Patent Publication Number: US-2023136380-A1

Title: Dunnage product transfer using an alignment reference plane

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to the field of packaging systems, and more particularly to a packaging system for transferring a dunnage product to a packaging container. 
     BACKGROUND 
     In the process of packing an article in a packaging container for shipping the article from one location to another, a protective packaging material (dunnage product) is typically placed in the packaging container with the article. The dunnage product is included to fill any voids or to cushion the article during the shipping process. While paper in sheet form could possibly be used as a protective packaging material, it may be preferable to convert the sheets of paper into a low-density dunnage product. This conversion may be accomplished by a dunnage conversion machine, such as those disclosed in commonly assigned U.S. Pat. Nos. 4,717,613; 5,829,231; and 7,722,519. 
     Once a dunnage product is formed by a dunnage conversion machine, it may be transferred to a transitional member or staging location, such as a table, a conveyor, a slide, a bin, etc., where the dunnage product may be stored until an operator manually transfers the dunnage product to a packaging container, as necessary. In doing so, an operator may need to manually manipulate the orientation and positioning of the dunnage product in the packaging container to ensure sufficient protective packaging of the article in the packaging container. 
     SUMMARY 
     The present disclosure describes a packaging system that consistently aligns and orients a dunnage product relative to a packaging container into which the dunnage product is to be transferred. The packaging system achieves this consistent alignment and orientation with respect to an alignment reference plane, at which both the dunnage product and the packaging container are to be registered in their respective locations prior to transferring the dunnage product into the packaging container. With both the dunnage product and the packaging container registered at the alignment reference plane, transferring the dunnage product into the packaging container with proper alignment and orientation may be accomplished without the need for further manipulation by an operator. For example, when the alignment reference plane extends vertically and the dunnage product is positioned above, in the vertical direction, the packaging container, and both the dunnage product and the packaging container are registered at the alignment reference plane, the dunnage product may be transferred into the packaging container, such as by being dropped. The dunnage product will retain its orientation relative to the alignment reference plane and the packaging container. This arrangement may be particularly useful for lining a bottom of a packaging container or for placing a dunnage product on top of the packaging container as a final step before closing the container for shipment. 
     An exemplary packaging system for transferring a dunnage product to a packaging container includes a dunnage sensor configured to detect the dunnage product registered at an alignment reference plane in a staging location. The packaging system also includes a package sensor configured to detect the packaging container registered at the alignment reference plane in a loading location. The packaging system further includes a dunnage placement apparatus configured to transfer the dunnage product from the staging location to the packaging container in the loading location after both the dunnage sensor detects the dunnage product registered at the alignment reference plane in the staging location and the package sensor detects the packaging container registered at the alignment reference plane in the loading location. 
     One or more embodiments of the packaging system may include one or more of the following features, such as a controller configured to receive a dunnage alignment signal, transmitted from the dunnage sensor, after the dunnage sensor detects the dunnage product registered at the alignment reference plane in the staging location. The controller also may be configured to receive a package alignment signal, transmitted from the package sensor, after the package sensor detects the packaging container registered at the alignment reference plane in the loading location. The controller further may be configured to transmit, upon receipt of both the dunnage alignment signal and the package alignment signal, a dunnage placement signal to the dunnage placement apparatus. Upon receipt of the dunnage placement signal, the dunnage placement apparatus may be configured to transfer the dunnage product from the staging location to the packaging container in the loading location. 
     The packaging system may include the dunnage sensor being configured to detect the dunnage product registered at the alignment reference plane in the staging location when at least one point, or at least one face, on a periphery of the dunnage product is aligned with the alignment reference plane. 
     The packaging system may include the package sensor being configured to detect the packaging container registered at the alignment reference plane in the loading location when at least one point, or at least one face, on a periphery of the packaging container is aligned with the alignment reference plane. 
     The staging location may be positioned above, in a vertical direction, the loading location. 
