Abstract:
In a packaging system for packing cases with product, a product metering system is provided. The product metering system includes a first product lane along which a first product travels and a second product lane along which a second product travels. The second product is different from the first product. A first movable barrier has a first position that obstructs progress of the first product along the first product lane and a second position that allows progress of the first product along the first product lane past the first movable barrier. The first product lane and second product lane merge into a first common lane downstream of the first movable barrier, wherein when the first movable barrier is in the first position only the second product is metered to the first common lane.

Description:
TECHNICAL FIELD 
       [0001]    The present application relates to packaging apparatus and more particularly to a packaging apparatus including a product metering system. 
       BACKGROUND 
       [0002]    Automated packaging machines are frequently used for packaging products for retail sale. Often times, the products are packaged by a producer or manufacturer of the product in cases. In some instances, the cases may be stacked onto a pallet forming a palletized unit so that many cases can be conveniently moved from one location to another during a single moving operation, for example, by a fork truck. 
         [0003]    The process by which the product is packaged by the producer may not be dictated by the retailer concerns. Considering beverages, for example, it may be simpler for the producer to package beverages having the same flavor together to form a single case or even to form a single pallet. By contrast, the retailer may desire a case and/or a pallet having an assortment of flavors, for example, corresponding more to consumer demand for the various flavors. It would be desirable to provide a process and apparatus for repackaging an assortment of already packaged product, for example, for delivery to a retail location. 
       SUMMARY 
       [0004]    In an aspect, in a packaging system for packing cases with product, a product metering system for metering first and second different products into a common lane in a controlled manner to result in a repeating sequence of X first product followed by Y second product in the common lane, where X and Y are whole numbers is provided. The product metering system includes a first product lane along which the first product travels and a second product lane along which the second product travels. A first movable barrier is associated with the first product lane and has a first position that obstructs progress of the first product and a second position that allows progress of the first product. A second movable barrier is associated with the first product lane and has a first position that allows progress of the first product and a second position that obstructs progress of the first product. The second movable barrier is upstream of the first moveable barrier and a spacing between the first movable barrier and the second movable barrier corresponds to the travel dimension of X first product. The first product lane and second product lane merge into the common lane downstream of the first movable barrier. 
         [0005]    In another aspect, in a packaging system for packing cases with product, a product metering system is provided. The product metering system includes a first product lane along which a first product travels and a second product lane along which a second product travels. The second product is different from the first product. A first movable barrier has a first position that obstructs progress of the first product along the first product lane and a second position that allows progress of the first product along the first product lane past the first movable barrier. The first product lane and second product lane merge into a first common lane downstream of the first movable barrier, wherein when the first movable barrier is in the first position only the second product is metered to the first common lane. 
         [0006]    In another aspect, a method for metering first and second different products traveling along first and second respective product lanes into a common lane in a controlled sequence is provided. The method includes moving the first product along the first product lane and moving the second product along the second product lane. Progress of the first product along the first product lane is obstructed to allow metering of only the second product to the common lane. The first product lane and second product lane merge into the common lane. 
