of substance increases due to plastic waste
Solution Approach 1:
The film sheet is cut with varying dimensions tailored to the specific support geometry. Areas requiring secure sealing have adequate film coverage, while areas where excess film would create waste are precisely trimmed. This local optimization ensures seal integrity where needed while minimizing overall material consumption.
Solution Approach 2:
The cutting assembly precisely trims the film to the exact dimensions needed, discarding only the minimal amount of material necessary to achieve proper fit and seal. This precise discarding approach eliminates the waste associated with using excessive film while maintaining packaging reliability.
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 solution enables efficient, flexible packaging with reduced plastic waste and improved productivity by precisely cutting and positioning film sheets, enhancing the packaging process for both skin and modified atmosphere packaging.
Implementation Method 1
a power supply provides an electrical current to a nearby induction coil which induces an electrical current into the metal foil to develop heat
Implementation Method 2
induces an electrical current into the metal foil to develop heat which melts portions of the lid and container
Implementation Method 3
The induction sealing assembly uses a vacuum source and a source of inert gas to flush air from the container prior to sealing
Implementation Method 4
The induction sealing assembly uses a vacuum source and a source of inert gas to flush air from the container prior to sealing
Implementation Method 5
a heating structure (40) peripherally associated to the film holding plate (36) and having a respective heating surface (41)
Implementation Method 6
heating the film sheet (18) to a predetermined temperature
Implementation Method 7
means (38) for holding the one or more film sheets (18) in correspondence of said active surface (37), said means (38) for holding comprising one or more in the group of: a vacuum source (39)
Implementation Method 8
said packaging assembly (8) being configured to operate at least in a first operating condition, where said packaging chamber (24) is open to receive one or more of said film sheets (18) and, in a second operating condition, where said packaging chamber (24) is, optionally hermetically, closed
Data Source
AI summary
A process for packaging a product (P) arranged in a support (4) comprising unrolling a film (10a), transversely cutting the unrolled portion of film (10a) and preparing cut film sheets (18), moving the cut film sheets (18) to a packaging assembly (8) defining at its inside a packaging chamber (24), progressively moving a number of supports (4) inside the packaging chamber (24) of a packaging assembly (8), keeping the packaging chamber (24) open for a time sufficient for a number of supports (4) and for a corresponding number of film sheets (18) to properly position inside said packaging chamber (24), hermetically closing the packaging chamber (24) with the film sheets held above the respective support (4) and at a distance sufficient to allow gas circulation inside the support (4), optionally causing one or both of: a gas withdrawal from the hermetically closed packaging chamber (24) and gas injection of a gas mixture of controlled composition, heat sealing the film sheet (18) to said support (4), wherein the cutting of the film (10a) into film sheets (18) takes place outside the packaging chamber (24) at a station remote from the location where the film sheets are coupled to the supports. An apparatus (1) for performing the above process is also disclosed.