Abstract:
A modular packaging system includes a base system configured to manipulate a product and configured to receive at least one of a group of packaging modules, wherein the base system is used with a variety of packaging modules depending on a desired packaged output. The system also includes a first packaging module selectively coupled to the base system, the packaging module having a first member coupled to the packaging module, the member configured to manipulate an object. The system may also include a second packaging module selectively coupled to the base system, the second packaging module having a lifting device coupled to the second packaging module, the lifting device configured to manipulate an object.

Description:
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS 
   This application claims the benefit of priority under 35 U.S.C. § 119(e) to U.S. Patent Application No. 60/704,002, filed Jul. 29, 2005, titled “Modular Packing System” and U.S. Patent Application No. 60/705,971, filed Aug. 5, 2005, titled “Case-Packaging System” which are both incorporated by reference in their entirety. 

   FIELD 
   The present invention relates to a modular packaging system. The present invention more specifically relates to a modular packaging system for packaging, bundling, bagging and/or wrapping an object or group of objects such as tissue or paper products. 
   BACKGROUND 
   Packaging systems for packaging, bundling, bagging or wrapping a product are generally known; however, such packaging systems do not realize certain advantageous features (and/or combinations of features). 
   For example, production lines for products such as tissue or paper products (e.g. toilet tissue, napkins, paper towels, etc.) are often used to produce many different labeled products. Traditionally, the product is packaged into cardboard cases to provide “case-packed” products for ease of handling and shipping. A more recent method packages a group of products in a film “overwrap” often referred to as a “bundle”. The bundles can be handled similarly to the case-packed products. The method of packaging products into a bundle is generally less expensive than the method of producing case-packed products due to a lower cost of the film packaging material. Bagging and wrapping are other available packaging methods. Wholesalers and distributors of the products may prefer a variety of packaging forms for the products (e.g. case-packed, bundled, bagged, wrapped, etc.), thus creating a need to be able to handle a variety of products using different packaging methods on a single production line. 
   A typical production line for the above mentioned methods of packaging usually includes an infeed conveyor (e.g. used to carry product to the machine) and a lane diverter (e.g. used to either combine multiple infeed lanes of product to less lanes or to expand from fewer to more lanes depending on the configuration of the production line and the product grouping being produced). Typical packaging methods on such a production line may include 1.) case-packing where diverted lanes of product are collated into the proper configuration for the case, the case is erected from its collapsed state, and the collated products are loaded into the case; 2.) bundling, where diverted lanes of product are oriented and grouped into bundle sized configurations then wrapped and sealed into the overwrap material; 3.) bagging, where diverted lanes of product are oriented and loaded into a bag; and 4.) wrapping, where diverted lanes of product are oriented and wrapped with either a paper or poly overwrap material. 
   Each packaging method typically includes independent infeed conveying and lane diverting equipment along with a manual conveyor switching device to switch between each packaging method. 
   Conventional production facilities will have at least one of these packaging methods; more frequently production facilities will have two, three or all four packaging methods. Production facilities with only one packaging method often lack floor space and/or capital for the required equipment of additional packaging methods, thus significantly limiting their marketing abilities. Thus, a need exists for a modular packaging system or the like of a type disclosed in the present application that includes any one or more of these or other advantageous features.
         1. A modular packaging system that is simple to use, construct, and manufacture.   2. A modular packaging system that provides for a variety of packaging methods.   3. A modular packaging system that provides for a variety of differently sized packaged products.   4. A modular packaging system that is capable of making efficient use of space through interchangeable packaging modules.   5. A modular packaging system that is capable of manipulating products in a small area.   6. A modular packaging system that is capable of upending products in a small area without tipping them over.   7. A modular packaging system that can be easily repositioned.   8. A modular packaging system that can be easily transformed from one packaging method to a second packaging method.   9. A modular packaging system that is easily coordinated with conventional production line equipment.   10. A modular packaging system that provides convenient and simple access for maintenance.   11. A modular packaging system that may be easily and conveniently adjusted for improved overall efficiency.       

   SUMMARY 
   The present invention relates to a modular packaging system that includes a base system configured to manipulate a product. The system also includes a packaging module selectively chosen to be used with the base system, the packaging module having a member coupled to the packaging module, the member configured to manipulate an object. 
   The present invention also relates to a modular packaging system that includes a base system configured to manipulate a product. The system also includes a packaging module selectively chosen to be used with the base system, the packaging module having a lifting device coupled to the packaging module, the lifting device configured to manipulate an object. 