         [0007]    The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1  is a diagrammatic, side view of an embodiment of a palletized unit including multiple stacked layers; 
           [0009]      FIG. 2  is a diagrammatic, top view of an embodiment of a layer of the palletized unit of  FIG. 1 ; 
           [0010]      FIG. 3  is a diagrammatic, top view of another embodiment of a layer of the palletized unit of  FIG. 1 ; 
           [0011]      FIG. 4  is a side view of an embodiment of a product case of the palletized unit of  FIG. 1 ; 
           [0012]      FIG. 5  is an unscaled, diagrammatic, plan view of an embodiment of a packaging system; 
           [0013]      FIG. 6  is a bottom view of an embodiment of a gripping mechanism for use in de-layering the palletized unit of  FIG. 1 ; 
           [0014]      FIG. 7  is a side view of the gripping mechanism of  FIG. 6 ; 
           [0015]      FIG. 8A  is a side view of an embodiment of an expander in a retracted configuration for use with the gripping mechanism of  FIG. 6 ; 
           [0016]      FIG. 8B  is a side view of the expander of  FIG. 8A  in an expanded configuration for use with the gripper mechanism of  FIG. 6 ; 
           [0017]      FIG. 9  is a side view of another embodiment of an expander for use with the gripper mechanism of  FIG. 6 ; 
           [0018]      FIG. 10  is a top view of another embodiment of an expander for use with the gripper mechanism of  FIG. 6  within a rectangular-shaped void; 
           [0019]      FIGS. 11 and 12  are diagrammatic, plan views of an embodiment of a film severing system; 
           [0020]      FIG. 13  is a diagrammatic, bottom view of a product case; 
           [0021]      FIGS. 14 and 15  are side views of a portion of the film severing system of  FIG. 11 ; 
           [0022]      FIG. 16  illustrates an embodiment of a knife assembly for use in the film severing system of  FIG. 11 ; 
           [0023]      FIG. 17  is a partial, end view of the knife assembly of  FIG. 16 ; 
           [0024]      FIG. 18  is a detail view of the knife assembly of  FIG. 16 ; 
           [0025]      FIGS. 19 and 20  are side views of an embodiment of a bottom film removal station; 
           [0026]      FIG. 21  is a front view of an embodiment of a film lifting device; 
           [0027]      FIGS. 22 and 23  are front and top views, respectively, of an embodiment of a product metering system; 
           [0028]      FIGS. 24 and 25  are diagrammatic, exemplary plan views illustrating operation of the product metering system of  FIG. 19 ; 
           [0029]      FIG. 26  is a diagrammatic, plan view of the metering system of  FIG. 18  along with an embodiment of a product merging system; and 
           [0030]      FIG. 27  is a diagrammatic, top view of a restocked product case having an assortment of products. 
       
    
    
     DETAILED DESCRIPTION 
       [0031]    A product metering system is described below as being used in a packaging system that can be used to disassemble pallets including an initial assortment of products (e.g., beverages), combine the products originating from different, disassembled pallets and then to re-assemble the pallets so that the re-assembled pallets include an assortment of products different from their initial assortment. It should be noted that the product metering system may be used with other product handling systems. 
         [0032]    Referring to  FIG. 1 , a palletized unit  10  of products  12  (e.g., beverages, such as a sports drink) includes multiple layers  14   a - 14   h  of product cases stacked upon pallet  15 . As used herein, the term “pallet” refers to a portable platform for handling, storing, and/or moving materials (as in warehouses, factories, or vehicles). The palletized unit  10  may be pre-assembled by, for example, a product manufacturer or distributor. In one embodiment, the products  12  of the palletized unit  10  are all beverages having the same flavor and/or color. In other embodiments, one layer may include products of one flavor and/or color and another layer may include products having a different flavor and/or color. Other flavor and/or color assortments are also possible. For purposes of this description, however, the pre-assembled palletized unit  10  includes beverages all having the same flavor and color. 
         [0033]    The layers  14   a - 14   h  are illustrated as being wrapped together in a plastic film  17  (e.g., by stretch wrapping). Referring also to  FIG. 2 , each layer  14   a - 14   h  includes multiple product cases  16   a - 16   i  in a particular arrangement where each product case includes multiple products  12  (e.g., 24 products per case). In some embodiments, each layer  14   a - 14   h  may be divided from an adjacent layer using a backing (not shown), such as a sheet of cardboard, plastic, wood, cloth, etc. The product cases  16   a - 16   i  are arranged in a particular pattern with a long axis of some of the product cases being arranged in one direction and a long axis of others of the product cases being arranged in a substantially transverse direction (e.g., see product case  16   a  and product case  16   b ). This arrangement of product cases  16   a - 16   i  creates a pair of voids  20  and  22  between adjacent cases. The voids  20  and  22  are respectively defined by portions  24   a ,  24   b , 24   d ,  24   e  and  26   e ,  26   f ,  26   h ,  26   i  of the product cases extending beyond an adjacent case. In some embodiments, the voids  20 ,  22  are about 5⅝ inches or more in width. Referring to FIG.  3 , in some embodiments, voids  28  and  30  of an adjacent layer  14  are located at different locations than (i.e., they are not aligned with) voids  20  and  22 . In  FIG. 3 , voids  28  and  30  are located about 90 degrees from voids  20  and  22  of  FIG. 2 . 
