Patent Publication Number: US-9896231-B2

Title: Packaging station system and related methods

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to and the benefit of PCT Application No. PCT/US2013/0020153, filed Jan. 3, 2013, entitled “PACKAGING STATION SYSTEM AND RELATED METHODS”, which claims the benefit of and priority to the following applications: U.S. Provisional Application No. 61/584,579, filed Jan. 9, 2012, entitled “PACKAGING STATION SYSTEM AND RELATED METHODS”. All the aforementioned applications are incorporated by reference herein in their entirety. 
    
    
     BACKGROUND 
     1. Technical Field 
     Exemplary embodiments of the invention relate to systems, methods, and devices for packaging orders. More specifically, exemplary embodiments relate to systems and methods for initiating requests for packaging templates and packaging orders. 
     2. Background and Relevant Art 
     Shipping and packaging industries frequently use paperboard and other fanfold material processing equipment that converts fanfold materials into box templates. One advantage of such equipment is that a shipper may prepare boxes of required sizes as needed in lieu of keeping a stock of standard, pre-made boxes of various sizes. Consequently, the shipper can eliminate the need to forecast its requirements for particular box sizes as well as to store pre-made boxes of standard sizes. Instead, the shipper may store one or more bales of fanfold material, which can be used to generate a variety of box sizes based on the specific box size requirements at the time of each shipment. This allows the shipper to reduce storage space normally required for periodically used shipping supplies as well as reduce the waste and costs associated with the inherently inaccurate process of forecasting box size requirements, as the items shipped and their respective dimensions vary from time to time. 
     In addition to reducing the inefficiencies associated with storing pre-made boxes of numerous sizes, creating custom sized boxes also reduces packaging and shipping costs. In the fulfillment industry it is estimated that shipped items are typically packaged in boxes that are about 40% larger than the shipped items. Boxes that are too large for a particular item are more expensive than a box that is custom sized for the item due to the cost of the excess material used to make the larger box. When an item is packaged in an oversized box, filling material (e.g., Styrofoam, foam peanuts, paper, air pillows, etc.) is often placed in the box to prevent the item from moving inside the box and to prevent the box from caving in when pressure is applied (e.g., when boxes are taped closed or stacked). These filling materials further increase the cost associated with packing an item in an oversized box. 
     Custom-sized boxes also reduce the shipping costs associated with shipping items compared to shipping the items in oversized boxes. A shipping vehicle filled with boxes that are 40% larger than the packaged items is much less cost efficient to operate than a shipping vehicle filled with boxes that are custom sized to fit the packaged items. In other words, a shipping vehicle filled with custom sized packages can carry a significantly larger number of packages, which can reduce the number of shipping vehicles required to ship that same number of items. Accordingly, in addition or as an alternative to calculating shipping prices based on the weight of a package, shipping prices are often affected by the size of the shipped package. Thus, reducing the size of an item&#39;s package can reduce the price of shipping the item. 
     Although sheet material processing machines and related equipment can potentially reduce inconveniences and costs associated with stocking and using standard sized shipping supplies, the process for making and using custom-made, just-in-time packaging templates can nevertheless be improved through the order in which the packaging templates are created and used. 
     BRIEF SUMMARY OF THE INVENTION 
     This disclosure relates to systems, methods, and devices for processing paperboard (such as corrugated cardboard) and similar fanfold materials and converting the same into packaging templates. In connection with a packaging system that includes a converting machine that makes packaging templates that may be assembled into custom sized boxes, this disclosure relates to a method for packaging multiple groups of one or more items. Such method can include initiating a packaging process for a first group of one or more items and initiating a packaging process for a second group of one or more items. The method also can include completing the packaging process for the first group of one or more items after initiating the packaging process for the second group of one or more items. Moreover, the method can also include initiating a packaging process for a third group of one or more items and completing the packaging process for the second group of one or more items after initiating the packaging process for the third group of one or more items. 
     In at least one embodiment, a method for utilizing a converting machine in a packaging system for packaging orders can include checking for orders available for packaging and, if available, initiating two available orders for processing, including requesting the creation by the converting machine of packaging templates for the two available orders. Such method also can include checking for a created packaging template for at least one of the two available orders and, if available, completing the processing of the at least one of the two available orders. Additionally, the method can include checking for orders available for packaging and, if available, initiating one available order for processing, including requesting the creation by the converting machine of a packaging template for the one available order. Moreover, the method can incorporate checking for a created packaging template for the other of the two available order and, if available, completing the processing of the other of the two available orders. The method also can incorporate checking for a created packaging template for the one available order and, if available, completing the processing of the one available order. 