   The present invention also relates to a base system configured to manipulate a product and configured to receive at least one of a group of packaging modules, wherein the base system is used with a variety of packaging modules depending on a desired packaged output. The base system includes multiple connectors configured to receive a packaging module. The base system also includes a diverter configured to expand or decrease incoming lanes of product. The base system further includes a flight bar conveyor system configured to move a product from the diverter to the packaging module. 
   The present invention also relates to a method for providing a packaging system including the step of providing a base system configured to manipulate products to be packaged. The method also includes the step of providing a first packaging module configured to package products into a case. The method further includes the step of providing a second packaging module configured to package products into a bundle. The method further includes the step of selecting either a first or second packaging module depending on the desired type of packaging output. 
   The present invention also relates to a modular packaging system for packaging an article including a base system configured to manipulate a product and configured to receive at least one of a group of packaging modules, the base system comprising multiple connectors configured to receive a packaging module; a diverter configured to expand or decrease incoming lanes of product; and a flight bar conveyor system configured to move a product from the diverter to the packaging module, wherein the base system is used with a variety of packaging modules depending on a desired packaged output. The system also includes a first packaging module selectively coupled to the base system, the packaging module having a first member coupled to the packaging module, the member configured to manipulate a case. The system further includes a second packaging module selectively coupled to the base system, the second packaging module having multiple fingers radially coupled to the second packaging module, the multiple fingers configured to manipulate an object from a horizontal orientation to a vertical orientation. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a front perspective view of a modular packaging system according to an exemplary embodiment. 
       FIG. 2  is a front perspective view of a base system according to an exemplary embodiment. 
       FIG. 3  is a front perspective view of a diverter system shown without a frame and guard system according to an exemplary embodiment. 
       FIG. 4A  is a top view of a diverter system according to an exemplary embodiment. 
       FIG. 4B  is a top view of a diverter system according to an exemplary embodiment. 
       FIG. 5  is a front perspective view of a base system according to an alternative embodiment and a flight bar conveyor system according to an exemplary embodiment. 
       FIG. 6A  is an isometric view of a flight bar conveyor system according to an exemplary embodiment. 
       FIG. 6B  is an isometric view of a flight bar conveyor drive system according to an exemplary embodiment. 
       FIG. 6C  is an isometric view of a flight bar conveyor drive system according to an exemplary embodiment. 
       FIG. 7  is a side view of a leveling pad according to an exemplary embodiment. 
       FIG. 8  is an isometric view of a hinge and pin connector according to an exemplary embodiment. 
       FIG. 9  is an isometric view of an electrical connection according to an exemplary embodiment. 
       FIG. 10A  is an isometric view of system according to an exemplary embodiment. 
       FIG. 10B  is a isometric view of an electrical system and a controller system according to an exemplary embodiment. 
       FIG. 11  is a front perspective view of an interchangeable case-packer module according to an exemplary embodiment. 
       FIG. 12A  is an isometric view of a caster according to an exemplary embodiment. 
       FIG. 12B  is an isometric view of a caster according to an exemplary embodiment. 
       FIG. 12C  is an isometric view of a self driven wheel according to an exemplary embodiment. 
       FIG. 13A  is a rear perspective view of an adjustable horn system and a chair system according to an exemplary embodiment. 
       FIG. 13B  is a rear perspective view of a chair system according to an exemplary embodiment. 
       FIG. 14  is a front perspective view of an interchangeable bundler module according to an exemplary embodiment. 
       FIG. 15  is a front perspective view of an upender system according to an exemplary embodiment. 
       FIG. 16A  is an isometric view of an upender system according to an exemplary embodiment. 
       FIG. 16B  is a side view of an upender system according to an exemplary embodiment. 
       FIG. 16C  is an isometric view of a finger according to an exemplary embodiment. 
       FIG. 17A  is a front perspective view of a former and unwind system according to an exemplary embodiment. 
       FIG. 17B  is a front perspective view of a lower former system according to an exemplary embodiment. 
       FIG. 17C  is a front perspective view of an upper former system according to an exemplary embodiment. 
       FIG. 18A  is a rear perspective view of a knife and exit conveyor system according to an exemplary embodiment. 
       FIG. 18B  is a rear view of a knife and exit conveyor system according to an exemplary embodiment. 
   

   DETAILED DESCRIPTION 
   Referring to  FIG. 1 , a modular packaging system  10  is shown to include a base system  100  and interchangeable packaging modules  50  according to an exemplary embodiment. The base system  100  is configured to receive an interchangeable packaging module  50 . The base system  100  may contain the common components to each interchangeable packaging module (i.e. an infeed conveyor, a lane diverter, motor drives, logic controller), thereby eliminating (or minimizing) redundant components. A modular packaging system  10  has a reduced “footprint” intended to more efficiently use floor space in a facility. Additionally, the interchangeable packaging modules maybe remotely storable (e.g. stored offline, stored onsite, stored offsite) when not in use to save additional floor space. Interchangeable packaging modules are shown here to include a case-packing module  200  and a bundling module  300 . Other interchangeable packaging modules may include a bagging module, a poly-wrapping module and a paper wrapping module. 