         [0034]    Referring also to  FIG. 4 , each product case  16  of each layer  14   a - 14   h  is individually wrapped in a plastic film  32  (e.g., of shrink wrap material). 
         [0035]      FIG. 5  is a diagrammatic plan view of a packaging process and system for disassembling palletized units  10  so that products  12  of different palletized units can be combined in forming another palletized unit of assorted products. Packaging system  40  includes multiple lines  42 ,  44  and  46  that receive and operate simultaneously on different palletized units  10 . In some instances, each line may be dedicated to receive palletized units of a certain product type. For example, line  42  may receive palletized units of beverages having a first flavor and/or color, line  44  may receive palletized units of beverages having a second flavor and/or color and line  46  may receive palletized units of beverages having a third flavor and/or color. In other embodiments, two or more of the lines may receive palletized units of beverages having the same flavor and/or color, while one or more of the other lines may receive palletized units of beverages having a different flavor and/or color. 
         [0036]    Each line  42 ,  44  and  46  includes a pallet infeed  48  where palletized units  10  of product  12  are introduced to the packaging system. An automated stretch film removal device  50  removes the stretch film  17  from the palletized unit  10 . In some embodiments, the removed stretch film  17  is delivered along a recycle path (not shown) to a shredder and bailer system. 
         [0037]    Once the stretch film  17  is removed, the layers  14  may be separated from each other at a layer removal station  52  including a pallet de-layering system  54 . The pallet de-layering system  54  removes each layer  14  of product cases  16  one-by-one, e.g., with the palletized unit  10  at rest and places the product cases on a singulating conveyor  56 . Once all the layers  14  are removed, the pallet is located on a pallet recycle path  57 , which carries the pallets (e.g., by conveyor) to the input side of a palletizer  112 . 
         [0038]    As indicated above, each layer  14  includes multiple product cases  16 . The singulating conveyor  56  is used to orient the product cases  16  in a desired alignment. In some instances, the product cases  16  are oriented by the singulating conveyor  56  such that their long axes are aligned with the direction of travel in single file. Other configurations are possible, however. 
         [0039]    A film removal station  58  is used to remove the plastic film  32  from the individual product cases  16  in an in-line process. The film removal station  58  cuts the plastic film  32 , removes the plastic film from the product cases  16  and sends the plastic film to the shredder and bailer system. In some embodiments, a detection system  59  (e.g., a vision system) is included. The detection system  59  may be used to detect film removal errors and/or product displacement. If a film removal error and/or product displacement is detected, the affected product case  16  may be diverted to a reject path  61 . 
         [0040]    Once the plastic film  32  is removed, the product cases  16  are directed to a product removal station  60 . Robots  62  at the product removal station  60  are used to lift products  12  from their trays  64  ( FIG. 3 ) and place the product on the product conveyor  66 . Empty trays  64  are placed on a recycle path  68  that leads to a tray accumulation station  70 , where empty trays wait to be delivered to a repacking station  86 ,  88 . In some embodiments, empty trays  64  may bypass the accumulation station  70  and be sent directly to the repacking station  86  and  88  as indicated by bypass path  89  of  FIG. 5 . 
         [0041]    The individual products  12  are delivered by the product conveyors  66  to a metering system  74 . Prior to reaching the metering system  74 , however, the three product lines  42 ,  44  and  46  are merged into two product lines  82  and  84  at merging station  85 . As can be appreciated, by merging the three product lines  42 ,  44 ,  46  into two product lines  82 ,  84 , an assortment of products associated with each product line  82  and  84  can be achieved. In the illustrated embodiment, each product line  42 ,  44  and  46  feeds product into each product line  82  and  84 . The two product lines  82 ,  84  are associated with two repacking stations  86  and  88  where trays  64  are repacked with an assortment of products  12  that is different than their initial assortment. 
         [0042]    The metering system  74  is used to meter out products based on a desired case product assortment. In some embodiments, the desired case product assortment is determined by the retailer based, for example, on consumer demand for each product type. As will be described in greater detail below, the metering system  74  is used to control the amount of each product flavor and/or color repacked into the trays  64 . 