     In yet another embodiment, a method for utilizing a packaging system for requesting packaging materials, assembling packages, and preparing packages for shipment can include obtaining dimensions of a first order and requesting a first packaging template to be prepared by the packaging system based on the obtained dimensions of the first order. The method also can include obtaining dimensions of a second order and requesting a second packaging template to be prepared by the packaging system based on the obtained dimensions of the second order. Additionally, the method can include assembling the first packaging template into a first box and packaging the first order therein. Furthermore, the method can include obtaining dimensions of a third order and requesting a third packaging template to be prepared by the packaging system based on the obtained dimensions of the third order. Such method also can incorporate assembling the second packaging template into a second box and packaging the second order therein. Still further, the method can include obtaining dimensions of a fourth order and requesting a fourth packaging template to be prepared by the packaging system based on the dimensions of the fourth order. Additionally, the method can include assembling the third packaging template into a third box and packaging the third order therein. 
     Additional features and advantages of exemplary implementations of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by the practice of such exemplary implementations. The features and advantages of such implementations may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features will become more fully apparent from the following description and appended claims, or may be learned by the practice of such exemplary implementations as set forth hereinafter. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In order to describe the manner in which the above-recited and other advantages and features of the invention can be obtained, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. For better understanding, like elements have been designated by like reference numbers throughout the various accompanying figures. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which: 
         FIG. 1  illustrates a packaging cell as described in one aspect of this disclosure; 
         FIG. 2  illustrates a flow chart of an exemplary process for packaging multiple orders as described in one aspect of this disclosure; 
         FIG. 3  illustrates a flow chart of exemplary sub-steps of the process shown in  FIG. 2 ; 
         FIG. 4  illustrates yet another flow chart of exemplary sub-steps of the process shown in  FIG. 2 ; 
         FIG. 5  illustrates a flow chart of an exemplary process for packaging multiple groups of one or more items as described in one aspect of this disclosure; 
         FIG. 6  illustrates a flow chart of another exemplary process for packaging multiple groups of one or more items as described in one aspect of this disclosure; and 
         FIG. 7  illustrates a flow chart of still another exemplary process for packaging orders as described in one aspect of this disclosure. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The embodiments described herein generally relate to systems and methods for processing paperboard and similar fanfold materials into packaging templates and packaging orders using the packaging templates. More specifically, the described embodiments relate to methods of processing orders available for packaging. In one or more implementations, the method can reduce the time and cost of producing custom-size packaging templates, building custom-sized packaging boxes, and packaging orders in the boxes. 
     Generally, as illustrated in  FIG. 1 , a shipper can have one or more packaging cells  100 , which can include equipment for packaging available orders and preparing the same for shipment. For example, the packaging cell  100  can include a packaging system  110 , an available-order transport system  120 , a work area  130 , and a processed-order transport system  140 . The packaging system  110  can include a converting machine  112  that can receive fanfold material  150  from one or more bales  152 . The packaging system  110  can process the fanfold material  150  into packaging templates  160 . An operator can retrieve the packaging templates  160  from the packaging system  110  and can form boxes  170  for shipment of available orders  180 . As used herein, the term “available order” refers to any order (whether a single-item order or multi-item order) that can be processed as one unit by the shipper. 
     The available-order transport system  120  can transport various available orders  180  to the work area  130  for packaging and preparation for shipment. In some embodiments, the available-order transport system  120  can be a conveyor system or movable shelving system that can transport the available orders  180  to the work area  130 . When the available orders  180  arrive at the work area  130 , the operator can request packaging templates  160  to be prepared by the packaging system  110 . As further described below, such packaging templates  160  can be custom-sized based on the particular dimensions of the available orders  180  to be packaged. 
     In addition to packaging the available orders  180 , the operator can prepare the available orders  180  for shipment by attaching required labels and other materials. Once the available order  180  is processed (i.e., packaged and/or prepared for shipment), such processed order  190  can be transported away from the work area  130  via the processed-order transport system  140 . For instance, the processed-order transport system  140  can transport the processed orders  190  to a shipping area. In some implementations, the processed-order transport system  140  can be a conveyor belt that can connect the work area  130  and a desired location for the processed orders  190 . In other embodiments, the processed-order transport system  140  can be a movable shelving system that can transport the processed orders  190  away from the work area  130 . 
     As illustrated in  FIG. 2 , in some embodiments, to process available orders  180 , check is made for available orders  180  at step  200 . If it is determined at step  210  that an available order  180  has arrived at the work area  130 , a request is initiated at step  220  for the creation of a packaging template  160  for the available order identified in step  210 . The process for initiating the request for the creation of a packaging template  160  is discussed in further detail below. 
