Abstract:
A semi-automated packaging apparatus allows for an operator to fill a presented container without contaminating the container rim. The presentation of an empty container and subsequent removal of a filled container are performed automatically under control of the operator. The apparatus comprises a plurality of separate, removable modules including: a de-nester module for separating the containers from a stack; a container-presenting module for moving the currently de-nested container into position to be filled by an operator and subsequently removing a filled container; a removable tray with a central opening to allow an operator to place foodstuffs in the presented container; and a user interface module, coupled to each of the other modules for allowing the selection of the proper container opening dimensions (associated with the proper tray selection) and depth dimension (associated with the proper movement of the container-presenting module), as well as to control the “pace” of the packaging operation.

Description:
TECHNICAL FIELD 
       [0001]    The present invention relates to an apparatus for packaging foodstuffs (such as, for example, various meats) and, more particularly, to a semi-automated apparatus that allows for an operator to fill a presented container without contaminating the container rim. The presentation of an empty container and subsequent removal of a filled container are performed automatically under control of the operator. 
       BACKGROUND OF THE INVENTION 
       [0002]    There is a product line in the food industry that is generally referred to as “case-ready” product. Case-ready product can include meat and vegetables, as well as other food products, in packages comprising a container and a cover. The cover is preferably clear for viewing the product in the container. Often, the product is fresh and needs to be maintained in an environment that prevents contamination and premature spoilage. Case-ready product packages preferably include a plastic sheet cover substantially the same size as the container opening wherein the cover is sealed to an upper portion (generally, a rim) of the container. 
         [0003]    The interiors of case-ready containers, because they are sealed, can be flushed with various gases to help preserve the freshness of the food product to extend shelf life. Shelf life is important to food processors, retailers and consumers in order to reduce costs and to provide safety for the end consumer. 
         [0004]    In case-ready products where the cover is heat-sealed to the upper portion of the container, the use of flushing gases is particularly important to provide a seal of the required integrity. Machines have been designed to introduce a gas into the container while simultaneously heat-sealing a durable film around the rim of the container, where the containers generally comprise a polymeric (plastic) tray-type container. The machines include sealing bars that apply pressure and heat to the film, creating a heat seal to secure the cover to the container. When executed correctly, a pillow of gas is captured under the covering film. However, in cases where a good seal is not formed between the container and the cover (for example, by the presence of moisture, fat and/or protein on the sealing area of the container) the cover will not be properly secured and the product will have to be re-worked. This adds to the cost of producing products and/or elevates the risk of premature failure of the product. Re-working requires that the container be removed from the production line and placed into the machine for re-processing, and typically requires a worker to remove foreign materials from the sealing area of the container. 
         [0005]    Currently in the meat industry, operators manually wipe the tops of the containers with towels prior to sealing. The use of operators for cleaning receptacles is expensive and sometimes results in receptacles being missed or not cleaned uniformly. In addition, when operators use towels to manually remove contaminants from the receptacles, it is up to the individual operator to determine when a towel should be disposed of and a new towel used. This can lead to sporadic quality of cleaning and can introduce the transfer of bacteria and other towel contaminants between and into receptacles. 
         [0006]    It is also known in the food processing industry to utilize air jets to clean the tops of containers prior to sealing. This method can be successfully used with food products that tend to leave loose particulate matter or water on the sealing surface of the receptacles. However, contaminants such as proteins, fats and starches adhere more securely to the sealing surfaces. Air streams are not effective for the removal of these contaminants, to a point where sealing can be effected. 
         [0007]    Another limitation common to most prior art meat packaging machines is that each machine is specifically developed and sized to accommodate specific package dimensions. Therefore, as container sizes change, a typical packaging machine must be taken out of service and essentially re-built to properly transport and fill the different-dimensioned package. Alternatively, a packaging facility may utilize several different pieces of apparatus, each “sized” for a different container size. As a result, the “floor space” required to perform the packaging is significantly increased, which is a concern for environments where refrigerated packaging facilities are used. 
         [0008]    Thus, there is a need for an improved apparatus and method for packaging foodstuffs, such as meats, that overcomes the aforementioned problems. 
       SUMMARY OF THE INVENTION 
       [0009]    The needs remaining in the art are addressed by the present invention, which relates to an apparatus for packaging foodstuffs (such as, for example, various meats) and, more particularly, to a semi-automated apparatus that allows for an operator to fill a presented container without contaminating the container rim. The presentation of an empty container and subsequent removal of a filled container are performed automatically under control of the operator. 