     The dunnage sensor may be configured to detect the dunnage product registered at the alignment reference plane in the staging location when the dunnage product has an orientation aligned with the packaging container registered at the alignment reference plane in the loading location. The package sensor may be configured to detect the packaging container registered at the alignment reference plane in the loading location when the packaging container has an orientation aligned with the dunnage product registered at the alignment reference plane in the staging location. 
     The packaging system may include a staging member for positioning the dunnage product in the staging location. The staging member may have a sloped bottom wall terminating at the alignment reference plane in the staging location. 
     The dunnage placement apparatus may include at least one gate member pivotably mounted to the staging member for pivoting between an open and closed position. In the closed position the at least one gate member may be configured to support the dunnage product in the staging location. In the open position the at least one gate member may be configured to transfer the dunnage product from the staging location to the packaging container in the loading location. 
     Upon receipt of the dunnage placement signal, the at least one gate member may be configured to pivot from the closed position to the open position. 
     The packaging system may include a supply of dunnage product. 
     The supply may include a dunnage conversion machine. 
     The supply may include a dunnage transfer assembly configured to transfer the dunnage product from the conversion machine to the staging member. 
     An exemplary method of transferring a dunnage product to a packaging container includes the step of detecting the dunnage product registered at an alignment reference plane in a staging location. The method also includes the step of detecting the packaging container registered at the alignment reference plane in a loading location. The method further includes the step of transporting the dunnage product from the staging location to the packaging container in the loading location after both the step of detecting the dunnage product registered at the alignment reference plane in the staging location and the step of detecting the packaging container registered at the alignment reference plane in the loading location. 
     One or more embodiments of the method may include one or more of the following features or steps, such as the step of detecting the dunnage product may be performed by a dunnage sensor, the step of detecting the packaging container may be performed by a package sensor, and the step of transporting may be performed by a dunnage placement apparatus. 
     The method may include the step of transmitting a dunnage alignment signal after the step of detecting the dunnage product registered at the alignment reference plane in the staging location. The method also may include the step of transmitting a package alignment signal after the step of detecting the packaging container registered at the alignment reference plane in the loading location. The method further may include the step of transmitting, by a controller, upon receipt of both the dunnage alignment signal and the package alignment signal, a dunnage placement signal to the dunnage placement apparatus. The step of transporting the dunnage product may occur upon receipt of the dunnage placement signal by the dunnage placement apparatus. 
     The step of detecting the dunnage product may occur when at least one point, or at least one face, on a periphery of the dunnage product is aligned with the alignment reference plane. 
     The step of detecting the packaging container may occur when at least one point, or at least one face, on a periphery of the packaging container is aligned with the alignment reference plane. 
     The step of detecting the dunnage product may occur when the dunnage product has an orientation aligned with the packaging container registered at the alignment reference plane in the loading location. The step of detecting the packaging container may occur when the packaging container has an orientation aligned with the dunnage product registered at the alignment reference plane in the staging location. 
     The dunnage placement apparatus may include at least one gate member pivotably mounted to a staging member, on which the staging location is located, for pivoting between an open and closed position. The step of transporting the dunnage product may include pivoting the at least one gate member from the closed position to the open position. 
     The step of transporting the dunnage product may include dropping the dunnage product from the staging location to the packaging container in the loading location. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a schematic layout of an exemplary packaging system; 
         FIG.  2    is a schematic diagram of the communications and control between components of the packaging system of  FIG.  1   ; 
         FIG.  3    is a perspective view of an exemplary embodiment of the packaging system of  FIG.  1   ; 
         FIG.  4    is a cross-sectional perspective view of an exemplary dunnage transfer assembly of the packaging system of  FIG.  3   ; 
         FIG.  5    is a perspective view of an exemplary dunnage placement apparatus of the packaging system of  FIG.  3   ; 
         FIG.  6    is a perspective view of the dunnage placement apparatus of  FIG.  5    in operation; 
         FIG.  7    is another perspective view of the packaging system of  FIG.  3   ; 
         FIG.  8    is a perspective view of the packaging system of  FIG.  3   ; 
         FIG.  9    is a cross-sectional perspective view of an exemplary packaging container having articles therein to be filled with a dunnage product using the packaging system of  FIG.  1   ; 
         FIG.  10    is a schematic diagram of an exemplary packaging method. 