   As shown in  FIG. 1 , both the base system  100  and interchangeable packaging modules have safety guards and panels  12 . Guards and panels  12  may be constructed from one or more of a variety of different materials, including, for example, sheet metal, polycarbonate or acrylic, and may be configured in any shape and size. In the remaining figures, the guards and panels  12  have been removed for clarity. 
   Base System 
   Referring to  FIGS. 1 and 2 , the base system  100  is shown to include a base frame system  110 , a diverter system  120 , a flight bar conveyor system  400 , a loader/transport system  160 , an electrical system  170 , a controller system  180  and a pneumatic system  190  according to an exemplary embodiment. 
   Again referring to  FIG. 2 , the base frame system  110  is shown to include multiple structural members  112  to support the systems and components of the base system  100 . The structure of the base frame system  110  is configured to be used with an interchangeable packaging module  50 . The base system  100  maybe physically connected to an interchangeable packaging module  50  (e.g. by mechanical, electrical, pneumatic connectors) or may be free standing (e.g. base system  100  is placed next to an interchangeable packaging module  50 ). Attached to the base frame system  110  is a module connect bracket  114  (as shown in  FIG. 8 ) intended to couple the interchangeable packaging modules  50  to the base system  100 . Attached to the base frame system  110  are multiple alignment devices (shown as leveling devices  116 , as shown in  FIG. 7 , and guide pads  118 ) that are intended to aid in leveling and/or aligning the base system  100  and the packaging module  50 . In an alternative embodiment, the base frame system  110  may contain, for example, a rail or a spline that is configured to receive a mating rail or spline on an interchangeable packaging module  50 . The frame structural members  112  are configured to provide a housing to contain wires, hoses, lines, etc. This may be done, for example, by having a hollow core inside the structural member and having access ports at various locations (as shown, for example, in  FIG. 2 ). 
   Referring to  FIG. 3 , the diverter system  120  is shown to include a diverter frame and guard system  122  and an actuating lane diverter system  124 . The diverter frame and guard system  122  is shown to include structural and support members  126  and guards  12  (shown in  FIGS. 1-3 ). The actuating lane diverter system  124  is shown to include a choke conveyor system  128  and a speed up conveyor system  130 . 
   Referring to  FIGS. 3 ,  4 A and  4 B, the choke conveyor system  128  includes a drive motor  132  (shown, for example, as a servo motor), a first drive device  134  (shown, for example, as a conveyor belt) and a second drive device  136  (also shown, for example, as a conveyor belt). The speedup conveyor system  130  is shown to include a first drive device  138  (shown, for example, as a conveyor belt) and a second drive device  140  (also shown, for example, as a conveyor belt). According to the illustrated embodiment, a single adjustment device  142  is provided to adjust the width between the first drive device  134 ,  138  and the second drive device  136 ,  140  of both the choke conveyor system  128  and the speedup conveyor system  130  to allow for various sizes of product widths (e.g., 3.5 inches-13.5 inches) or other suitable size. 
   Products may be moved to the diverter system  120  by any conventional product conveyor infeed system known in the art. For example, products may arrive in a single lane, in two lanes, or more than two lanes. The products are then divided into various lane configurations by the actuating lane diverter system  124 . According to one exemplary embodiment, up to six lanes of product can be created. According to an alternative embodiment, multiple vertical lanes of product can be created. Actuation of the actuating lane diverter system  124  may be achieved, for example, by a servo drive motor. 
   The choke conveyor system  128  advances the product forward at a first speed. The speedup conveyor system  130  advances the product forward at a second speed, faster than the first speed. The faster speed of the speedup conveyor  130  produces a gap between successive products; this gap is used in subsequent product handling by the flight bar conveyor system  400 . The choke conveyor system  128  and the speedup conveyor system  130  may be driven by a single drive motor, for instance, the servo drive motor of the choke conveyor system  128 . The faster speed of the speedup conveyer system  130  may be achieved, for example, by a suitable gearing arrangement, or other conventional equipment. In an alternative embodiment, the faster speed of the speedup conveyer system  130  may be achieved by using a single drive belt, but by using a different size pulley than a choke conveyor system pulley. In another alternative embodiment, each conveyor system may be driven by its own drive motor. 
