Settling Device for Product Compaction in Packaging
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Solution Overview
Problem
Traditional packaging methods result in settling of products during shipping and handling, leading to void spaces and inefficient use of packaging materials, as well as consumer dissatisfaction with less-than-full appearances.
Innovation Solution
An apparatus with a settling device that forms and compacts a slug of product using a settling chamber and optional vibration, allowing for increased product density and reduced settling, adaptable for use on various packaging machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional vertical form, fill, and seal machine is used to package product, then packaging speed is high (up to 100 bags per minute), but product settles during shipping and handling creating void spaces and making package appear less full
Solution Approach 1:
The apparatus applies preliminary action by compacting the product slug in a settling chamber before it enters the packaging machine. The settling chamber allows product to settle and compact under gravity and vibration prior to packaging, so that when the package is sealed, the product is already in a compacted state. This preliminary compaction prevents settling during subsequent shipping and handling while maintaining high packaging speeds.
Solution Approach 2:
The apparatus uses mechanical vibration as a key mechanism to compact product in the settling chamber. Vibration is applied to the settling chamber to facilitate product settling and compaction. The vibration causes product particles to rearrange and settle into a more compact configuration, reducing void spaces while maintaining packaging speed.
2Stability of the object's composition
If package is made larger to accommodate settled product, then product appears fuller during shipping, but packaging material is wasted and retail shelf space is inefficiently used
Solution Approach 1:
The settling chamber performs preliminary compaction of product before packaging. By compacting product in advance, the package can be made to the correct size with minimal material, and product will remain compacted during shipping, maintaining fullness appearance without requiring excessive packaging material.
Solution Approach 2:
The apparatus changes physical parameters of product by applying vibration and gravity in the settling chamber to alter product density and compaction. This parameter change allows product to be packaged at optimal density, eliminating the need for oversized packaging while maintaining fullness appearance throughout the product lifecycle.
3Stability of the object's composition
If product is partially filled and vibrated to settle, then compaction is improved, but packaging rate becomes very slow and cannot be conducted at high rates
Solution Approach 1:
The settling chamber is positioned before the packaging machine and performs compaction in advance. This allows high-speed packaging to occur without slowing down for repeated partial filling and vibration cycles. The preliminary compaction is done in a dedicated chamber, and fully compacted slugs are then rapidly packaged at high speed.
Solution Approach 2:
The apparatus segments the process into two distinct stages: compaction in a settling chamber and rapid packaging in the vertical form, fill, and seal machine. This segmentation allows each stage to be optimized independently - compaction can be thorough while packaging operates at high speed, resolving the contradiction between compaction quality and packaging rate.
4Stability of the object's composition
If settling chamber with vibration is used to compact product, then product density is increased and settling is reduced, but device complexity increases
Solution Approach 1:
The settling chamber is designed as a multi-functional component that can be integrated into existing vertical form, fill, and seal machines. It serves multiple purposes: compacting product, allowing settling, and preparing slugs for packaging. This universal design reduces overall system complexity by consolidating functions into a single apparatus that can be added with minor modifications to existing equipment.
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 apparatus maintains product compaction throughout packaging, reducing post-manufacturing settling, enabling smaller, more efficient packaging that appears fuller and uses less material, thus saving space and resources.
Implementation Method 1
a settling chamber to receive and compact the slug of product
Implementation Method 2
using a settling chamber and optional vibration
Data Source
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AI summary
A method for compacting a slug of product and apparatus for accomplishing the same. The invention describes collecting weighed product in an intermediate settling device to form a compact slug of product. The device can comprise a single settling chamber or can comprise multiple settling chambers which are axially rotatable. The slug can be compacting by jostling and/or vibrating the settling device. Thereafter, the product is discharged to a packaging apparatus. Because the product in the final package is denser, a smaller package can be utilized reducing manufacturing and shipping costs.