     
    
    
     DETAILED DESCRIPTION 
     Turning now to the drawings, and initially to  FIG.  1   ,  FIG.  1    shows a schematic representation of an exemplary automated packaging system  10  for transferring a dunnage product  12  to (or into) a packaging container  14 . The illustrated packaging system  10  includes a dunnage supply  16  for supplying the dunnage product  12 , examples of which will be described in more detail below. The packaging system  10  also includes a staging member  18  for receiving the dunnage product  12  from the dunnage supply  16  and positioning, transferring, or conveying the dunnage product  12  to a staging location  20  on the staging member  18 . The staging location  20  is adjacent an alignment reference plane  28 . The alignment reference plane  28  forms part of a boundary of the staging location  20 , such that when the dunnage product  12  is properly positioned in the staging location  20 , the dunnage product  12  is registered at the alignment reference plane  28 . For example, the dunnage product  12  may be registered at the alignment reference plane  28  when at least one point, or at least one face, of a periphery of the dunnage product  12  is aligned with the alignment reference plane  28 . A dunnage sensor  30  is positioned adjacent the staging location  20  and the alignment reference plane  28  to detect the presence (or absence) of the dunnage product  12  registered at the alignment reference plane  28  in the staging location  20 . 
     The packaging system  10  also includes a package conveyor assembly  24 , for positioning, transferring, or conveying the packaging container  14  to a loading location  26 . The loading location  26  also is adjacent the alignment reference plane  28 . The alignment reference plane  28  forms part of a boundary of the loading location  26 , such that when the packaging container  14  is properly positioned in the loading location  26 , the packaging container  14  is registered at the alignment reference plane  28 . For example, the packaging container  14  may be registered at the alignment reference plane  28  when at least one point, or at least one face, on a periphery of the packaging container  14  is aligned with the alignment reference plane  28 . A package sensor  32  is positioned adjacent the loading location  26  and the alignment reference plane  28  to detect the presence (or absence) of the packaging container  14  registered at the alignment reference plane  28  in the loading location  26 . 
     In the illustrated embodiment, the alignment reference plane  28  extends vertically, and the staging location  20  is positioned directly above the loading location  26 . In this embodiment, therefore, the dunnage product  12  registered at the alignment reference plane  28  in the staging location  20  is oriented and aligned above, in the vertical direction, the packaging container  14  registered at the alignment reference plane  28  in the loading location  26 . Thus, at least one point, or at least one face, on a periphery of the dunnage product  12  (i.e., an end of the dunnage product  12 ) is aligned with at least one point, or at least one face, on a periphery of the packaging container  14  (i.e., an end wall of the packaging container  14 ) since both are registered at the reference plane  28 . 
     The packaging system  10  further includes a dunnage placement apparatus  22  for transferring the dunnage product  12  registered at the alignment reference plane  28  from the staging location  20  to a packaging container  14  registered at the alignment reference plane  28  in the loading location  26 . Specifically, after detection of the dunnage product  12  registered at the alignment reference plane  28  in the staging location  20  and detection of the packaging container  14  registered at the alignment reference plane  28  in the loading location  26 , the dunnage placement apparatus  22  transfers the dunnage product  12  to the packaging container  14  in such a way as to maintain the alignment and orientation of the dunnage product  12  relative to the packaging container  14 . 
     The packaging system  10  includes a system controller  34  for controlling the coaction and interaction of the various components of the packaging system  10 . The components of the packaging system  10  may, however, be controlled manually or independently of each other. The controller  34  may be a programmable controller, suitably programmed to operate the packaging system  10  in a desired manner for a given application. The functions of the controller  34  may be carried out by a single processor device or by separate devices for the various components of the packaging system  10 , suitably interfaced to coordinate the operation of packaging system  10  as a whole. 