         [0043]    The metered out product  12  is fed to outfeed  90 . The amount of product  12  fed to the outfeed  90  corresponds to the number of products carried by the trays  64  and the number of trays to be repacked at a time and the assortment of the products is predetermined as indicated above. 
         [0044]    Robots  92  and  94  are used to transfer the assortment of products  12  from the outfeed  90  to the trays  64 , which are delivered from the tray accumulation station  70  or product removal station  60 . The repacked trays  64  have a product assortment that is different from their original product assortment. In some embodiments, the robot  92 ,  94  repackages more than one tray  64  at a time, such as four trays at a time at the repacking stations  86  and  88 . After the trays  64  are repacked with the desired assortment of products  12  forming repacked product cases (e.g., at a rate of about 35 repacked product cases per minute), the repacked product cases are delivered to a shrink wrap system  93 ,  95  where the repacked product cases are rewrapped with shrink wrap film (e.g., e.g., at a rate of between about 35 and about 70 cases per minute) and delivered through a shrink film shrinking station  98  (e.g., that heats the shrink film for a shrinking operation). In some embodiments, a detection system  100  is provided that detects whether the trays  64  are correctly repackaged, for example, looking at number of products (or filled product spaces), product color, etc. If a repacked product case is not correctly repacked, that case may be diverted onto reject path  102 , before it reaches the shrink wrap station. 
         [0045]    The repacked product cases are then delivered from the shrinking station  98  to a merging station  104  that merges conveyor lanes  106  and  108  into a single lane  110 . The repacked product cases are then palletized at the palletizer  112  by arranging and stacking the repacked product cases onto the pallets  15  transported from the de-layering system  54 . In some embodiments, the palletizer  112  stacks the repacked product cases onto the pallets  15  in substantially the same arrangement as described above with reference to  FIGS. 1-3  to form a palletized unit of assorted products. Alternatively, the palletizer  112  may stack the repacked product cases in some other arrangement, for example, dictated by the retailer. The palletized units are then stretch wrapped at a stretch wrap station  114  and transported from the packaging system  40 . 
         [0046]    The Pallet De-Layering System 
         [0047]    As indicated above, the pallet de-layering system  54  removes each layer  14  of product cases  16  one-by-one and places the product cases on the singulating conveyor  56 . The pallet de-layering system  54  includes a robot arm  116  (e.g., capable of both lateral, vertical and rotational movement) with a gripper mechanism  118  that can be moved by the robot arm  116  over to the palletized unit  10  to grip each layer  14  in consecutive gripping operations. A suitable robot arm is a M-410 Intelligent Palletizing Robot, commercially available from Fanuc, Ltd. 
         [0048]    Referring to  FIG. 6 , the gripper mechanism  118  is somewhat square in shape (e.g., corresponding to the shape of each layer  14 ) and includes a frame  120  and opposing grippers  122 ,  124  and  126 ,  128 . The opposing grippers  122 ,  124  and  126 ,  128  have a gripping surface that extends substantially parallel to respective edges of the layer  14  and are moveable (e.g., pneumatically, motor driven, etc.) inwardly toward each other in order to apply a gripping force (e.g., of between about 1508 lbs and about 2010 lbs) to product cases  16  of a layer  14  of the palletized unit  10 . In an alternative embodiment, only some of the grippers may be moveable (e.g., such as grippers  122  and  128  or grippers  128  and  124  or grippers  124  and  126  or grippers  126  and  122 ) and the other grippers stationary. 
         [0049]    Referring briefly back to  FIG. 2 , layers  14  of product cases  16  include a pair of voids (e.g., voids  20 ,  22 ) located between adjacent product cases. These voids  20 ,  22  tend to allow the product cases  16  to move inwardly when a gripping force is applied to the periphery of the layer  14 , which may increase the probability of an ineffective gripping operation. 