     After initiating the request in step  220 , it is determined in step  230  whether there is an additional available order  180  at the work area  130 . If so, a request is initiated at step  240  for the creation of another packaging template  160  for the additional available order  180  identified in step  230 . After initiating the request for the additional packaging template  160  identified in step  240 , or when it is determined at step  230  that there is not an additional available order  180 , a check is made in step  250  to determine whether the packaging system  110  has completed the creation of the packaging template for the initial order identified in step  210 . If the requested packaging template  160  for the order identified in step  210  is available, as determined in step  260 , the order identified in step  210  is packaged in step  270  using the packaging temple  160  requested in step  220 . The packaging of an available order in a packaging template  160  is discussed in greater detail below. 
     After the initial available order identified in step  210  is packaged, the process returns to step  230  and cycles through again. Specifically, the process returns to step  230  to determine whether yet another available order  180  has arrived at the work area  130 , in which case a request is initiated at step  240  for the creation of a packaging template  160  for the available order identified in the second occurrence of step  230 . The process then moves to step  250  for the second time, where it is determined whether the packaging system  110  has completed the creation of the packaging template for the available order  180  identified during the first occurrence of step  230 . If the requested packaging template  160  for the order identified in the first occurrence of step  230  is available, as determined in step  260 , the order identified in the first occurrence of step  230  is packaged in step  270  using the packaging temple  160  requested in step  240 . 
     The process illustrated in  FIG. 2  can continue to cycle through steps  230 - 270  so long as there are additional orders at the work area  130  that need to be packaged. If no additional orders are identified in step  230 , the orders that are already at the work area  130  and which have not been packaged may be packaged using the packaging templates  160  requested in connection therewith. 
     As described above, the packaging cell  100  can be operated in a manner that the packaging templates  160  are custom sized to the available orders  180  that arrive at the work area  130 . As noted above, and as indicated in  FIG. 2  at steps  220 ,  240 , the packaging of available orders  180  in custom sized packages can begin by initiating a request for the creation of a custom sized packaging template  160 . The initiation of the process can include multiple steps. As illustrated in  FIG. 3 , for example, initiation of the process can include obtaining the sizes of the available orders  180  (step  300 ) and requesting packaging templates  160  to be prepared based on the sizes of the available orders  180  (step  310 ). 
     For example, to obtain the sizes of the available orders  180 , the available orders  180  can be measured, such as with a measuring tape, laser measuring device, or the like. Alternatively, the available order  180  can have a tracking number, such as a barcode, that can be associated with information related to the available order  180 , including the size and/or shape of the available order, as well as other packaging requirements (e.g., needed padding). Thus, barcode can be scanned to obtain the size as well as other relevant parameters of the available order  180  (step  300 ). Furthermore, based on the obtained measurements and/or other information relating to the available order  180 , a computer system can request a packaging template  160  be prepared by the packaging system  110  that corresponds to the size of the available order  180 , as indicated in step  310 . 
     As described above, and as indicated in  FIG. 2  at step  270 , when the packaging template  160  is available, the packaging process can be completed by packaging the available order  180  using the packaging template  160  that corresponds to the available order  180 .  FIG. 4  illustrates exemplary steps is completing the packaging process for an available order. As shown, this portion of the packaging process can begin with retrieving the available packaging template  160  from the packaging system  110  (step  320 ). The retrieved packaging template  160  is them formed into a box  170  in step  330 . In step  340 , the available order  180  is placed in the box  170 . Next, in step  350 , the box  170  is closed and/or sealed and any needed labels, such as shipping labels, are placed on the box  170 . Once the available order  180  is processed, the processed order  190  can be transported away from the work area  130  via the processed-order transport system  140 . 
     In some embodiments, as illustrated in  FIG. 5 , the packaging process can be initiated in step  400  for a first group of one or more items from the available orders  180 . The initiation of the packaging process may be similar or identical to that shown in and discussed in connection with  FIG. 3 . As used herein, the term “items” refers to any item that is individually identifiable within an available order. For example, an order may comprise two items that can be packaged in the same or in two separate boxes, depending on the shipper&#39;s preferences. In addition to the above description, initiating the packaging process also can include creating the packaging template  160 , which can be assembled into the box  170 , custom-sized for one or more available orders  180  or for one or more items within one or more of the available orders  180 . 