     Turning to the schematic diagram depicted in  FIG.  2   , the controller  34  is configured to receive a dunnage alignment signal  64 , transmitted from the dunnage sensor  30 , after the dunnage sensor  30  detects the dunnage product  12  registered at the alignment reference plane  28  in the staging location  20 . The controller  34  also is configured to receive a package alignment signal  66 , transmitted from the package sensor  32 , after the package sensor  32  detects the packaging container  14  registered at the alignment reference plane  28  in the loading location  26 . After receipt of both the dunnage alignment signal  64  from the dunnage sensor  30  and the package alignment signal  66  from the package sensor  32 , the controller  34  is configured to transmit a dunnage placement signal  68  to the dunnage placement apparatus  22 . The controller  34  is configured to receive and send the aforementioned signals  64 ,  66 ,  68  over signal lines, depicted in  FIG.  2   . These signal lines may be wireless communication paths, dedicated conductors or wires, in a serial or parallel arrangement, or any other suitable means of communication as will be understood by a person of ordinary skill in the art. 
     Exemplary components of the packaging system  10  just described now will be described in more detail, starting with an exemplary embodiment of the dunnage supply  16  with reference to  FIGS.  3  and  4   . In the illustrated embodiment, the dunnage supply  16  includes a conversion machine  36  for producing the dunnage product  12  from a stock of sheet material  38 . The sheet stock material  38  may be provided in the form of a roll that may be supported on an integral stock roll holder assembly  40 , or the sheet stock material  38  may be provided in the form of a fan-folded stack. The sheet stock material  38  may consist of one or more, typically two or three, superimposed plies of paper, such as kraft paper. Paper is an exemplary stock material because it is biodegradable, recyclable, and composed of a renewable resource. 
     The sheet stock material  38  enters the conversion machine  36  at an upstream end and travels in a downstream direction through the conversion machine  36  to a downstream end. The conversion machine  36  converts the stock material  38  into a crumpled strip of dunnage that is relatively less dense than the sheet stock material  38  from which it was produced. The strip of dunnage produced by the illustrated conversion machine  36  has inwardly folded edge portions interconnected to maintain the integrity of the dunnage product  12 . The conversion machine  36  also may include provision for severing, as by cutting, the strip to form a discrete dunnage product  12  of desired length. The conversion machine  36  includes an outlet opening at the downstream end through which the conversion machine  36  may discharge a fully formed dunnage product  12 . The outlet opening thus may be referred to as a discharge opening and the downstream end may be referred to as the discharge end. 
     An exemplary dunnage product  12  produced by the illustrated conversion machine  36  includes one or more plies of sheet material that have side portions folded over center portions thereof to form laterally spaced-apart pillow portions extending along the length of the dunnage product  12 . The pillow portions are separated by a central band where lateral edge portions are brought together. The lateral edge portions, which may be overlapped, interleaved, or some combination thereof, are connected together and generally also connected to underlying center portions of the plies along the central band. 
     The packaging system  10  is not limited to the illustrated conversion machine  36 , and other types of conversion machines may be used to produce the same or other forms of dunnage products. The packaging system  10  also may operate without any conversion machine and may instead be supplied with a pre-formed dunnage product  12 . 
     As illustrated in  FIGS.  3  and  4   , the dunnage supply  16  may additionally or alternatively include a dunnage transfer assembly  42 , depicted in cross-section in  FIG.  4   . The dunnage transfer assembly  42  receives the dunnage product  12  and transfers the dunnage product  12  in a controlled manner to the staging member  18 . This controlled movement of the dunnage product  12  avoids problems that may arise from random movement of the dunnage product  12 , such as, for example, the dunnage product  12  skewing, tilting, or falling obliquely onto the staging member  18 . As a consequence of such random movements, the dunnage product  12  may not be properly oriented or aligned with the alignment reference plane  28  when it arrives at the staging location  20 . The dunnage transfer assembly  42  therefore is configured to avoid those problems. 