         [0050]    To obviate the possible effect of the voids on the gripping operation, the gripper mechanism  118  includes expanders  130   a - 130   d  shown in  FIGS. 6 and 7 . As represented by arrows  131  and  133 , the expanders  130  are vertically moveable up-and-down relative to the frame  120  so that they may be placed into voids, when applicable. The expanders  130   a - 130   d  also have a collapsed configuration ( FIG. 8A ) and an expanded configuration (shown by  FIGS. 7 and 8A ). The collapsed configuration is used when extending the expanders  130  and inserting the expanders into the voids and the expanded configuration is used to occupy a greater volume within the voids relative to the collapsed configuration to inhibit movement of the adjacent product cases  16  into the voids. 
         [0051]    In some embodiments, a controller  132  is used to control operation of the gripper mechanism  118  including grippers  122 ,  124 ,  126  and  128  and expanders  130 . The pairs of grippers  122 ,  124  and  126 ,  128  may be mechanically linked so that they move together (e.g., in opposing pairs) or they may each move independently. The expanders  130 , in the illustrated embodiment, are driven using pneumatics  134 . The controller  132  controls actuation of the pneumatics  134  using a void detection system  136 . The void detection system  136  includes sensors  138  that can be used to detect the presence of a void and to send a corresponding indication to the controller  132 . In one embodiment, magnetic sensors  138  are associated with the pneumatic cylinders to detect movement of the cylinder rods out of their extended positions. However, other void detection sensing systems could be used. The controller  132 , upon receipt of the indication, raises and/or lowers the corresponding expanders  130  relative to the frame  120  as needed to fill the identified voids. Once the extended expanders  130  are in the voids, the controller  132  then expands the expanders to their expanded configurations. 
         [0052]    For example, layer  14  of  FIG. 2  has voids  20  and  22  at the illustrated positions. The gripper mechanism  118  includes layer edge detecting sensors  139 , each sensor used by the controller  132  to detect an edge  141   a  and  141   b  of the layer  14 , which can be used by the controller to center the gripper mechanism above the layer. In some embodiments, the edge detecting sensors  139  may be used for each layer, only some layers or even only the top layer. The expanders  130   a - 130   d  are initially in their lowered positions and the gripper mechanism  118  is lowered onto the layer  14 . As the gripper mechanism  118  is lowered, expanders  130   a  and  130   d  contact product cases  16 , which forces the expanders  130   a  and  130   d  to move upward. The magnetic sensors  138  are used to detect this movement, which indicates that expanders  30   a  and  30   d  are not aligned with voids  20  and  22 . The lack of any signal change from the sensors  138  associated with the expanders  130   b  and  130   c  indicates that these expanders are aligned with respective voids  10 ,  22 . The controller  132  then controls the pneumatics to raise the expanders  130   a  and  130   d . Expanders  130   b  and  130   c  are lowered into the voids  20  and  22  as the gripper mechanism  118  is lowered into its gripping position. 
         [0053]    For layer  14  of  FIG. 3  having voids  28  and  30 , the controller  132 , upon receipt of the indication from the detectors  138 , retracts expanders  130   b  and  130   c  as expanders  130   a  and  130   d  are lowered into the voids  28  and  30 . In alternative embodiments, the expanders  130  may be lowered relative to the frame  120  before, while or after the gripper mechanism  118  is lowered onto the respective layer  14  for the gripping operation. 
         [0054]    Once the appropriate expanders  130  are in the voids  20 ,  22 ,  28 ,  30 , they are expanded using an actuator  140  (e.g., an air cylinder), which is connected to linkages  142  shown most clearly by  FIGS. 8A and 8B . The linkages  142  cause pivot arms  144  to pivot outwardly as the actuator  140  extends to its position illustrated by  FIG. 8B  by riding along angled surfaces  143  of the linkages. In some embodiments, the expander  130  locks in its expanded position during layer gripping. Locking the expander  130  in its expanded position inhibits the collapse of the expander during a gripping operation, even if pneumatic pressure is lost, which can decrease the probability of a failed gripping operation. Specifically, when the grippers  122 ,  124 ,  126  and  128  move to engage the sides of the pallet layer  14 , the product cases  16  responsively move and apply pressure against the expander pivot arms  144 . This in turn causes the pivot linkages  142  to press against the lowered portion of the actuator  140 , thereby holding the actuator against upward movement until the side grippers  122 ,  124 ,  126  and  128  are moved to release the layer  14 . In some embodiments, springs (not shown) are used to spring bias the pivot arms  144  toward their collapsed configurations. 
