Food service set assembly system

A device and method for assembling a food service set comprising at least one napkin wrapped around one or more utensils and secured by an adhesive band. The device includes a magazine subsystem including one or more magazines for containing and dispensing the at least one napkin, the one or more utensils, and the adhesive band. The device further includes an integrator subsystem configured to integrate the at least one napkin, the one or more utensils, and the adhesive band together. A processor subsystem is configured to roll the at least one napkin around the one or more utensils and to secure the adhesive band around the at least one napkin. A receiver subsystem is configured for receiving the service set. A sterilization system is provided to sterilize the utensils prior to, or after, being assembled into a service pack.

BACKGROUND

The present invention relates generally to packaging one or more food utensils, and more particularly to an apparatus and method for assembling a service set having one or more utensils wrapped by a napkin.

Despite advances in automation, many processes within the food service industry are still largely manual. For example, preparing and providing a napkin and utensils for use by a customer is typically done manually. Some food service establishments, especially those that serve a large number of customers, attempt to conserve time by providing a “service set,” that is, one or more utensils wrapped inside a napkin and secured by a piece of paper tape. The service pack can then be given to a customer so that setting utensils and the napkin at a table is unnecessary. Unfortunately, large amounts of manual labor time are still consumed in the formation of these service packs.

For each service set, a human must still select and bundle one or more utensils must still be manually bundled, wrapped in a napkin and then sometimes taped in place. At large food service establishments, such as with large chain restaurants, hotels, casinos, resorts, etc., the labor costs involved in forming and providing a large number of service sets can be substantial, particularly when all costs such as wages or other compensation and benefits are taken into account. Further, human contact with the various components of a service pack during the assembly process can lead to contamination and the transmission of disease.

SUMMARY

An apparatus and method for assembling a service set are disclosed, for saving time and energy that would normally be required of a person to manually assemble such a service set. The apparatus and method for assembling a service set also achieve a high throughput for outputting assembled service sets. Further, human contact with the various components of a service set is minimized by the disclosed apparatus and method, minimizing the risk of contamination and transmission of disease.

A device for assembling a service pack is disclosed. A service pack includes a napkin and a utensil set. The device includes a folding stage, and a vacuum chuck configured to lift a napkin from a stack of napkins, and place the napkin onto the folding stage. The device further includes a grabber that moves to a utensil assembly holding a number of utensils, the grabber configured to pick up a utensil set from the number of utensils, and place the utensil set onto the napkin. The device further includes a sterilization mechanism, configured to sterilize the utensil set.

DETAILED DESCRIPTION

This document describes apparatuses and methods for assembling a service set, in which many previously manually-performed tasks are automated and performed to a high degree of precision. Further, these apparatuses and methods reduce potential contamination of any of the components of a service set to provide a service set that is free of germs and/or disease-causing agents.

FIG. 1graphically depicts a general process100for mechanically assembling a service set in accordance with one embodiment. At102, a napkin10from a napkin stack12is provided to a napkin feeder14, which feeds the napkin10to a receiving position at106. At104, one or more utensils16are provided to individual utensil feeders18, which feeds the one or more utensils to the napkin10in the receiving position106. The one or more utensils16may include a knife, a fork, a spoon, or some combination thereof. Each utensil feeder18may include a cartridge or other detachable holding mechanism that can be attached to a mechanism for holding and feeding the one or more utensils16one at a time to the napkin10. In an alternative embodiment, a combination of utensils16may be provided to a single utensil feeder18. The one or more utensils16provided to the napkin10in the receiving position106form a utensil set20.

After the utensil set20has been fed to the napkin10in the receiving position106, a folding mechanism22folds the napkin10around the utensil set20, also shown at108, to a folded position110. The folding mechanism22can include a first folder for folding the napkin along a first axis23shown at106, and a second folder for folding the napkin along a second axis25, shown at108, where the second axis25can be substantially normal to the first axis23. Any sized portion of the napkin10can be part of the folding of the first or second folder. For example, as shown inFIG. 1, the first folder can fold the napkin10substantially in half, while the second folder may fold only a small lower portion of the napkin back on itself. The folding mechanism22may also be configured to perform all folds of the napkin10in one integrated step.