     In an embodiment having both the conversion machine  36  and the dunnage transfer assembly  42 , the dunnage transfer assembly  42  receives the dunnage product  12  from the conversion machine  36  and transfers the dunnage product  12  onto the staging member  18 . In the illustrated arrangement, the dunnage transfer assembly  42  receives the dunnage product from the opening at the discharge end of the conversion machine  36  in a first direction. The dunnage transfer assembly  42  then moves the dunnage product  12  in a second direction different from the first direction to the staging member  18 . In doing so, the dunnage transfer assembly  42  separates and makes independent the movement of the dunnage product  12  in the first direction and the movement of the dunnage product  12  in the second direction. 
     The dunnage transfer assembly  42  may be of any suitable structure or type. The dunnage transfer assembly  42  includes a mobile or stationary transfer surface  44  that receives the dunnage product  12 . The transfer surface  44  may be mounted for example between opposing side walls of the dunnage transfer assembly  42 . Once received on the transfer surface  44 , the dunnage transfer assembly  42  may slide the dunnage product  12  along the transfer surface  44 . In the illustrated embodiment, the dunnage transfer assembly  42  includes a plurality moving paddle members  46  for this purpose. The paddle members  46  may be mounted on a moving roller assembly  48  within the dunnage transfer assembly  42 , as depicted. The paddle members  46  may be uniformly spaced apart such that the space between relatively adjacent paddle members  46  is sized to accommodate a single dunnage product  12 . Accordingly, in an embodiment in which multiple dunnage products  12  are being supplied to the dunnage transfer assembly  42 , the dunnage transfer assembly  42  is configured to capture each dunnage product  12  separately, partitioning them one by one as they are advanced along the transfer surface  44 . 
     In the illustrated embodiment, the dunnage supply  16  includes a pair of dunnage conversion machines  36 , arranged to supply dunnage products  12  to the dunnage transfer assembly  42  from opposite sides. Thus, each dunnage conversion machine  36  fills alternate spaces between the paddle members  46 . 
     In another embodiment, the transfer surface  44  may itself be a conveyor, such as a series of powered rollers or a belt, that urges the dunnage product  12  along the transfer surface  44  toward the staging member  18 . In this embodiment, the transfer surface  44  may have at least one paddle member  46  mounted on the transfer surface  44  to partition the dunnage products  12  from each other in the same way as described in the previously described embodiment. This controlled partitioning and transferring of the dunnage products  12  also avoids problems that may arise from random or collective movement of more than one dunnage product  12  along the transfer surface  44  and onto the staging member  18 . For example, random or collective movement of the dunnage products  12  may result in the dunnage products  12  skewing, tilting, falling obliquely, or piling up on the staging member  18 . As a consequence of this, the dunnage products  12  may be improperly oriented or aligned with the alignment reference plane  28  when they arrive in the staging location  20 . As previously described, the dunnage transfer assembly  42  is therefore configured to avoid those problems. 
     The dunnage product  12  may be transferred to the staging member  18  through an opening  50  of the dunnage transfer assembly  42  located at a downstream end of the transfer surface  44 . The opening  50 , for example, may extend transversely with respect to the longitudinal axis of the dunnage transfer assembly  42  and have dimensions slightly greater than the dimensions of the dunnage product  12 . The staging member  18  may be positioned adjacent the opening  50  of the dunnage transfer assembly  42 , for example underneath the opening  50 . Accordingly, when the dunnage product  12  reaches the opening  50 , it will pass through the opening  50  onto the staging member  18  in a controlled manner, maintaining its alignment and orientation. 
     Now turning to  FIG.  5   , an exemplary embodiment of the staging member  18  will be described. In the illustrated embodiment, the staging member  18  includes a sloped bottom wall  52 , the top surface of which may be a smooth surface, much like a slide. The sloped bottom wall  52  may extend from underneath the opening  50  of the dunnage transfer assembly  42  to the staging location  20  and may have a width at least the width of the dunnage product  12 . Other forms of staging members may be used in conjunction with the packaging system  10 , such as receptacles, conveyors, etc. The staging member  18  may be positioned relative to the opening of the dunnage transfer assembly  42  to provide a different controlled path to the staging location  20 . 