         [0055]    In some implementations, the locations, sizes and/or shapes of the voids may change, for example, depending on product and/or product case characteristics, such as size/shape of the product container, number of products per product case, etc. Thus, it may be desirable to provide the gripper mechanism  118  with interchangeable expanders and/or provide the gripper mechanism with the capability to change the positions of the expanders relative to the frame  120 . Referring to  FIG. 8B , for example, the expander  130  includes a quick disconnect pin  145  that can be used to disconnect the expander  130  from the lower end of the pneumatic cylinder rod, which remains with the gripper mechanism  118 . Removal of the pin and disconnecting of the air lines that operate the cylinder  140  allows the expander  130  to be readily removed. Expander  147  of  FIG. 9  may then be connected to the gripper mechanism that includes an offset design where the expander  147  has an actuation axis E that is offset from an actuation axis A. The offset actuation axis configuration is used to account for differences in void location as between pallet layers for different products. Various other expander configurations are possible. For example, referring to  FIG. 10 , a rectangular expander  149  is shown within a rectangular void  151 . 
         [0056]    In some implementations, the gripper mechanism  118  may also be used to move the pallet  15  onto the pallet recycle path  57  ( FIG. 5 ) after all the layers  14  are removed there from. The controller  132 , in this instance, may not lower any of the expanders  130  as the detectors  138  may not detect any voids. Similar to moving the layers  14 , the gripper mechanism  118  may grip the pallet  15  using gripper pairs  122 ,  124  and  126 ,  128  to apply a gripping force to the pallet. 
         [0057]    The Film Removal Station 
         [0058]    The film removal station  58  ( FIG. 5 ) is used to remove the plastic film  32  ( FIG. 4 ) from the individual product cases  16  in an in-line process. Referring to  FIG. 11 , a film cutting process for use in removing the plastic film  32  is illustrated diagrammatically. The film removal station  58  includes a first knife pair  146  and a second knife pair  148 . The first knife pair  146  is illustrated as being initially outside of and oriented substantially perpendicular to the conveyor path  150 , while the second knife pair  148  is located at opposite edges of and oriented substantially parallel to conveyor path  150 , downstream of the first knife pair. As the product case  16  is held stationary at location A, the first knife pair  146  is moved across the conveyor path and cuts the plastic film  32  along opposite bottom edges  156 ,  158  of the product case  16  (see  FIG. 13 ). Referring to  FIG. 12 , with the product case  16  moving to location B, the second knife pair  148  utilizes the movement of the product case to cut the plastic film  32  along opposite bottom edges  152 ,  154  (see  FIG. 13 ). In some embodiments, element  159  is a conveyor segment that allows the first knife pair  146  to pass thereby. As an alternative, element  159  may be one or more spaced rollers that are arranged and configured to allow the first knife pair  146  to pass thereby. 
         [0059]    Referring now to  FIG. 13 , the knife pairs  146 ,  148  cut the bottom of the plastic film entirely across the length and width of the bottom. The first knife pair  146  cuts at a bottom leading edge (e.g., at most about 1 inch or less from the leading edge, such as about ½ inch) and at bottom trailing edge (e.g., at most about 1 inch or less from the trailing edge, such as about ½ inch) of the product case  16 , while the second knife pair  148  cut at bottom machine direction edges (e.g., at most about 1 inch or less from the trailing edge, such as about ½ inch) of the product case. These full cross-cuts allow for easier removal of the plastic film  32 , as will be described below. 
         [0060]      FIGS. 14 and 15  show a heated knife assembly  161  of the second knife pair  148  in greater detail. Referring first to  FIG. 14 , the heated knife assembly  161  includes a mount  160  and parallel arms  162  and  163  pivotally connected to the mount. A heated knife  164  is mounted to the arms  162 . The heated knife  164  is pivotally mounted to the arms  162  and  163  so that the knife can pivot in the direction of arrows  166  and  168  to accommodate tray bottom irregularities and to assure the knife cut is made all the way to the edge of the product case  16 . 