   Referring to  FIGS. 5 ,  6 A,  6 B and  6 B, the flight bar conveyor system  400  is shown to include multiple flight bars  402 , multiple drive motors  404  (e.g. servo motors), a conveying system  406  and structural members  408 . The conveying system  406  is shown to include lane dividers  410 , a platform  412 , and multiple drive systems  414 . The drive systems  414  are shown to include multiple drive devices  416  (e.g. belts, chains, pulleys, chain sprockets, etc.). 
   According to the illustrated embodiments, products are moved to the flight bar conveyor system  400  by the diverter system  120 . Products are moved forward in a substantially uniform row on the platform by a flight bar  402 . According to a preferred embodiment, there are two flight bars  402  per drive system  414 , for a total of four flight bars  402  (two for each of the two drive systems  414 ). Each drive system  414  operates independent of the other drive systems  414 , allowing for independent loading and unloading of products. The drive device  416  is shown to be longer along the underside of the platform  412  than the topside of the platform  412  to allow the first drive system  414  to unload a product by one fight bar  402  before a product is loaded by the second flight bar  402  of the first drive system (as shown by  FIGS. 6A and 6B ). 
   Referring to  FIG. 5 , the loader/transport system  160  is shown to include a loader/transport device  162  and a trolley rail system  164 . According to an exemplary embodiment, the loader/transport device  162  is an L-shaped element  166  rigidly coupled to a plate  168  configured to move product(s). According to an alternative embodiment, the loader/transport device  162  may include multiple finger elements  450  rigidly coupled to an arm element  452 . In another alternative embodiment, the loader/transport device may consist of two arm elements  452  rigidly coupled to multiple finger elements  450 . 
   Referring to  FIG. 5 , the loader/transport system  160  is shown attached to the base system  100 . In an alternative embodiment, the loader/transport system  160  may be attached to an interchangeable packaging module  50 . 
   Referring to  FIGS. 5 and 11 , in a case-packing operation, the loader/transport system  160  moves product(s) from a cassette system  204  to an open case that is around a horn system  212 . Referring to  FIGS. 5 and 14 , in a bundling operation, the loader/transport system  160  moves product(s) from an upender table  326  to a former system  306 . 
   Referring to  FIGS. 9 ,  10 A and  10 B, an electrical system  170  is shown to include multiple electrical connectors  172  (e.g. connectors that allow multiple circuits through one plug connector such as those commercially available as Phoenix Contact), an air conditioner  174  and multiple drive motor amplifiers  176  (e.g. servo motor amps, AC motor amplifiers) according to an exemplary embodiment. 
   Remote monitoring (e.g. video, data, troubleshooting, electrical, mechanical, process control) of the modular packaging system  10  may be accomplished, for example, through an Ethernet or similar networking device (e.g. wireless connection, router, etc.). Remote I/O may be accomplished, for example, by an Ethernet connection. In a preferred embodiment, each interchangeable packaging module has a separate IP address intended to allow auto recognition when connected to the base system. Use of an Ethernet connection between the base system  100  and the individual packaging module  50  is intended to aid in a speedy change over between modules (e.g. connecting a single connection instead of connecting multiple (e.g. 50) connections). 
   Referring further to  FIG. 10A , a controller system  180  is shown to include a controller  182  (e.g. programmable logic controller), an interface device  184  (e.g. touch screen) for interfacing with the controller  182  and a safety control circuit  186 . The interfacing device  184  may be located, for example, directly on the base system  100 . According to an alternative embodiment, the interfacing device  184  may be located on a swing arm. According to an exemplary embodiment, the controller system  180  automatically recognizes the type of interchangeable packaging module  50  that is connected to the base system  100 . According to an exemplary embodiment, a specific set of user interface screens are available to the user based on the type of interchangeable packaging module  50  that is connected to the base system  100 . According to a preferred embodiment, the user interface screens for the base system components are the same regardless of which interchangeable packaging module  50  is connected to the base system  100  and is intended to reduce the amount of training needed to train users of the modular packaging system  10 . 
   Case-Packer Module 
   Referring to  FIG. 11 , a case-packer module  200  is shown to include a case-packer frame system  202 , a cassette system  204 , a cassette lift frame system  206 , a cassette lift carriage system  208 , an adjustable horn system  212 , a chair system  214 , a knockdown transport system  210 , a knockdown guide track side air cylinder system  216 , a knockdown lift system, a knockdown lift frame system, a knockdown back fold system  222 , an outside knockdown conveyor system, a knockdown side clamping system  226 , a knockdown conveyor infeed system  228  and a case exit conveyor system  230 . A knockdown refers to a case (made from cardboard, for example) in a flat configuration. 