         [0010]    In accordance with the present invention, the packaging apparatus comprises a plurality of separate, removable modules including: a de-nester module for separating the containers from a stack; a container-presenting module for moving the currently de-nested container into position to be filled by an operator and subsequently removing a filled container; a removable tray with a central opening to allow an operator to place foodstuffs in the presented container; and a user interface module, coupled to each of the other modules for allowing the operator to select the proper container opening dimensions (associated with the proper tray selection) and depth dimension (associated with the proper movement of the container-presenting module), as well as to control the “pace” of the packaging operation. 
         [0011]    In a preferred embodiment of the present invention, the container-presenting module includes a first translator element for moving a de-nested container away from the remaining stack, an elevator element for raising/lowering the de-nested container into proper position underneath the tray opening, and a second translator element for moving the filled container away from the packaging apparatus and onto another station for sealing. 
         [0012]    It is a feature of the present invention that an operator is used to properly position the foodstuffs in the container, an advantage for packaging certain meat cuts and other items that are best presented for sale when placed in the container in an attractive arrangement. Indeed, the operator remains in control of the “pace” of the packaging apparatus, using a simple push button to signal that a container has been filled and may be moved out by the container-presenting module, and another empty container may be presented (also under the automatic control of the container-presenting module). 
         [0013]    In use, the machine operator enters the information regarding the dimensions of the package currently in production in the user interface module. This information is used to automatically adjust the positioning and movements of the de-nester, translators and elevator. Also, this information is checked against the dimensions of the tray currently in place at the machine. If the dimensions of the tray opening do not match the information submitted by the operator, an error message will prevent the machine from starting until the properly-dimensioned tray is in place. 
         [0014]    By virtue of using the interface module to control the positions of the various elements within the packaging apparatus with respect to the dimensions of the container currently being used, the packaging apparatus of the present invention may be used with virtually any size or type of container, eliminating the need for a “dedicated” packaging machine for each different size of container, as was common in the prior art. 
         [0015]    It is another advantage of the present invention that each of the modules may be individually removed for repair or replacement. The use of programmed logic control (PLC) in conjunction with the user interface provides a means for the machine operator or other technician to quickly “de-bug” any problems with the apparatus, as well as collect data regarding the packaging rate, errors in the system, and the like. 
         [0016]    Other and further embodiments and advantages of the present invention will become apparent during the course of the following discussion, and by reference to the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0017]    Referring now to the drawings, where like numerals represent like parts in several views: 
           [0018]      FIG. 1  illustrates, in an isometric view, an exemplary foodstuff packaging apparatus formed in accordance with the present invention; 
           [0019]      FIG. 2  is an alternative view of the packaging apparatus of  FIG. 1 , in this case with the tray removed from position; 
           [0020]      FIG. 3  illustrates an exemplary tray sensor formed in accordance with the present invention; 
           [0021]      FIG. 4  is a side view of a portion of the inventive packaging apparatus, particularly illustrating in this view selected elements of an exemplary container-presenting module; 
           [0022]      FIG. 5  is an isometric view of the packaging apparatus of the present invention, in this view showing the position of three different containers along the path from the de-nester module; 
           [0023]      FIG. 6  contains a view of the inventive packaging apparatus, with a container in the removal position along the exit rail; 
           [0024]      FIG. 7  illustrates in a view of a portion of the inventive packaging apparatus, an exemplary de-nester module and an exemplary x-dimension adjustment component; 
           [0025]      FIG. 8  illustrates an exemplary y-dimension adjustment component; 
           [0026]      FIG. 9  illustrates, in a partial view of the inventive packaging apparatus, an exemplary user interface module, as removed from the remainder of the apparatus; 
           [0027]      FIG. 10  is a view from the opposite direction as that of  FIG. 9 , illustrating some of the interior processing elements of the user interface module; and 
           [0028]      FIG. 11  illustrates a pair of exemplary touch screen displays that may sequentially presented and used to control the operation of the packaging apparatus of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0029]      FIG. 1  illustrates, in an isometric view, an exemplary foodstuff packaging apparatus  10  formed in accordance with the present invention. Particularly shown in this view is de-nester module  12 , removable tray  14  and user interface module  16 . In operation, a stack of empty containers (not shown) is loaded into opening  18  of de-nester module  12 . Using an arrangement that will be described in detail hereinbelow, opening  18  is properly sized/adjusted to support the dimensions of the loaded containers, where each individual container is “de-nested” from the stack in turn. A container-presenting module (not shown in this view) then moves the de-nested container and positions the empty container underneath opening  20  of removable tray  14 . An operator standing in front of removable tray  14  then proceeds to fill the empty container. Once filled, the operator presses a control button  22  to signal completion. At this point, the container-presenting module will lower the filled container, and move it along exit rail  24  toward a sealing system (not shown). 