         [0061]    The heated knife  164  is biased upwardly by biasing mechanism  170  that is connected to the arms  162 . Biasing mechanism  170  includes an air cylinder  172  that acts as an adjustable spring supplying a vertical biasing force that can be used to hold the heated knife  164  against the bottom of the product case  16  (see  FIG. 15 ). The first knife pair  146  can include similar pivoting and biasing structure. 
         [0062]    Referring to  FIGS. 16-18 , the heated knife  164  has a double truncated pyramid shape with two peaks  174  and  176  separated by a valley  178 . As can be seen best by  FIG. 18 , the cutting edge (see element  176 ) of the heated knife  164  is thin and sharpened to a point to provide for film burn off, which can improve cutting during use. Peaks  174  and  176  include the cutting surfaces. A cartridge heater  190  is used to heat the knife  164 . An insulating base  180  supports the heated knife  164 . A pair of wave springs  182  and  186  located on opposite sides of pivot joint  188  provide opposing biasing forces that are used to bias the heated knife in the illustrated horizontal position. The cutting edge  175  of the knife  164  is heated to a temperature such that during the cutting operation, the plastic film  32  melts away from the knife, which along with the sharpened edge  175  can improve film burn off and inhibit accumulation of plastic on the cutting edge. In some embodiments, the knife  164  is heated to a temperature between about 800 and 900 degrees F. 
         [0063]    The two peak construction of the knife cutting edge  175 , in combination with the pivoting action, enables a single pass of a knife against the bottom of a case to perform two cuts along the same line, but separated slightly in time. These two cuts separated in time can be advantageous for cutting thicker or multilayer plastic film. 
         [0064]    Referring to  FIG. 19 , a bottom film removal station  190  is used to remove a portion  192  ( FIG. 14 ) of the plastic film  32  from the product case  16  after it has been cut. Bottom film removal station  190  includes a bottom vacuum conveyor  193  that moves in the direction of arrow  194  and a counter rotating nip roller  196 . A film vacuum removal nozzle  198  is located below the counter rotating nip roller  196 . Referring to  FIG. 20 , the film portion  192  is pulled between the counter rotating nip roller and the bottom vacuum conveyor  192  as the product case  16  moves thereover. The removed film portion  192  is then drawn into the film vacuum removal nozzle  198  using negative pressure. A second film vacuum removal nozzle  200  is then used to draw a remaining portion  202  of the plastic film  32  from the product case  16 , thereby removing the plastic film. As noted above, the full cross-cuts  152 ,  154 ,  156 ,  158  facilitate removal of the portions  192  and  202  of the plastic film  32 . 
         [0065]    Referring to  FIG. 21 , in some embodiments, a film lifting device  203  is used to lift the remaining portion  202  of the plastic film  32  from the product case  16  prior to reaching the vacuum removal nozzle  200 . In the illustrated embodiment, counter-rotating mechanisms  204  are placed on opposite sides of the case conveying path and include includes rotating fingers  205  (e.g., having rubber ends  207 ) that come into contact with the remaining portion  202  of the plastic film  32  and apply a lifting force to the plastic film at the machine direction sides of the product case. The lifting force loosens the remaining portion  202  of the plastic film  32 , which is then removed using the vacuum nozzle  200 . 
         [0066]    Product Metering System 
         [0067]    Once the plastic film  32  is removed, the product cases  16  are directed to the product removal station  60  where the robots  62  lift products  12  from their trays  64  and place the product on the product conveyor  66  ( FIG. 5 ). The individual products  12  are delivered to the metering system  74 .  FIGS. 22 and 23  illustrate the metering system  74  associated with one of the product lines  82  or  84 . The metering system  74  is used to control the amount of a certain product flavor and/or color delivered to the repacking stations  86  or  88 . 
         [0068]    Pins  208  are used as removable barriers to control feeding of products  12  from certain product columns, which columns are separated by rails which are not shown. The pins  208  are connected to rails  210  and  212 , which are operatively connected to a reversible motor  214  (e.g., using a rack and pinion drive) so that the motor can slide the rails  210  and  212  back and forth to move the pins into and out of the associated product path. The end product columns  216 ,  218 ,  236 ,  238  and middle product column  244  do not have any associated pins  208  so that products travel through these columns unimpeded. 
