Patent Publication Number: US-2005120674-A1

Title: Apparatus for manufacturing and packaging cigarettes and arrangement of appropriate apparatuses

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
      The present application is a Continuation of International Application No. PCT/EP2003/007467, filed Jul. 10, 2003 and claims priority of German Patent Application No. DE 102 34 761.1, filed on Jul. 30, 2002. Moreover, the disclosure of International Patent Application No. PCT/EP2003/007467, filed Jul. 10, 2003 is expressly incorporated by reference herein in its entirety. 
    
    
     BACKGROUND OF THE INVENTION  
      1. Field of the Invention  
      The present invention relates to an apparatus for manufacturing and packaging cigarettes, which includes a cigarette manufacturing machine including at least one cigarette machine unit that is specifically a distributor unit, a strand-forming unit, a filter-producing unit and/or a filter tipping unit, as well as a packaging machine for packaging the cigarettes into packages, packing units, cartons and/or on pallets.  
      The invention moreover relates to an arrangement of such apparatuses.  
      2. Discussion of Background Information  
      German patent DE 40 18 266 C2 discloses a cigarette manufacturing and packaging line. The cigarette manufacturing machine and the packaging machine are disposed in a square cell. The material is supplied there via a separate zone on one side of the cell.  
     SUMMARY OF THE INVENTION  
      In distinction therefrom, the present invention is based on the problem of providing an apparatus of the claimed general type for manufacturing and packaging cigarettes, which requires the smallest floor space possible and simplifies servicing or operation, respectively.  
      This problem is solved by an apparatus for manufacturing and packaging cigarettes, including a cigarette machine having at least one cigarette machine unit that is specifically a distributing unit, a strand unit, a filter-manufacturing unit and/or a filter-tipping unit, as well as a packaging machine for packaging the cigarettes in packages, packing units, cartons and/or on pallets, with the packaging unit and at least one cigarette machine unit being arranged along a substantially straight line.  
      The inventive apparatus minimizes the floor space required for the apparatus.  
      Within the scope of the invention, a packaging machine includes one or several packaging units such as a cigarette block-forming unit that may also provide, in particular, an inner wrapper around the cigarette block, e.g. with tin foil, a collar-attaching unit, by which a collar may be disposed on the block provided with an inner wrapper, a blanks unit by which the blanks are folded and adhesively fastened around the block, a film wrapper unit by which a film may be applied around the completely folded and adhesively fastened cigarette packages, a carton packaging unit by which the cigarette package cartons may be packaged, and a carton-wrapping unit by which the cigarette cartons so produced may be wrapped, for instance by a propylene film. The cigarette machine Includes at least one cigarette machine unit such as a distributing unit in which the tobacco is fed, possibly screened and stacked, in particular, to form several tobacco strands, a strand unit by which the tobacco strand is wrapped with cigarette paper, a filter-manufacturing unit by which the filters are produced, for instance, from a filter tow, and a filter-tipping unit. Appropriate packaging unit and cigarette machine units are substantially known. The cigarette machine of the “Protos” type, made by Hauni Maschinenbau AG, includes, for example, a distributing unit and a strand unit and moreover a filter-tipping unit that is marketed by Hauni Maschinenbau AG by the brand “Max.” Applicant&#39;s “Chronos” packaging machine includes a block-forming unit, a collar-attaching unit, a blanks unit, and a film wrapper unit. The Chronos machine may be completed with an appropriate carton packaging unit and a carton-wrapping unit. The tobacco-distributing unit of the “Protos” machine may be preceded by a filter-manufacturing unit upstream along the conveying direction, which includes the well-known “AF” and “KDF” units. The “AF” unit serves to produce a filter strand from filter tow and the “KDF” unit serves to wrap this filter strand by a filter paper. The respective filter-producing unit or filter-producing machine, respectively, is equally marketed by Hauni Maschinenbau AG and is well-known to those skilled in the art.  
      When the filter-tipping unit is arranged along a substantially straight line relative to the packaging machine an even more space-saving variant of the invention is achieved. When, additionally, the strand unit is disposed along a substantially straight line relative to the packaging machine and the filter-tipping unit even less floor space is required. When, eventually, all of the cigarette machine units of the cigarette machine and the packaging machine are arranged along a substantially straight line only a minimum of floor space is required.  