         [0030]    In accordance with the present invention, opening  20  of removable tray  14  is sized such that the rim of the underlying container remains protected as the operator fills the container, thus eliminating the possibility of any contaminants from adhering to the sealing rim. By virtue of utilizing a “removable” tray, other trays with different-sized openings may be used to accommodate different container dimensions, allowing for quick change-over of the packaging process. Such a change-over is not possible utilizing the dedicated packaging apparatus of the prior art. 
         [0031]    In particular,  FIG. 2  is an alternative view of packaging apparatus  10  of  FIG. 1 , in this case with tray  14  removed from the remainder of apparatus  10 . Indeed, a set of four removable trays  14 - 1 ,  14 - 2 ,  14 - 3  and  14 - 4  is shown in  FIG. 2 , where each tray  14  has a differently-sized opening,  20 - 1 ,  20 - 2 ,  20 - 3 , and  20 - 4 , respectively, for accommodating a different-sized container. It is to be understood that openings  20  are associated only with the “x” and “y” dimensions of a container, and the depth of a particular container (the “z” dimension) is controlled through the operation of the container-presenting module, as will be shown hereinbelow. Another portion of the container-presenting module, a translation support member  25 , is shown in  FIG. 2 . 
         [0032]    Also evident in the view of  FIG. 2  is a tray opening sensor  26 . In accordance with the present invention, sensor  26  engages with another sensor  28  located on the backside of tray  14 .  FIG. 3  illustrates an exemplary tray sensor  28 . As shown in  FIG. 2 , tray opening sensor  26  comprises a set of three metal contacts  30 - 1 ,  30 - 2  and  30 - 3  (it is to be understood that fewer or more metal contacts may be required and/or used). Tray sensor  28 , as shown in  FIG. 3 , includes a particular sensor arrangement of one or more contact elements  32  that will be disposed adjacent to sensor  26  when tray  14  is in place. The number/location of contact elements  32 , when located physically adjacent to contacts  30 , is used in accordance with the present invention to ascertain the size of opening  20  of in-place tray  14 . For example, it is presumed in the illustration of  FIG. 3  that tray sensor  28 - 1  on tray  14 - 1  includes only a single contact element  32 , which will contact middle metal contact  30 - 2  of tray opening sensor  26  when tray  14 - 1  is loaded in place. The activation of only this single, middle contact is then used as an input to user interface module  16 , which then matches this signal with the specific “x” and “y” dimensions of tray opening  20 - 1 . As will be explained hereinbelow, this signal will then properly size opening  18  and properly adjust the movement of the container-presenting module. It is an aspect of the present invention that by virtue of having mechanized opening adjustments, apparatus  10  may be utilized with packages of various dimensions and, in particular, may be programmed once “on site” to the specific dimensions associated with the containers utilized by a specific packaging facility. 
         [0033]      FIG. 4  is a side view of a portion of packaging apparatus  10 , particularly illustrating in this view selected elements of a container-presenting module  50 , as well as the placement of a stack of containers  100  within opening  18  of de-nester  12 . In accordance with the present invention, a set of variable-pitch indexing screws  40 - 1 ,  40 - 2  are used to individually separate the bottom-most container from stack  100 , and allow this container (illustrated as container  100 - 1  in  FIG. 4 ) to drop into position on a conveyor element  52  of container-presenting module  50 . A first containing wall  51  of conveyor element  52  is shown in  FIG. 4 , where a similar containing wall  53  (shown best in  FIG. 5 ) is positioned on the opposite side. As will be discussed in detail below, containing walls  51 ,  53  are adjustable in accordance with the “y” dimension of container  100 , so that the empty container is properly guided along conveyor element  52 . Once container  100 - 1  drops into place between adjustable containing walls  51 ,  53 , a first push bar of container-presenting module is activated to move container  100 - 1  (in the direction shown by the arrows) into position underneath tray  14 . An elevation element  56  of container-presenting module  50  then raises container  100 - 1  into position at the underside of tray  14 . In accordance with the present invention, by knowing the depth of the container (i.e., the “z” dimension of the container, information supplied by the operator), elevation element  56  will raise container  100 - 1  the proper distance so as to be directly underneath opening  20 . 