     After initiating the packaging process for the first group of items, the packaging process for a second group of one or more items from the available orders  180  can be initiated in step  410 . Subsequently, the packaging process for the first group of one or more items can be completed in step  420 . As described above, completing the packaging process can include packaging the items or the available orders  180  within the box  170 . Thereafter, the packaging process for a third group of one or more items from the available orders  180  can be initiated in step  430 . After initiated the packaging process for the third group of items, the packaging process for the second group of one or more items from the available orders  180  can be completed in step  440 . 
     While not illustrated, the packaging process can continue for any number of groups of items in the same manner as described above. For instance, the packaging process for a fourth group of one or more items from the available orders  180  can be initiated, after which the packaging process for the third group of one or more items can be completed. 
     Additionally or alternatively, as illustrated in  FIG. 6 , the operator can check whether there are available orders  180  within the packaging cell  100  (step  500 ). If there are at least two available orders  180  within the packaging cell  100  (step  510 ), the operator can initiate the processing of two available orders  180  (step  520 ), as described above. Subsequently, the operator can check whether the packaging system  110  prepared packaging templates  160  for at least one of the initiated orders (step  530 ). If at least one packaging template  160  is available, the operator can complete the processing of one of the available orders  180  (step  550 ), as described above. 
     After completing processing of one of the available orders  180 , the operator can check whether additional available orders  180  are present within the packaging cell  100  (step  560 ). If at least one available order  180  is present within the packaging cell  100  (step  570 ), the operator can initiate the packaging process for one of the additional available orders  180  (step  580 ). Subsequently, the operator can check whether the packaging system  110  has prepared at least one packaging template  160 , which can be used to package one of the available orders  180  (steps  590 ,  600 ). If there is at least one packaging template  160  that is available for packaging at least one of the available orders  180 , the operator can complete the processing of the available order  180  that corresponds with the available packaging template  160  (step  610 ). After completing the step  610 , the operator can check whether additional available orders  180  are present within the packaging cell  100  (step  560 ). 
     If at the outset of the process there is only one available order  180  within the packaging cell  100  (steps  500 ,  510 ,  620 ), the operator can initiate processing of the one available order  180  (step  630 ). Subsequently, the operator can check whether the packaging template  160  has been prepared for the available order  180  (step  640 ) and, if the packaging template  160  is available (step  650 ), the operator can complete processing of the order (step  660 ). After the operator has completed the order (step  660 ), the operator can once again check for more available orders (step  500 ). 
     In yet another embodiment, as illustrated in  FIG. 7 , the operator can obtain dimensions of a first available order  180  (step  700 ), as described above. Subsequently, the operator can request a first packaging template  160  from the packaging system  110  for packaging the first available order  180  (step  710 ). After requesting the first packaging template  160 , the operator can obtain dimensions of a second available order  180  (step  720 ) and can request a second packaging template  160  for the second available order  180  (step  730 ). 
     After requesting the second packaging template  160 , the operator can assemble the first packaging template  160  into a first box  170  (step  740 ) and can package the first available order  180  in the first box  170  (step  750 ). Subsequently, the operator also can obtain dimensions of a third available order  180  (step  760 ) and can request a third packaging template  160  from the packaging system  110  for packaging the third available order  180  (step  770 ). After requesting the third packaging template  160 , the operator can assemble the second packaging template  160  into a second box  170  (step  780 ) and can package the second available order  180  in the second box  170  (step  790 ). 
     After completing the step  790 , the operator also can obtain dimensions of a fourth available order  180  (step  800 ) and can request a fourth packaging template  160  from the packaging system  110  for packaging the fourth available order  180  (step  810 ). After requesting the fourth packaging template  160 , the operator can assemble the third packaging template  160  into a third box  170  (step  820 ) and can package the third available order  180  in the third box  170  (step  830 ). 
     Furthermore, the operator can continue to operate within the packaging cell  100  in the same manner as described above. For instance, the operator can obtain dimensions of a fifth available order  180  and can request a fifth packaging template  160  from the packaging system  110  for packaging the fifth available order  180 . The operator also can assemble the fourth packaging template  160  into a fourth box  170  and can package the fourth available order  180  in the fourth box  170 , and so on. 
     In light of this disclosure, those skilled in the art should appreciate various methods of packaging that can be used in conjunction with the methods and systems described herein. For instance, the operator can assemble the packaging templates  160  into boxes  170  by securing various portions of the packaging templates  160  with an adhesive tape or staples. Additionally or alternatively, one operator can assembly the packaging templates  160  into boxes  170  and place the available orders  180  into the assembled boxes  170 , and another operator can secure various portions of the boxes  170  with an adhesive tape. 
     The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.