   Referring to  FIGS. 11 ,  12 A,  12 B and  12 C, a case-packer frame system  202  is shown to include multiple structural and support members  232 , a module connect hitch  234 , multiple roller casters  238  intended to aid in the movement of the case-packer module  200  and a swivel roller caster  240  intended to aid in the turning of the case-packer module  200  during movement. The case-packer module  200  may be moved by a transport device, for example, by hand, by forktruck, or be self driven, as shown in  FIGS. 12A ,  12 B and  12 C. A self driven (self propelled) transport device maybe powered by, for example, a gas engine, a propane engine, or an electric battery. 
   Referring to  FIG. 11 , a cassette system  204  is shown to include multiple product guide panels (cassette paddles), a platform (cassette dead plate), a device for adjusting the width of the cassette paddles and multiple structural members used to slidably couple the cassette system  204  to the case-packing module. 
   Referring to  FIG. 11 , a cassette lift frame system  206  is shown to include multiple cassette lift mounting plates, multiple cassette lift guides, multiple cassette lift frames, a cassette lift plate, a cassette lift shaft, multiple pulleys, multiple of cassette lift shafts, a cassette lift motor mount, a cassette lift motor bracket, a multiple pulley bracket supports, a gear box, multiple radial bearings, multiple pulleys, a belt, multiple bushings, and a servo motor. 
   Referring to  FIG. 11 , a cassette lift carriage system  208  is shown to include multiple cassette lift carriage plates, multiple belt tensioner blocks, multiple loader carriage mounts, multiple belt tensioner blocks, multiple loader carriage mounts and multiple cam bearings. 
   Products enter the cassette system  204  via the flight bar conveyor system. The flight bar unloads a product row onto the cassette dead plate. If required, multiple product rows may be stacked on top of one another to create multiple product layers. This may be done by adjusting the vertical height of the cassette system  204  by one product height. Optional cassette shelf panels may also be employed when stacking multiple product rows according to an alternative embodiment. Additionally, multiple product rows may be grouped together to produce various product row depths. Once the desired product stack configuration is obtained, the product stack is pushed forward via the loader/transport system into an open case. 
   Referring to  FIGS. 13A and 13B , an adjustable horn system  212  is shown to include multiple overlapping panels  242  (made, for example, from sheet metal, plastic or cardboard) and multiple support members  244  which couple the adjustable horn  212  to the case-packing module  200 . An adjustment device  246  is provided to adjust the horn system  212  in a first direction (height) and a second direction (width). Adjustment in a third direction (depth) is generally not required due to the adjustability of a chair system  214 , which facilitates setup, maintenance and changeover between different products. 
   Referring to  FIGS. 13A and 13B , a chair system  214  is shown to include multiple chair pivot plates  250 , multiple chair pivot shafts  252 , multiple chair adjustment plates  254 , multiple chair adjustment spacers  256 , a chair cylinder clevis support  258 , multiple chair arm tubes  260 , multiple chair connecting arm brackets  262 , an arm spacer plate  264 , multiple chair plates  266 , multiple cassette mounting tie-bars  268 , multiple chair arms  270 , multiple rod end ball bearings  276 , an air cylinder  282 , an air cylinder shaft  284 , multiple air cylinder pivots  286 , multiple air cylinder shaft pins  288 , and an air cylinder shaft pivot end  290 . 
   The chair system  214  is shown in the product loading position in  FIG. 13A . The chair arms  270  butt up against the bottom side of the case. The position of the chair arms  270  is adjustable via the various chair shaft mounting holes in the chair adjusting plates  254  to adapt to various case depth positions. This is accomplished, for example, by pivotly attaching a first end of the chair arm tube  260  to one of the chair shaft mounting holes and pivotly attaching a second end of the chair arm tube  260  to a chair connecting arm bracket  262 . 
   Once the stacked grouping of products are moved by the loader/transport system  160  from the cassette system  204  through the adjustable horn system  212  and into a case, the chair system  214  moves to the unloading position, as shown in  FIG. 13B . The design of the chair system  214  allows for variability of case depths (as noted above) but keeps the unloading position height constant. Keeping the unloading position height constant eliminates any need to change the height of the case exit conveyor system  230 . This is accomplished by, for example, pivotly attaching a first end of an air cylinder  282  to a first air cylinder shaft pivot end  290  and pivotly attaching a second end of an air cylinder  282  to a second air cylinder shaft pivot end  290 . Actuating the air cylinder  282  moves the chair system  214  from the loading position to the unloading position. When the chair system  214  is set up to receive small case depths, the chair arms  270  slide along chair pivot plates  270  when the chair system  214  is moved from the loading position to the unloading position. When the chair system  214  is set up to receive large case depths, the chair arms  270  do not need to slide (or slide less) along chair pivot plates  270  when the chair system  214  is moved from the loading position to the unloading position. 