     To optimize the “smoothness” of the top surface of the sloped bottom wall  52 , the sloped bottom wall  52  may be made of a material or have a top surface formed from a material having a low coefficient of friction with respect to the dunnage product  12 , such that the dunnage product  12  can slide substantially frictionlessly down the sloped bottom wall  52  with the force of gravity. Such a material may be, for example, ultra-high molecular weight (UHMW) plastic, stainless steel with a polytetrafluoroethylene (PTFE) coating, or # 2 B finish stainless steel, which is annealed, pickled, and bright cold rolled. As another alterative or additional feature, the staging member  18  may be configured to vibrate, either using actuators (not shown) that also provide rotational movement of the sloped bottom wall  52  of the staging member  18  (to drop the pads) by sequentially activating the actuators to ‘wiggle’ the wall  52  up and down to advance the pad to the staging location  20 , or with an added vibration actuator electrically connected to the staging member  18 , to encourage movement of the dunnage product  12  down the sloped bottom wall  52  of the staging member  18  and to the staging location  20  while maintaining proper alignment and orientation of the dunnage product  12 . 
     The angle of the sloped bottom wall  52  may be fixed or may be adjustable. For example, the bottom wall  52  may be sloped or inclined with respect to a horizontal axis by an angle that is sufficient to cause the dunnage product  12  to slide down the sloped bottom wall  52  with the force of gravity. An exemplary angle may be about ten to seventy degrees, more preferably about ten to forty-five degrees, and preferably about twenty-five to thirty degrees. The staging member  18  may include a hinge that provides for angular adjustments and a locking mechanism for securing the sloped bottom wall  52  in a fixed angular orientation. 
     As another alternative, the sloped bottom wall  52  may have varying pitch angles along its slope. For example, the sloped bottom wall  52  may have a first pitch angle at a lower end portion and a slightly steeper second pitch angle at an upper portion thereof, or vice-versa. The first and second pitch angles may be selected to ensure that a dunnage product  12  deposited thereon will slide along the sloped bottom wall  52  to the staging location  20  located at the bottom thereof, where the dunnage product  12  may be registered with the alignment reference plane  28 . 
     The staging member  18  also may include sidewalls (not shown) extending from at least one peripheral edge of the bottom wall  52 . The height of the sidewalls may be at least the height of the dunnage product  12 . The upstream end of the staging member  18  (proximal to the dunnage transfer assembly  42 ) may have a bottom wall  52  and sidewalls that are outwardly flared to form a wide mouth for capturing and guiding a leading end of the dunnage product  12  onto the staging member  18  atop the bottom wall  52  and between the sidewalls. 
     In the illustrated embodiment, the sloped bottom wall  52  of the staging member  18  may terminate at the alignment reference plane  28  with an end wall or stop mechanism  54 . The stop mechanism  54  is configured to provide a stop at the downstream end of the staging member  18  (distal to the dunnage transfer assembly  42 ), against which a dunnage product  12  moving down the sloped bottom wall  52  will stop. The stop mechanism  54  generally is aligned with the alignment reference plane  28 , such that when the dunnage product  12  reaches and stops at the stop mechanism  54 , the dunnage product  12  is registered at the alignment reference plane  28 . In other words, in the illustrated embodiment, the dunnage product  12  is registered at the alignment reference plane  28  when at least one point or at least one face of the dunnage product  12  is aligned with the stop mechanism  54  of the staging member  18  in the staging location  20 . 
     Once the dunnage product  12  is registered at the alignment reference plane  28 , its presence (and registration) may be detected by the dunnage sensor  30 . The dunnage sensor  30  is configured to transmit the dunnage alignment signal to the controller  34  of the packaging system  10  after the dunnage sensor  30  detects the dunnage product  12  registered at the alignment reference plane  28 , informing the controller  34  that the dunnage product  12  is registered with the alignment reference plane  28  in the staging location  20 . The controller  34  thus knows that the dunnage product  12  is at the staging location  20 , ready for the dunnage placement apparatus  22  to transfer the dunnage product  12  into the packaging container  14 . 