In the folded position the napkin16and utensil set20therein are provided to a rolling mechanism24, at110and112. The rolling mechanism24can include a first roller251for rolling the napkin16and utensil set20in a first, i.e. clockwise, direction, and a second roller252for rolling the napkin16and utensil set20in a second, i.e. counter-clockwise direction. The rolling mechanism24tightens the folded napkin16around the utensil set20to a rolled position, shown at112. A tape feeder26provides a tape piece28from a tape stack or tape roll30to an outer surface of the napkin16that has been rolled around the utensil set20to secure the napkin16and utensil set20in a rolled-up position, and to complete the assembly of a service set32, depicted at114. The assembled service set32can then be provided to a basket or other type of service set holder.

In one exemplary embodiment, the process for assembling a service pack utilizes a standard 15×17 inch napkin, however any size napkin10can be used, as shown inFIG. 2. The napkin10is preferably formed of paper, but linen or other cloth-like material napkin can also be used. As shown inFIG. 3, the tape piece28can include one or two adhesive end areas that are configured to adhere to each other. An adhesive can be provided on one or both adhesive end areas. In an embodiment, the adhesive end areas are provided on opposite sides of the tape piece28, such that when the tape piece is rolled around the napkin10and utensil set20, one adhesive end area is juxtaposed with, and at least partially overlaps, another adhesive end area.

In accordance with a specific embodiment, a service set includes the following: a napkin, such as those commonly available from restaurant supply houses, preferably in a “Quarter Fold” configuration, (unfolded, 15×17 inches); flatware or “Dinnerware Utensils”, (knives and forks, and optionally spoons), which can be metallic or plastic, such as are commonly available from restaurant supply houses; a napkin band, which are also commonly available (in stacked format) from restaurant supply houses. In a specific embodiment, the napkin band is approximately 1.5×4.3 inches. The napkin bands are preferably paper strips with adhesive backing. The adhesive backing sticks to itself only and requires no treatment to activate the tackiness. The adhesive backing is a film applied to both sides of the strip but only at the (i.e. approximately 1.5″ wide) opposite ends and extending approximately one third of the length from the end, as shown above with respect toFIG. 3.

FIG. 4shows a service set assembly system200in accordance with an exemplary embodiment. The system200includes an assembly device202configured to assemble and output a number of service sets, which includes utensils in a folded and/or rolled napkin contained by a tape piece or napkin band. The device202can use napkins, utensils and napkin bands typically found in restaurants, or napkins of unique dimensions, and a combination of common automation machine components such as pick-and-place assemblies, customized clamps, motorized linear and rotational bearings and slides, stepper motor and/or solenoid type actuators. An electronic control system212provides a control interface for activating the individual internal components of the device202in a particular sequence employed to assemble the service set.

This device202incorporates features that facilitate loading and installation of magazines, installation and removal of the receiver. The device202is easy to operate and includes safety features such as GFCI circuitry, an EPO switch and tamper-proof access panels for service. To increase reliability of the device, and to simplify manufacturing assembly and maintenance in the field, no hydraulics or pneumatics are employed with the preferred embodiment.

The device202includes a housing204. The housing204is preferably squared or cubed, formed of rigid plastic or stainless steel, and may have a number of padded legs or feet on which the housing204is positioned upon a planar surface. The housing204includes one or more inlets206for receiving a cartridge226containing a number of utensils228. For example, there may be two inlets206, each for accepting individual cartridges226for forks and knives. A third inlet206may be provided to receive a cartridge226of spoons. The cartridges226provide the utensils228in a generally stacked configuration for serial placement to the device202one-at-a-time.

The housing204also includes a napkin inlet208that is sized and configured to receive a napkin cartridge228containing a stack of individual napkins229. Alternatively, the stack of individual napkins229can be fed directly to the napkin inlet208. The device202also includes an outlet214through which assembled service packs are sent to a basket216or other receiving mechanism.

In an alternative exemplary embodiment, a device300for assembling a service pack includes a number of sub-systems, as generally shown inFIG. 5. A magazine subsystem302includes one or more magazines for containing, sorting and/or dispensing the napkins, utensils and napkin bands. Each of these service pack components may be provided or dispensed in its own magazine, or a magazine may contain one or more items. An integrator subsystem304includes an integrator306that transfers the napkins and utensils from their magazines and positions them appropriately to a processor subsystem305.