   Referring further to  FIG. 11 , a knockdown transport system  215  is shown to include a knockdown transport thruster support mount, a transport suction support plate, multiple transport suction mounts, a transport top flap closing arm, a knockdown top flap closing plate, multiple transport suction support plates, multiple transport spacers, a hand wheel stop bracket, a hand wheel clamp bracket, a threaded transport adjusting shaft (e.g. ACME threaded transport adjusting shaft), a transport adjusting plate, multiple transport height-adjusting stop spacers, a transport carriage height adjustment plate, a transport adjusting support, a transport carriage top support plate, a threaded transport adjusting shaft (e.g. ACME threaded transport adjusting shaft), a transport carriage adjusting shaft, multiple fasteners, a gear box, multiple bearings, multiple chain sprockets, a connecting link chain, multiple couplings, a pneumatic air cylinder, a linear thruster cylinder, multiple vacuum cups, multiple air cylinder mount brackets, and multiple spacers. 
   Referring further to  FIG. 11 , a knockdown guide track/side air cylinder system  216  is shown to include multiple case side cylinder adjustment plates, multiple case side air cylinder mounts, multiple knockdown side cylinder adjustment brackets, multiple knockdown transport guide mounts, a guide, multiple aluminum track extrusions, multiple linear bearings, multiple air cylinders and multiple vacuum cups. 
   Referring further to  FIG. 11 , a knockdown lift/erector system  218  is shown to include multiple loader carriage plates, a carriage lift support, a belt tensioning spacer, multiple adjusting knockdown lift brackets, multiple knockdown lift suction brackets, a cable track support plate, multiple cam bearings, multiple vacuum cups and a mounting bracket. 
   Referring further to  FIG. 11 , a knockdown lift frame system  220  is shown to include multiple carriage tracks, a gearbox, multiple pulleys, a taperlock bushing, an idler shaft, a servo motor, a knockdown lift frame, a motor mounting plate, and a cable track support. 
   Referring further to  11 , a knockdown back fold system  222  is shown to include multiple knockdown side flap cylinder mounts, a knockdown side flap closing support right side, a knockdown side flap closing support left side, multiple knockdown side door clamp supports, multiple knockdown side flap closing adjustment plates, multiple knockdown side flap closing adjustment block supports, multiple knockdown side flap adjustment shaft support blocks, multiple shafts, a cassette frame, multiple counters, multiple aluminum tracks, multiple linear bearings, multiple bronze bushings, multiple pneumatic air cylinders and a knockdown lift frame system  220 . 
   Referring further to  FIG. 11 , a knockdown side clamping system  226  is shown to include multiple knockdown side door clamp supports, multiple knockdown capturing supports, multiple knockdown capturing clamps, multiple knockdown capturing swivel brackets, multiple knockdown capturing brackets, multiple knockdown capturing threaded adjustment blocks (e.g. ACME threaded adjustment blocks), multiple knockdown capturing end blocks, multiple threaded adjusting shafts (e.g. ACME threaded adjusting shafts), multiple threaded knockdown capturing shafts (e.g. ACME threaded knockdown capturing shafts), multiple knockdown capturing spacer blocks, a cassette frame, multiple counters, multiple handwheels, multiple tracks, multiple linear bearings, multiple bronze bushing bearings, multiple rod end bearings, multiple chain sprockets, multiple chains, multiple pneumatic air cylinders and a knockdown lift frame assembly. 
   Referring further to  FIG. 11 , a knockdown infeed conveyor system  228  is shown to include a conveyor roller, a knockdown infeed conveyor frame, a knockdown infeed conveyor side frame, multiple conveyor rollers, a knockdown infeed conveyor drive guide, a knockdown infeed bottom support frame, a drive motor, a gear box reducer, a motor mounting plate, multiple motor support spacer mounts, a knockdown infeed chain guard, multiple knockdown infeed end frames, a chain, a knockdown infeed chain drive guard, multiple aluminum tracks, multiple threaded adjusting knockdown capturing shafts (e.g. ACME threaded adjusting knockdown capturing shafts), multiple bushings, a handwheel, multiple leveling pads, multiple chain sprockets, multiple aluminum linear-bearing extrusion guides, a knockdown capturing plate clamp, multiple pneumatic air cylinders, a knockdown capturing adjustment plate, a knockdown plate adjustment plate, multiple knockdown capturing plate supports, a mount banding bracket, and a banding to hold air lines. 