         [0034]    Once the operator has filled the container, he/she activates push button  22 , which then lowers elevation element  56 , still supporting filled container  100 - 1 . A second push bar  58  moves filled container  100 - 1  out from apparatus  10  along exit rail  24  (as shown in  FIG. 1 ). 
         [0035]      FIG. 5  is an isometric view of apparatus  10 , in this view showing the position of three different containers  100  along the path from de-nester module  12 , along container-presenting module  50  and then into place under opening  20  of removable tray  14 . A second container  100 - 2  is shown in the dropped position on conveyor element  52  of container-presenting module  50 , where in this view second containing wall  53  is shown. A third container  100 - 3  is shown within de-nester module  12  as engaged with variable-pitch indexing screws  40 - 1  and  40 - 2 , so as to be the next container to be dropped once container  100 - 2  has been translated along conveyor element  52 , where  FIG. 6  contains a view of packaging apparatus  10  with (presumably filled) container  100 - 1  in the removal position along exit rail  24 . 
         [0036]    As mentioned above, a significant aspect of the present invention is the ability to adjust various components of the packaging apparatus as a function of the dimensions of the container currently being packaged. The ability to easily and quickly adapt the packaging apparatus itself eliminates the need to either use several machines, each dedicated to a specific container, or create “down-time” when a packaging must be turned off and manually re-arranged for use with a different-sized package. 
         [0037]    Shown in both  FIGS. 5 and 6  is an x-dimension adjustment component  60  of the present invention, comprised of a number of separate elements that respond to the container dimensions input by the operator (via user interface module  16 ) to adjust the x-direction dimensions of various elements within apparatus  10 . As mentioned above, by allowing this dimension (as well as the y- and z-dimensions) to be adjusted, packaging apparatus  10  can be utilized with virtually any of the various standard-dimensioned packaging containers (as compared to prior art packaging machines which are dedicated to a specific container size). 
         [0038]      FIG. 7  illustrates, in greater detail, this particular portion of apparatus  10 , showing de-nester  12  and x-dimension adjustment component  60 . Referring collectively to  FIGS. 5 ,  6  and  7 , x-dimension adjustment component  60  is shown as comprising a pair of threaded rods  62 - 1  and  62 - 2  and a set of internally-threaded adjusters  64 , with a first pair of adjusters  64  disposed to engage rod  62 - 1  and a second pair of adjusters  64  disposed to engage rod  62 - 2 . A series of drive belts  66  and associated servo-motor  68  are utilized to simultaneously rotate threaded rods  62 - 1  and  62 - 2 , which will then bring adjusters  64  closer together or further apart, depending on the rotation direction of rods  62 . Referring now in particular to  FIG. 7 , a pair of movable walls  17  and  19  are shown as being attached to adjusters  64 . Therefore, as adjusters  64  move, walls  17  and  19  will move in an overlapping fashion to adjust the x-dimension spacing of opening  18 . For example, a control signal from an “x dimension” processor element within user interface  16  may transmit a signal for the “x” dimension of “8 inches” to servo-motor  68 , which will then activate drive belts  66  for a period of time sufficient to rotate rods  62 - 1  and  62 - 2  until adjusters  64 , and associated walls  17  and  19 , are eight inches apart in the x direction. 
         [0039]    As will be discussed hereinbelow in association with  FIG. 8 , this same “x” dimension signal is used to adjust a pair of sidewalls  23 ,  25  associated with exit rail  24  and similarly control the x-direction spacing between sidewalls  23 ,  25  so that a container will remain properly positioned and supported as it exits packaging apparatus  10 . 
         [0040]    Container-presenting module  50  comprises, as mentioned above, a pair of containing walls  51 ,  53  that are used to control the y-direction spacing along conveyor element  52 . A similar arrangement of threaded rods, belts and adjusters is utilized to control the spacing between walls  51  and  53 , in response to a “y” dimension signal supplied by the operation. In particular, an exemplary y-dimension adjustment component  70  is illustrated in  FIG. 8 , which is an underside isometric view of packaging apparatus  10 . As with x-dimension adjustment component  60 , y-dimension adjustment component  70  comprises a pair of threaded rods  72 - 1  and  72 - 2  and an associated set of internally-threaded adjusters  74 , with a first pair of adjusters  74  disposed to engage rod  72 - 1  and a second pair of adjusters  74  disposed to engage rod  72 - 2 . A series of drive belts  76  and servo-motor  78  are used to control the rotation of rods  72 - 1  and  72 - 2 , thus modifying the position of adjusters  74  (in response to a control signal from a “y dimension” processor element, not shown, within user interface  16 ) and associated containing walls  51 ,  53  to define the proper y-direction spacing for the containers as they are translated along conveyor element  52 . 