The processor subsystem305includes a processor308that folds and rolls a napkin to surround the utensils and then applies a napkin band to the napkin to form a service set. A receiver subsystem310includes a container that receives and holds the assembled, banded service set. These subsystems are described in further detail below. The receiver subsystem includes a basket-like container with a spring-loaded feature that facilitates a uniform filling of the container.

FIG. 6is a plan view and side view of a napkin magazine400. The napkin magazine400includes a spring-loaded plate402for supporting one or more napkins404in a napkin stack406, and a foam pad408on the plate402to lift one or more corners of the last one or more napkins404in the napkin stack406. The magazine400also includes a lift rod410. The lift rod410lifts a selected number of napkins404, i.e. one, from the napkin stack406for preparing the lifted napkin404for transfer to the integrator subsystem.

The integrator subsystem includes a napkin transfer assembly500that includes a clip and mechanism that picks a single napkin from its magazine and moves the napkin to a specific location in a particular orientation on the platen.FIG. 7shows plan and side views of the napkin transfer assembly500, in which an arm502is movable to the napkin magazine400. The arm502includes a clip504that grasps a lifted corner of a napkin404, and then moves the napkin404to the platen.

FIG. 8graphically illustrates a process600by which a napkin is grabbed, positioned, folded, and rolled around set utensil to secure the utensil set inside the napkin. More particularly, the process600includes the following steps: transfer napkin from napkin magazine to platen (at602); transfer fork from fork magazine to flatware clamp; transfer knife from knife magazine to flatware clamp; position loaded flatware clamp at napkin (604); move curler clamp to lift napkin corner into fold over handle ends of flatware (606); close curler clamp on folded napkin corner to capture flatware; release flatware clamp; move open roller jaws to surround flatware and napkin (608); close roller jaws to capture flatware in napkin; rotate closed roller jaws, as many full revolutions as are required to complete “roll-up” of napkin (610); move napkin band from napkin band magazine to roller jaw insertion point; rotate closed roller jaws to apply napkin band to assembled service set; open roller jaws; and dispense banded service set into receiver.

As described above, one or more utensils can be combined in a common magazine, be separated in a common magazine, or be separated in separate magazines and fed individually. Additionally, one magazine may be provided with multiple compartments for storing and providing all of the components of a service set. The above-described method need not necessarily be performed in the order or manner described, and can include variations on one or more of the steps.

FIG. 9is a perspective view of a portion700of a service set assembly device, including a fork magazine and a knife magazine. These magazines can include a coil or other structure that is rotated to convey the items to a dispensing point. In a rifle configuration, the magazines are stacked in proximity to each other. In a bailing machine configuration, a row of utensils is lifted into the bailing mechanism by a moving belt which has protruding tines to engage and move the utensils. The magazines702and704are preferably compact, of simple construction, and allow one of a kind of utensil to be removed at a time. As shown inFIG. 9, the magazines702,704can be positioned opposite a pivot arm706and a motor and drive mechanism710for rotating the pivot arm706. The pivot arm706can include at its end closest to the magazines a jaw clamp712that can grasp a utensil714from one of the magazines702,704. positioned below the level of the pivot arm706and the magazines702,704can be a platen802for receiving and holding a napkin and a curler clamp and roller jaws as well as motors for operating these devices to assemble the service set. The pivot arm706can be rotated 90° downward by the drive mechanism710after the jaw clamp712has grasped a utensil714. In this manner the utensil714is delivered to the napkin on the platen802. The jaw clamp can also be capable of rotation by 90° to orient the utensil714properly on the napkin. Also positioned below the pivot arm706and the magazines702,704can be a napkin dispenser to provide a napkin to the platen802. A napkin band facilitates extraction of a single band from either a stack or a roll format.