      In a preferred embodiment of the inventive apparatus provisions are made to permit operation of the apparatus exclusively from a first side of the apparatus whilst provisions for feed of packaging material to the apparatus are made from a second side that is opposite to the first side In particular. With this preferred embodiment of the inventive device, the expenditure in terms of labor of the operators is minimized and moreover the floor space required on the manufacturing floor for the production of cigarettes and cigarette packages is optimized. Within the scope of the present invention, film material, collars, blanks are used as packaging material for packaging machine units, with the requirement that the collars and the blanks must previously have been cut or may be present in the form of bobbins and are then cut. The packaging material is preferably arranged on bobbins and is supplied to the packaging units from the second side.  
      Logistic provisions are made for automatic feed of the packaging material via a loading device and material-handling stations. The respective packaging materials supplies may be replenished by portal robots, as is described in the German Patent DE 40 18 266 C2. When provisions are made for feed to the apparatus from a second side exclusively it is possible to save path lengths so that stock-keeping may be made highly efficient and extensive in terms of time. Supply of the cigarette machine unit with at least one part of the materials required for handling cigarettes is preferably made possible from the second side. The materials required for producing cigarettes are tobacco, filter tow, filter paper, cigarette paper, and lining paper in particular. A particularly preferred embodiment of the invention is provided when the tobacco is fed to the apparatus from the top and the further cigarette machine units are supplied from the second side.  
      In order to provide for optimized utilization of the floor space on the cigarette production and packaging floor, in accordance with the present invention, an arrangement of the inventive apparatus described above is characterized by the provisions that at least two adjacent apparatuses are spaced from each other in such a way that aisles are formed between the apparatuses, which are exclusively provided for feeding packaging material to the apparatuses or exclusively for operating the apparatuses. Due to the inventive arrangement of the inventive apparatuses, either short path lengths are created for feed to the apparatuses or short walking distances for operating the apparatuses. Moreover, optimum utilization of the floor space or the area, respectively, becomes possible. In the context of the present invention, the term “spacing” is to be understood in the sense, in particular, that a space is provided transversely with respect to the substantially straight line of the apparatuses.  
      A plurality of apparatuses is preferably so arranged that respectively adjacent apparatuses are spaced from each other by such a distance that aisles are formed along the substantially straight lines that are provided exclusively for feeding packaging materials to the apparatus and/or exclusively for operation of the apparatuses. Due to one preferred embodiment of the inventive arrangement, an even enhanced utilization of floor space available for the apparatuses becomes possible. An arrangement that allows for an even higher feed rate or operating speed, respectively, due to shorter ways to be covered includes aisles formed by spacing apparatuses along the respective substantially straight line, with the aisles being extended along this line of adjacent apparatuses.  
      One aspect of the invention includes an apparatus for manufacturing and packaging cigarettes that includes a cigarette machine including at least one cigarette machine unit, a packaging machine structured and arranged to package the cigarettes one of in packages, in packing units, in cartons, and on pallets; and the packaging machine and the at least one cigarette machine unit being arranged along a substantially straight line.  