   Referring further to  FIG. 11 , a case exit conveyor system  230  is shown to include a case exit conveyor roller, a case exit conveyor frame, a case exit conveyor side frame, multiple conveyor rollers, a case exit conveyor drive guide, a case exit bottom support frame, a drive motor, a gear box reducer, a motor mounting plate, multiple motor support spacer mounts, a case exit chain guard, multiple case exit end frames, a chain sprocket, a chain and a case exit chain drive guard. According to an exemplary embodiment, the case exit conveyor maybe set up so a case can exit the modular packaging system  10  in either a right- or left-hand direction. 
   Bundler Module 
   Referring to  FIG. 14 , a bundler module  300  is shown to include a bundler frame system  302 , an upender system  304 , an unwind system  305 , a former system  306  and a knife and exit conveyor system  308 . 
   A bundler frame system  302  is shown to include multiple structural and support members  310 , a module connect hitch  312 , multiple roller casters  316  intended to aid in the movement of the bundler module  300  and a swivel roller caster intended to aid in the turning of the bundler module  300  during movement. The bundler module  300  may be moved by a transport device, for example, by hand, by forktruck, or be self driven, as shown in  FIGS. 12A ,  12 B and  12 C. A self driven (self propelled) transport device maybe powered by, for example, a gas engine, a propane engine, or an electric battery. 
   Referring to  FIGS. 15 ,  16 A and  16 B, an upender system  304  is shown to include an upender frame system  320 , a spool system  322 , a product guide system  324 , and a table conveyor system  326 . The upender frame system  320  is shown to include multiple structural and support members  328  to provide support for the upender system components. 
   Again referring to  FIGS. 15 ,  16 A,  16 B and  16 C, the spool system  322  is shown to a lifting device  330  (shown as multiple upender fingers) that are linearly coupled to a spool shaft  332 . According to a preferred embodiment, there are six lines, or spool shafts, of upender fingers  330 . According to a preferred embodiment, there are eight upender fingers  330  per line. However, any arrangement of fingers and lines may be possible. In an alternative embodiment, the lifting device may be a paddle of any shape or size, a grid, a mesh, a horizontal rod or vertical rod. The spool shafts  332  are rotationally coupled to a spool wheel  334  on both ends of the spool shaft  332  via a cam following device  336 , shown here as a cam follower. A first end of the cam following device  336  is rotationally attached to the spool wheel  334 ; a second end of the cam following device  336  is inserted into a cam groove  338  in a cam plate  340 . The cam plate  340  is attached to the upender frame system  320 . The spool wheel  334  is driven by a drive motor  342 , shown here as a servo motor. A platform  344  with slots that correspond to the upender fingers is rigidly coupled to the upender frame system  320  and provides a surface for a product to be upended by the upender fingers. 
   Further referring to  FIGS. 16A and 16B , the cam action of the cam groove  338  and corresponding components provide for a product to be picked up in a first (horizontal) position and rotated 90 degrees to a second (vertical) position. In addition, once a product is in the vertical position, the cam action provides for the line of upender fingers  330  to remain vertical while moving the product forward. This ensures that the product(s) is not tipped over. Product(s) are then moved forward, for example, by a loading/transport system  160 . According to an alternative embodiment, a conveyor system moves product forward from the upender system  304 . According to another embodiment, the table conveyor system  326  comprises multiple individual conveyor belts that are arranged in between the upender fingers  330  of the upender system  304 . 
   The product guide system  324  is shown to include multiple rectilinear panels  346  (e.g. product guide panels, side compression panels) and roller arms  348  to aid in guiding the product along a table conveyor system  326  as shown in  FIG. 15 . An adjustment device  350  is provided to adjust the distance between the rectilinear panels  346  to accommodate various product grouping sizes. The roller arms  348  are rotationally coupled to the upender frame system  320 . Tension arms  352  are slidibly fixed to the roller arms  348  to keep pressure on products as they advance along the table conveyor system  326 . 
   Referring to  FIG. 17A , an unwind system  305  is shown to include a frame system  354 , a conveyor  356 , a drive motor  358 , and multiple unwind shafts  360 . 
   Referring to  FIGS. 17A ,  17 B and  17 C, a former system  306  is shown to include a former frame system  362 , an upper former system  364 , a lower former system  366 , a drive motor  368 , multiple belts  372 , an adjusting member  376 , multiple forming plates  378  and a vacuum tube  380 . 
   Referring to  FIG. 18A , a knife and exit conveyor system  308  is shown to include a knife and exit conveyor frame system  390 , a carriage  392 , a drive motor  394 , a folding jaw  396  a knife  398  and an exit conveyor  399 . 