         [0069]      FIG. 24  shows a diagrammatic, simplified metering system  74  to illustrate its operation in metering products. The illustrated metering system  74  includes a first product path  220  and a second product path  222 . Products Y of a first flavor and/or color (e.g., yellow) travel along path  220  and products B of a second flavor and/or color (e.g., blue) travel along path  222 . In this example, it is desired to feed three product Y for every one product B. Pins  208 B are connected to rail B (represented by dotted lines) and pins  208 F are connected to rail F (represented by dotted lines). When motor  214  rotates in a counter-clockwise direction, pins  208 F are positioned out of the associated product path to allow products to pass thereby and pins  208 B are positioned in the associated product path to prevent products from passing thereby. In these illustrated pin positions, the first product path  220  is in a feed cycle where three product Y is fed from the metering system  74  while the second product path  222  is in a reload cycle where no product B is fed from the metering system. During the reload cycle, the products B are advanced along second product path  222  up to the pin  208 B. 
         [0070]    As shown by  FIG. 25 , when motor  214  rotates in a clockwise direction, pins  208 B are positioned out of the associated product path to allow products to pass thereby and pins  208 F are positioned in the associated product path to prevent products from passing thereby. In these illustrated pin positions, the second product path  222  is in a feed cycle where one product B is fed from the metering system while the first product path  220  is in a reload cycle where no product Y is fed from the metering system. During the reload cycle, the products Y are advanced along the first product path  220  up to the pin  208 F. As can be appreciated, the upstream pins are located a distance from the downstream pins to allow the desired amount of product (e.g., 1 blue and 3 yellow) to fit therebetween. For example, linkages  225  shown most clearly by  FIG. 23  allow for placement of the pins  208  at spaced-apart distances. In some embodiments, the pins  208  are moveable along the length of the linkages to change the distances between the upstream pins and the downstream pins and thus the amount of product that can fit therebetween. 
         [0071]    Referring now to  FIG. 26 , the above-described metering process is repeated and products  12  are fed from the metering system  74  to a merging station  232  where products from some adjacent rows leaving the metering system are merged together to create rows of products having different flavors and/or colors. In the illustrated embodiment, the metering system  74  includes nine product columns  216 ,  218 ,  240 ,  242 ,  244 ,  246 ,  248 ,  236  and  238 . Each column  216 ,  218 ,  240 ,  242 ,  244 ,  246 ,  248 ,  236  and  238  has products  12  of a particular color and/or flavor associated therewith represented by R (e.g., red), Y (e.g., yellow) and B (e.g., blue). End columns  216 ,  218 ,  236 ,  238  and middle column  244  feed directly into respective paths  250 ,  252 ,  254 ,  256  and  258  of the merging station  232  without any merging of products  12 . By contrast, columns  240  and  242  merge into path  260  to provide a column of both R and Y products as the products are metered using pins  208 F and  208 B from the metering system  74  and columns  246  and  248  merge into path  262  to provide a column of both Y and B products as the products are metered using pins  208 F and  208 B from the metering system. The metering system  74  meters the products so that, once merged in paths  260  and  262 , repeating patterns of products are created. In one embodiment, for example, it may be desirable to create repeating patterns of three Y products and one red product along path  260  and three Y products and one B product along path  262 . 
         [0072]    Each path  250 ,  252 ,  254 ,  256 ,  258 ,  260  and  262  feeds product into the repacking stations  86  and  88  ( FIG. 5 ) where the products are accumulated. Once products are accumulated, they are transferred back into trays  64 .  FIG. 27  illustrates repacked trays of an assortment of products  12  including a predetermined number of B, Y and R products  12 . In this example, each row  264 ,  266 ,  268 ,  270  of repacked products includes individual product delivered along each path  250 ,  252 ,  254 ,  256 ,  258 ,  260  and  262 . Once repacked, the reconstituted product cases are shrink wrapped, stacked into layers onto a pallet and then stretch wrapped as described above. 
         [0073]    It is to be clearly understood that the above description is intended by way of illustration and example only and is not intended to be taken by way of limitation, and that changes and modifications are possible. Accordingly, other embodiments are within the scope of the following claims.