         [0041]    A similarly-controlled z-dimension adjustment component  80  (shown in  FIG. 5 ) is used to control the z-direction movement of elevation element  56  so that container  100  is properly positioned underneath opening  20  of removable tray  14 . 
         [0042]    An important feature of the present invention is the modularity of apparatus  10 , where each module may be separately removed, replaced, repaired, cleaned, etc., without the need to dismantle the entire system. As mentioned above, removable tray  14  simply lifts out of place to allow for quick changeover of the dimensions of opening  20  and/or to allow for tray  14  to be cleaned off. In a similar fashion, x-dimension adjustment component  60 , y-dimension adjustment component  70  and z-dimension adjustment component  80  may all be individually removed for any desired repair, upgrade, cleaning, or the like. 
         [0043]    Moreover, it is significant that user interface module  16  may similarly be removed from the remainder of apparatus  10 . Inasmuch as user interface module  16  contains all of the processing and control functionality for apparatus  10 , it is important that this component be “portable”—for example, to be tested in an electronics testing facility, manufactured by a separate entity, and the like.  FIG. 9  illustrates, in a partial view of apparatus  10 , a view with user interface module  16  removed from the remainder of the apparatus.  FIG. 10  is a view from the opposite direction, illustrating some of the interior processing elements of user interface module  16 . 
         [0044]    Referring back to  FIG. 9 , user interface module  16  is shown as comprising a data entry element  90 , in this particular example a touch screen. In use, an individual responsible for the packaging process (such as, for example, a technician or maintenance personnel) will enter information via touch screen  90 , perhaps in response to a series of prompts, as discussed below in association with  FIG. 11 . The technician&#39;s inputs are then used by a plurality of programmed logic circuits  91  (see  FIG. 10 ) to generate the necessary signals which are then transmitted via the appropriate connections to the remainder of apparatus  10 . As shown in  FIG. 9 , a set of five separate signal connections  92  may be used,  92 -x providing the “x dimension” signal,  92 -y providing the “y dimension” signal,  92 -z providing the “z dimension” signal,  92 -d for activating variable-pitch indexing screws  40  to initiate the de-nesting process, and  92 -o for turning “on” and “off” apparatus  10 . By virtue of using a removable user interface module  16 , each circuit path within module  16 , as well as the operation of each of the PLCs, may be individually programmed and tested prior to attaching module  16  to apparatus  10 . 
         [0045]    Moreover, it is to be understood that the specific interactions with apparatus  10  via user interface module  16  may be configured in any arrangement suitable for the user of the apparatus. The specifics of PLC  91  and associated processing circuits, not germane to the subject matter of the present invention, may be properly designed and configured for the particular type of interface that is desired.  FIG. 11  illustrates a pair of exemplary touch screen displays that may sequentially presented and used by a technician to control the operation of apparatus  10 .  FIG. 11(   a ) illustrates an exemplary “main menu” display for touch screen  90 , including four separate touch-sensitive initialization modes of operation. As shown, these four include “resume” mode  93 - 1 , “remove trays” mode  93 - 2 , “maintenance” mode  93 - 3 , and “change tray” mode  93 - 4 . For the purposes of discussion, it will be presumed that mode  93 - 4  has been selected, as shown by the highlighting in  FIG. 11(   a ), in order to change the size of the container being used. By touching mode  93 - 4 , the next screen that appears (in this example) is associated with defining the proper x-dimension for the new tray. In this embodiment, screen  90  illustrates an exemplary container width  95  (width A) and prompts the technician to respond at either touchpoint  96  for “yes”—proper width, or at touchpoint  97  for “no”—change width. Other arrangements may be used, where a particular packaging plant may have pre-defined package dimensions referred to by codes that may be used to select the correct container dimensions. 
         [0046]    It is to be understood that many changes, modifications, variations and other users and applications of the present invention, including equivalents thereof, may become apparent to those skilled in the art after considering this specification and the accompanying drawings. All such changes, modifications, variations, equivalents and other uses and applications which do not depart from the spirit and scope of the present invention are deemed to be covered by the invention which is limited only by the claims appended hereto.