As illustrated inFIG. 10, the processor subsystem includes a platen802. The platen is a two-part plate on which the napkin is positioned to facilitate the folding, rolling and banding processes. The processor subsystem further includes a curler clamp assembly804. The curler clamp assembly804moves linearly to fold the napkin over the handle end of the utensil set, and closes to grasp the utensil set in the folded corner of the napkin. The curler clamp assembly804can be stationary while rolling and banding occurs.

A roller jaws assembly806surrounds the napkin and utensil set so as to facilitate the rolling of the napkin. The roller jaws assembly806is rotated to effect the rolling of the napkin. The roller jaws assembly806also introduces the napkin band to the napkin. The roller jaws assembly806is rotated again to effect the application of the band. When the service set has been banded, the roller jaws assembly is retracted. To dispense the banded service set into the receiver, one side of the platen may be tilted. This will allow the banded service set to be gravity-fed into a receiver.

FIG. 11shows a flatware clamp assembly900that includes a clamp mechanism902that picks a single fork and knife from their respective magazines and moves them to a specific location on the napkin. The clamp mechanism is powered and controlled by a motorized linear motion mechanism904, that opens a knife jaw while closing a fork jaw. Alternatively, the fork jaw can be sandwiched between two knife jaws, which are configured for alternative opening and closing. The position and orientation of the utensils to each other and to the napkin is provided by the path traveled by the flatware clamp assembly900.

FIG. 12shows an alternative embodiment of a device1000for assembling a service pack. The device1000includes a vacuum chuck1102powered by an air compressor and tank1101. The vacuum chuck1102is configured to employ a vacuum force to a stack of napkins, which force will be adapted so that one napkin at a time is lifted from the stack of napkins. The vacuum chuck1102moves along a linear guide1105to place and orient the lifted napkin on folding stage1103.

The device1000also includes a grabber1104that is positioned and movable to pick up one utensil from a utensil assembly1106that holds a number of utensils. The grabber1104may be adapted to pick up more than one utensil, such as one of each of a fork and knife, or a fork, knife and spoon. The grabber1104may pick up each utensil individually, or in a set. Each utensil picked up by grabber1104is positioned on the napkin on the folding stage1103. The grabber1104can include a hand that includes a pneumatic cylinder to engage and disengage a pin or other type of mechanism, for grabbing the utensil.

The utensil assembly1106can include one or more cartridges holding utensils. The cartridges can be stacked. The utensil assembly1106also includes a sterilization system1120such as UV lights for sterilizing at least a utensil to be picked up by the grabber1104prior to positioning on the folding stage1103. However, the sterilization system1120may be configured for sterilizing the utensils after they have been positioned on the folding stage1103. The utensil assembly1106further includes a number of cylinders1110to push a utensil toward a position at which the grabber1104can engage the utensil.

The folding stage1103includes one or more leverage arms1107to fold the napkin over the utensils placed thereon. For example, a first leverage arm can fold a first corner over a lower end of the utensils, and a second leverage arm can fold the napkin from one side over to the opposite side of the utensils. The folding stage1103can include a channel1109that is sized for receiving the one or more utensils, to hold the utensils in place and assist in the folding process.

The device1000further includes a roller and banding assembly1111, which includes a rotary grabber1112that is moved laterally toward the folded napkin and utensils to grab the napkin and utensil combination. The rotating grabber1112is moved by a rotating cylinder to rotate the grabbed napkin and utensil combination, and then retracted back to an original banding position above a napkin band strip1114.

In the banding position, an electric motor1116or other mechanism drives the napkin band strip1114over the napkin/utensil combination. A roller1118activates to apply pressure to the band as the rotary grabber1112now rotates in an opposite direction to complete the banding operation. A portion of the napkin band strip is cut at a predetermined length, and the band is sealed around the napkin/utensil combination to create a service pack. The service pack is then dropped into a tray or forwarded to a service pack area for use.

Although a few embodiments have been described in detail above, other modifications are possible. For example, the one or more utensils can include a spoon. The napkin may be paper-based or linen-based. The utensils may be plastic-based or metal-based. The device may be adapted for high-throughput and/or high volume for large-scale operations. The device may also be adapted to allow more complex or elaborate napkin folding or design arrangements. The device may also be adapted to apply a logo to the napkin and/or napkin band/tape piece. Other embodiments may be within the scope of this document.