Web-Based Closure Feeder for Dairy Packaging Sterility
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Solution Overview
Problem
Existing container closure systems for fresh dairy products are inefficient and prone to contamination due to manual handling of loose closure blanks, leading to production stops and hygiene issues.
Innovation Solution
A container closure application system using a web of interconnected closure blanks that are sterilized and applied automatically, minimizing material waste and reducing contamination risks by using a feeder mechanism and sterilization means like UV-sterilization and hydrogen peroxide baths, with the option to fix closures using thermo-sealing or laser welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If manual handling of loose closure blanks is used, then flexibility in operation is maintained, but contamination risk and production efficiency deteriorate
Solution Approach 1:
The closure blanks are segmented into individual units within a continuous web structure, allowing automatic feeding and application while maintaining sterility. Each closure blank is separated by tear lines or perforations, enabling individual handling without manual intervention.
Solution Approach 2:
A sterile web structure acts as an intermediary carrier for the closure blanks, transporting them through the automated system without direct manual contact. This web can be sterilized independently and fed through the packaging machine, reducing contamination risk while enabling automation.
2Productivity
If stacks of individual closure blanks are used, then ease of storage is improved, but production stops and jamming worsen
Solution Approach 1:
The closure blanks are provided as a continuous web rather than discrete stacks, enabling uninterrupted feeding into the packaging machine. This continuous supply eliminates production stops and jamming associated with stack-based systems while maintaining manageable storage through rolled web configuration.
Solution Approach 2:
The feeder mechanism is designed to dynamically adjust to the continuous web format, with flexible guiding and tensioning systems that accommodate the roll-to-roll feeding process, reducing complexity compared to rigid stack-handling mechanisms.
3Loss of substance
If web of closure blanks is used, then material efficiency is improved, but handling and separation complexity worsen
Solution Approach 1:
The web is designed with built-in segmentation features such as tear lines, perforations, or weakened sections between individual closure blanks. This allows easy separation at the point of application without requiring complex handling equipment, while minimizing material waste through precise blank definition.
Solution Approach 2:
The web structure incorporates self-separating features that allow closure blanks to be easily detached without external intervention. The tear lines or perforations enable operators or automated systems to separate blanks with minimal force and complexity, maintaining ease of operation while improving material efficiency.
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 system ensures continuous, contamination-free production with reduced material usage and labor, maintaining a controlled atmosphere and minimizing unscheduled stops, while providing a cost-effective and hygienic closure application process.
Implementation Method 1
sterilization means like UV-sterilization
Implementation Method 2
hydrogen peroxide baths
Implementation Method 3
fix closures using thermo-sealing
Implementation Method 4
laser welding
Data Source
AI summary
The invention relates to a container closure application system comprising a feeder mechanism for advancing a closure blank to a container and a compartment for bringing the closure blank in register with an opening of the container, wherein succeeding closure blanks are provided as a web. The invention furthermore relates to a method for applying closures to a container by means of such system, a web of closure blanks or membranes, and a method for preparing such a web.