      In a further aspect of the invention, the at least one cigarette machine unit can include at least one of a distributing unit, a strand unit, a filter-manufacturing unit, and a filter-tipping unit. Moreover, the at least one cigarette machine unit can include a filter-tipping unit arranged along a substantially straight line with the packaging machine. Furthermore the at least one cigarette machine unit can further include a strand unit arranged along a substantially straight line with the packaging machine and the filter-tipping unit. Additionally, the at least one cigarette machine unit can further include a distributing unit and a filter-manufacturing unit, and the distributing unit, the filter-manufacturing unit, the strand unit, the filter-tipping unit, and the packaging machine are arranged along a substantially straight line. Moreover the cigarette machine and the packaging machine can be structured and arranged for operation exclusively from one side of the cigarette machine and the packaging machine; and wherein the packaging machine is structured and arranged for supply of packaging material to the packaging machine exclusively from a second side that is opposite to the first side. Furthermore the at least one cigarette machine unit can be structured and arranged such that at least one part of the materials required for manufacturing cigarettes is suppliable from the second side. Additionally the at least one cigarette machine unit can be structured and arranged such that tobacco is suppliable from above, and the at least one cigarette machine unit comprises a plurality of cigarette machine units, in which each of the plurality of cigarette machine units is suppliable from the second side. Moreover an arrangement composed of a plurality of apparatuses can include at least two adjacent apparatuses are arranged such that aisles are formed between the at least two adjacent apparatuses, wherein the aisles are formed by the first sides of the two adjacent apparatuses or the second sides of the two adjacent apparatuses. Additionally, the arrangement can include a plurality of apparatuses arranged such that respective adjacent apparatuses are spaced from each other such that aisles are formed by sides of adjacent apparatuses. Furthermore, the arrangement can include additional apparatuses arranged to continue the aisles formed by the arrangement of apparatuses along the substantially straight line.  
      Another aspect of the invention includes a method of arranging an apparatus for manufacturing and packaging cigarettes, the apparatus comprising a cigarette machine having at least one cigarette machine unit and a packaging machine structured and arranged to package the cigarettes one of in packages, in packing units, in cartons, and on pallets. The method includes arranging the packaging machine and the at least one cigarette machine unit along a substantially straight line.  
      In a further aspect of the invention, at least one cigarette machine unit can include at least one of a distributing unit, a strand unit, a filter-manufacturing unit, and a filter-tipping unit. Moreover, the at least one cigarette machine unit can include a filter-tipping unit arranged along a substantially straight line with the packaging machine. Furthermore, the at least one cigarette machine unit can further include a strand unit arranged along a substantially straight line with the packaging machine and the filter-tipping unit. Additionally, the at least one cigarette machine unit can further include a distributing unit and a filter-manufacturing unit, and the distributing unit, the filter-manufacturing unit, the strand unit, the filter-tipping unit, and the packaging machine are arranged along a substantially straight line. Moreover, the method can further include arranging the cigarette machine and the packaging machine for operation exclusively from one side of the cigarette machine and the packaging machine, and arranging the packaging machine for supply of packaging material to the packaging machine exclusively from a second side that is opposite to the first side. Additionally, the method can include arranging the at least one cigarette machine unit such that at least one part of the materials required for manufacturing cigarettes is suppliable from the second side. Moreover, the at least one cigarette machine unit can be structured and arranged such that tobacco is suppliable from above, and the at least one cigarette machine unit comprises a plurality of cigarette machine units, in which each of the plurality of cigarette machine units is suppliable from the second side. Furthermore, the method can include arranging at least two adjacent apparatuses such that aisles are formed between the at least two adjacent apparatuses, wherein the aisles are formed by the first sides of the two adjacent apparatuses or the second sides of the two adjacent apparatuses. Additionally, the method can include arranging a plurality of apparatuses such that respective adjacent apparatuses are spaced from each other such that aisles are formed by sides of adjacent apparatuses. Furthermore, the aisles formed by the arrangement of apparatuses along the substantially straight line can be continued by apparatuses adjacent along the direction of the line.  
      In a further aspect of the invention the apparatus for manufacturing and packaging cigarettes can include a cigarette machine comprising a plurality of components, a packaging machine structured and arranged to package the cigarettes in one of packages, packing units, cartons, and on pallets, and the packaging machine and at least one of the components being arranged along a substantially straight line.  
      In a further aspect of the invention at least one of the components can include at least one of a distributing unit, a strand unit, a filter-manufacturing unit, and a filter-tipping unit. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      In the following, the invention will be described by embodiments, without any restriction of the general inventive idea, with reference to the drawings. As far as all inventive details are concerned that are not explained in more details in the text, explicit reference is made to the drawings wherein:  
       FIG. 1  shows a schematic plan view of an inventive apparatus for manufacturing and packaging cigarettes;  
       FIG. 2  illustrates a schematic plan view of another inventive apparatus;  
       FIG. 3  is a schematic plan view of a third inventive apparatus;  
       FIG. 4  illustrates a schematic plan view of a still further inventive apparatus;  
       FIG. 5  is a schematic plan view of an arrangement of inventive apparatuses;  
       FIG. 6  shows a schematic plan view of another arrangement of inventive apparatuses;  
       FIG. 7  is a schematic plan view of a third arrangement of inventive apparatuses;  
       FIG. 8  illustrates a schematic plan view of another arrangement of the inventive apparatuses; and  
       FIG. 9  is a schematic plan view of another arrangement of inventive apparatuses. 