   A product grouping arrives into the former system  306  by being moved by the loader/transport system of the base system from the table conveyor system  326  of the upender system  304 . A product grouping may also enter the former system  306  by a conveyor device, as shown in  FIG. 18B . The product grouping is then bundled with a bundling material (e.g. plastic film) that has been unwound and formed by the unwind and former systems. As the product grouping advances through the former system  306  via former conveyor belts  372  (e.g. top conveyor belt(s), bottom conveyor belt(s), side conveyor belt(s)), the bundling material is sealed at the top by a sealing method known in the art. The folding device  396  (e.g. clamp plates, folding jaw) and knife  398  act simultaneously or independently to fold, or tuck, the bundle material ends at the end of the product grouping at the same time the bundle material is cut by the knife  398 . The vacuum tube  380  (made, for example, from spring steel) is attached to the former system  306  to suck air out of the bundle while being welded. According to a preferred embodiment, the vacuum tube  380  comprises a fish tail design, as shown in  FIG. 18B . 
   According to one exemplary embodiment, the knife and exit conveyor system  308  is slidably retractable from the unwind system  305  and former system  306 . This is intended to allow, for example, easy maintenance of both the unwind system  305 , the former system  306  and the knife and conveyor system  308 . Additionally, this allows for “running” bundling of products and cutting bundle material. Having the knife and exit conveyor system  308  move with the product(s) and bundle material allows for extra time during sealing, extra time for air extraction from the bundle and continuous movement of product flow. This provides for less bad seals and faster bundling of products. 
   Finished bundled product groupings exit the bundler module  300  by the exit conveyor  399 , as shown in  FIGS. 18A and 18B . According to an alternative embodiment, a bundle may exit the modular packaging system  10  in either a straight or right- or left-hand direction. According to another alternative embodiment, the exit conveyor  399  comprises a first exit conveyor (bottom) and a second exit conveyor (top) located directly vertical of the first exit conveyor. A top and bottom conveyor configuration allows for a product grouping to be pulled out of the knife  398 , and then back in, to create a space for tucking and cutting the bundle material. This provides less stress on the bundling material resulting in fewer bad seals. 
   Materials and Construction 
   According to various exemplary embodiments, the assemblies and components of the modular packaging system  10  may be constructed from a variety of suitable materials, including metals, metal alloys, aluminum, polymers, composites, plastics (including polycarbonates, acrylics, high impact plastics and injection molded plastic), ceramics, rubbers, fabrics, ropes, etc. According to various exemplary embodiments, any suitable material may be used for the components of the modular packaging system  10 . For example, the base may be constructed from steel, aluminum and the like. 
   The frame members may be constructed from metal, metal alloys, aluminum, plastics, polymers, composites, plastics, rubbers, etc. According to other alternative embodiments, any other suitable material may be used to construct the frame members. According to an exemplary embodiment, the frame members may be painted to improve aesthetic appeal. 
   Basic Operation 
   According to the exemplary embodiments shown in  FIGS. 1-18B , many different types of objects and products may be packaged with the modular packaging system  10 . For example, toilet paper rolls, paper towel rolls, tissue paper, napkins and single and multiple fold towels may be packaged with the system. 
   The modular packaging system  10  may be assembled according to standard practices and as described herein to provide a structure as shown in  FIGS. 1-18B . 
   According to any preferred embodiment, a modular packing system  10  has a base system  100  that contains the lane diverter  120 , along with much of the electrical system  170 , control system  180  and drive devices  176  for the entire packaging system. Also provided are interchangeable packaging modules  50  for each of the packaging methods (case-packing, bundling, bagging and wrapping). The modular packing system  10  provides considerable overall cost savings because (among others) there is no need for the redundant equipment and costly electrical components. An additional feature is the reduced floor space required along with considerably less equipment to maintain and operate. This type of modular system allows for increased flexibility as new packaging methods become industry standards. 
   It is important to note that the construction and arrangement of the elements of the modular packaging system  10  as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present inventions have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the types of interfaces (e.g., signs, letterings, pictures, etc.) may be varied, the length or width of the structures and/or members or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied (e.g., by variations in the number of engagements, size of the engagement areas, or type of engagements). It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures and combinations. Accordingly, all such modifications are intended to be included within the scope of the present inventions. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the exemplary embodiments without departing from the spirit of the present invention. 
   The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Any means-plus-function clause is intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes and omissions may be made in the design, operating configuration and arrangement of the preferred and other exemplary embodiments without departing from the spirit of the appended claims.