    
    
     DETAILED DESCRIPTION OF THE PRESENT INVENTION  
      In the following figures, the same elements are identified by the same reference numerals so that a repeated discussion of the respective elements may be dispensed with.  
       FIG. 1  is a schematic plan view of an inventive cigarette manufacturing and packaging apparatus  60 . The cigarette manufacturing and packaging apparatus  60  includes a packaging machine  9  and a cigarette machine  10 . The cigarette machine  10  includes a conventional tobacco distributor  11  that is known from the German Patent DE 36 19 579 C2. In this distributing unit  11 , tobacco is screened, for instance, for subsequent separation and final feed to two suction strand conveyors on which tobacco strands are formed. Downstream of the tobacco distributor  11 , a strand unit  12  is provided in which the tobacco strands so created are formed in a forming-fittings set (forming garniture) into the shape envisaged for the cigarette and are then wrapped up in cigarette paper. The cigarette paper is withdrawn from a cigarette paper supply  21  that may include cigarette paper bobbins in this example. A materials-handling station  41  is provided in order to permit perfect withdrawal. A loading device  31  serves to replenish the cigarette paper supply  21 . The production of the cigarette strand is described, for example, in the European Patent EP 0 582 136 B1 in the name of Hauni Maschinenbau AG. That document equally discloses also the formatting apparatus for the creation of the cigarette shape in an appropriate form.  
      Downstream of the strand unit, a filter-tipping unit  13  is provided by which the filter elements of double useful length are carried between two tobacco stocks wrapped up in cigarette paper for subsequently wrapping with lining paper and gluing. Then, the filter elements of double length are severed in the middle so that complete filter cigarettes are produced. A lining paper supply  22  is associated with the filter-tipping unit  13 , which is fed to the filter-tipping unit  13  by a materials-handling unit  42 . A loading device  32  is provided for charging the lining paper supply  22 . The cigarette machine  10  includes a tobacco distributor  11 , the strand unit  12 , and the filter-tipping unit  13 . Packaging material is arranged downstream of the cigarette machine  10 , which is composed of six units in this example. These units are a block-forming unit  14 , a collar-attaching unit  15 , a blanks unit  16 , a film wrapper unit  17 , a carton-packaging unit  18 , and a carton-wrapping unit  19 . It is equally possible to provide more or fewer units in the packaging machine  9 .  
      Initially, blocks are formed from a desired number of filter cigarettes in the block-forming unit  14 , which are then wrapped with an inner wrapper such as a tin foil. To this end, an inner-wrapper supply  23  is provided that is fed to the block-forming unit by a materials-handling station  43 . A loading device  33  is provided for replenishing the inner-wrapper supply  23 . Subsequently, a collar-attaching unit  15  is provided that attaches a collar to or under the block provided with an inner wrapper. In this embodiment, the collar-attaching unit  15  is provided with a collar supply  24  available in the form of bobbins. The respective collar material, for example cardboard, is withdrawn from a bobbin by the materials-handling station  44  and cut into an appropriate collar shape, if necessary punched for providing folding lines. A loading device  34  is provided for replenishing the collar supply  24 .  
      The wrapped cigarette blocks provided with a collar are then conveyed to a blanks unit  16  in which a cigarette package blank is folded around the cigarette block provided with a collar, and is then appropriately adhesively fastened. The blanks are available from a blanks supply  25  and fed by a materials-handling station  45 . The blanks supply  25 , is appropriately replenished by a loading device  35 . Then the cigarette package arrives in a film wrapper unit  17  where, for instance, a transparent polypropylene film is wrapped around the cigarette package. A package wrapper supply  26  is associated with the film wrapper unit  17 , with the wrapping paper being supplied to the film wrapper unit  17  by a materials-handling station  46 . The package wrapper supply  26  is replenished by a loading device  36 . Then, the cigarette packages provided with a carton wrapper in groups of 2×5 cigarette packages, for example, and provided with a folded blank for forming a carton. This is done by a carton packaging unit  18 . A carton blanks supply  27  is associated with the carton packaging unit  18 . The carton blanks are fed from the carton blanks supply  27  by a materials-handling station  47  to the carton packaging unit  18 . The carton blanks supply  27  is replenished by a loading device  37 .  
      Finally, the cigarette cartons arrive in a carton-wrapping unit  19  where, for instance, transparent polypropylene film is wrapped around the cartons. To this end, a carton wrapper supply  28  is provided. The carton-wrapping material is fed to the carton-wrapping unit  19  by a materials-handling station  48 . The carton wrapper supply  28  is  28  is replenished by a loading device  38 .  
       FIG. 1  moreover illustrates a tobacco inlet  52  that roughly indicates a tobacco supply from above at the tobacco distributor  11 .  
       FIG. 2  shows another inventive cigarette manufacturing and packaging apparatus  61 . The distinction from  FIG. 1  is in that the tobacco distributor  11  is not arranged along a straight line with the packaging machine  9  but rather crosswise relative to it. To this end, two units of the cigarette machine  10  are arranged along a line with the packaging machine  9 , i.e. the strand unit  12  and the filter-tipping unit  13 . Actually, however, all the supplies of the cigarette machine, are arranged along a substantially straight line directly on the cigarette machine and the packaging machine.  
       FIG. 3  is another schematic plan view of an inventive cigarette manufacturing and packaging apparatus  62 . This embodiment is in essential correspondence with the embodiment shown in  FIG. 1 . Here, merely a filter producing unit  20  is arranged ahead of the tobacco distributor. The filter producing unit  20  produces a rod-shaped filter from a filter tow arranged in a filter tow supply  50 . To this end, initially the filter tow is fed to a filter tow conveyor device by a filter tow stripper  51  and is then provided with a filter paper in a format in a manner known per se for being then conveyed into an endless filter strand. The endless filter strand is then cut into filter segments of a desired length. The filter paper is made available from a filter paper supply to the filter producing unit  20  by a materials handling station  49 . The filter paper supply  29  is replenished by a loading device  39 .  
      In the cigarette manufacturing and packaging device  62 , all the units of the cigarette machine, which includes also the filter producing unit  20  in this embodiment, all the units of the packaging machine  9  are arranged substantially along a straight line.  
       FIG. 4  illustrates another inventive embodiment of a cigarette manufacturing and packaging apparatus  63  wherein one part of the filter producing unit  20  is arranged at an angle of substantially 90° relative to the substantially straight line of the other units. This angled unit is the known AF unit marketed by Hauni Maschinenbau AG. This unit is joined by a KDF unit of Hauni Maschinenbau AG, which, in this embodiment, extends along a substantially straight line relative to the other units.  
      Elements shown in dashed lines in FIGS.  1  to  4  are envisaged to indicate doors that can be opened and closed in correspondence with the manipulation of the device.  
       FIG. 5  is a plan view of an arrangement of six inventive cigarette manufacturing and packaging apparatuses  60  according to  FIG. 1 . With this inventive arrangement, very small floor space is required for the installation of the cigarette manufacturing and packaging apparatuses  60 . Apart therefrom, the operation of the cigarette manufacturing and packaging apparatuses  60  is simplified and eventually the feed of packaging material and the material required for cigarette manufacture to the apparatus or the latter&#39;s supply with these materials is facilitated.  
      The inventive apparatuses  60  are arranged in such a way that respective operating sides  70  of the cigarette manufacturing and packaging apparatuses  60  are adjacent to each other and that supply or servicing sides  71  are adjacent to each other. This arrangement creates operator aisles  73  and supply aisles  72 . In the present embodiment, two respective operator aisles  73  are aligned on each other whilst two respective supply aisles  72  are aligned on each other. An operator is now only required to move in an operator aisle  73  in order to supervise two or even four cigarette manufacturing and packaging apparatuses  60 . Appropriate automatic apparatuses or robots, respectively, for supplying the cigarette manufacturing and packaging apparatuses  60  must move only in a supply aisle  72  so that the path length covered to supply of the apparatus can be minimized, with the result that possibly a smaller number of supply robots or automatic supply machinery may be utilized with the same output of the cigarette manufacturing and packaging apparatuses  60 .  
      In the embodiment according to  FIG. 5 , an additional intermediate aisle  74  is provided between the cigarette manufacturing and packaging apparatuses  60 , which intermediate aisle  74  extends transversely with respect to the substantially straight line of the arrangement of the units of the cigarette machines  10  and the packaging machines  9 .  
       FIG. 6  is a schematic plan view of another inventive arrangement of six cigarette manufacturing and packaging apparatuses  61  according to  FIG. 2 . In this case, corresponding supply aisles and intermediate aisles  74  are created. The same applies to  FIG. 7  illustrating a schematic plan view of an inventive arrangement of a cigarette manufacturing and packaging apparatuses  62  according to  FIG. 3 .  
       FIG. 8  accordingly illustrates another inventive arrangement of six cigarette manufacturing and packaging apparatuses  63  in correspondence with  FIG. 3 . In this embodiment, the preferred operator aisles  73  and supply aisles  72  are created. The inventive arrangements according to  FIGS. 6 and 8  require already a smaller floor space. The inventive arrangements according to  FIGS. 5 and 7  require even less floor space.  
      In a further inventive arrangement according to  FIG. 9 , four cigarette manufacturing and packaging apparatuses  64  are shown which, compared against the cigarette manufacturing and packaging apparatuses  60  to  63  described above are different. In this case, the wrapper supplies or materials supplies for the tobacco production, respectively, are not directly adjacent to the units of the packaging machine and the cigarette machine but are rather spaced therefrom. The feed of the respective materials is realized in this embodiment via supply lines  40  that are located above the heads of the operators or underneath the operators. In this embodiment, two supply aisles  72  are disposed between the respective supplies for alignment on each other. This permits a very rapid and efficient replenishment of the supplies by respective automatic feeders or robots, respectively. One respective supply aisle  73  for the operators is provided per cigarette manufacturing and packaging apparatus  64 , from where there is simple access to the supply side  70  of the cigarette machine and the respective packaging machine. Two respective supply sides  71  can be handled in the supply aisles  72 .  
      The arrangement according to  FIG. 9 , permits a very efficient utilization of the available space or of the given floor space made available.  
      It is possible to provide common logistics systems for coupling the individual cigarette machine units  11 ,  12 ,  13 ,  20  and packaging machine units or packaging machine elements  14  to  19 , which may also include buffer storages for completely finished or partly finished products. The well-known logistics systems may be mass flow systems, storage systems or rack systems. An optimum utilization of the installation area is achieved, however, when the apparatus are coupled to each other directly, as far as this is possible, without installing appropriate logistics components or systems between them.  
     List of Reference Numerals  
     
         
           9  packaging machine  
           10  cigarette machine  
           11  tobacco distributor  
           12  strand unit  
           13  filter-tipping unit  
           14  block-forming unit  
           15  collar-attaching unit  
           16  blanks unit  
           17  film wrapper unit  
           18  carton-packaging unit  
           19  carton-wrapping unit  
           20  filter-manufacturing unit  
           21  cigarette paper supply  
           22  lining paper supply  
           23  inner-wrapper supply  
           24  collar supply  
           25  blanks supply  
           26  package wrapper supply  
           27  carton blanks supply  
           28  carton wrapper supply  
           29  filter paper supply  
           31  to  39  loading device  
           40  supply line  
           41  to  49  materials-handling station  
           50  filter tow supply  
           51  filter tow stripper  
           52  tobacco inlet  
           60  to  65  cigarette manufacturing and packaging apparatus  
           70  operating side  
           71  supply side  
           72  supply aisle  
           73  operator aisle  
           74  intermediate aisle