     As shown in  FIG.  6   , the dunnage placement apparatus  22  may be integrated into the staging member  18  itself and include at least one pivotable gate member  56 . For example, the sloped bottom wall  52  of the staging member  18  may include the at least one pivotable gate member  56 . The at least one pivotable gate member  56  may be mounted for pivotal movement between open and closed positions, for example, by brackets or hinges attached to the sidewalls or bottom wall  52  of the staging member  18 . Such pivotable movement may be effected by any suitable means, for example by an actuator operatively connected to the at least one gate member  56 . When the at least one gate member  56  is in its closed position, the at least one gate member  56  (effectively forming the sloped bottom wall  52  of the staging member  18 ) supports the dunnage product  12  in the staging location  20 . When the at least one gate member  56  is in its open position, however, the at least one gate member  56  no longer supports the dunnage product  12  in the staging location  20  (creating a passage through the sloped bottom wall  52  of the staging member  18 ) and instead transfers the dunnage product  12  to the packaging container  14  in the loading location  26 . For example, in the embodiment in which the packaging container  14  is located in the loading location  26  underneath the staging location  20 , when the at least one gate member  56  is in its open position, the dunnage product  12  may drop directly into the packaging container  14 . 
     The dunnage placement apparatus  22 , however, may be configured or operated in another manner to effect transfer of a dunnage product  12  from the staging location  20  into the packaging container  14  in the loading location  26 . For example, the dunnage placement apparatus  22  may include a pick and place unit which is capable of engaging the dunnage product  12  when registered at the alignment reference plane  28  in the staging location  20  and transferring it into the packaging container  14  registered at the alignment reference plane  28  in the loading location  26 . 
     Turning now to  FIGS.  6 - 8   , the package conveyor assembly  24  of the packaging system  10  will now be described in more detail. As previously mentioned, the package conveyor assembly  24  of the packaging system  10  is configured to position, transfer, or convey the packaging container  14  to the loading location  26 , where it may be accessible by the dunnage placement apparatus  22 . The package conveyor assembly  24  may include a conveyor  25  made of, for example, a series of powered rollers or a belt that urges the packaging container  14  along the conveyor assembly  24  toward the loading location  26 . 
     In the illustrated embodiment, the conveyor assembly  24  includes a package fill requirement sensor  58 , depicted best in  FIGS.  7  and  8   . The package fill requirement sensor  58  may be of any suitable type, such as an optical sensor, and may be located adjacent to or on the conveyor  25  of the conveyor assembly  24 . The package fill requirement sensor  58  is configured to determine the size and quantity of dunnage products  12  necessary to be transferred into any given packaging container  14  passing thereby. For example, as the packaging container  14  passes the packaging fill requirement sensor  58  on the conveyor  25 , the packaging fill requirement sensor  58  may be configured to measure or detect a distance D between the tallest article  60  in the packaging container  14  and a max fill line  62  of the packaging container  14 , depicted in  FIG.  9   . The packaging fill requirement sensor  58  may then be configured to send a fill requirement signal to the controller  34  after measuring the distance D, the fill requirement signal corresponding to a size and quantity of dunnage products  12  required to fill the packaging container  14 . The controller  32  may then be configured to send a dunnage size and quantity signal to the dunnage supply  16 , instructing the dunnage supply  16  to provide the required size and quantity of dunnage products  12  to the staging member  18  and in turn to the packaging container  14 . The supply of multiple dunnage products  12  may be performed in a controlled manner using the dunnage transfer assembly  42  as previously described. 
     Other types of package fill requirement sensors may be used with the packaging system  10 , such as ones that employ the use of reading elements. For example, the package fill requirement sensor may include a bar code reader for reading a code associated with the packaging container  14  passing thereby, the code being indicative of the size and quantity of dunnage products  12  required to be transferred to the packaging container  14 . In the same way as previously described, the bar code reader may be configured to send the code as the fill requirement signal to the controller  32  and the controller  34  may be configured to send a dunnage size and quantity signal to the dunnage supply  16 . 
     The conveyor  25  of the conveyor assembly  24  is configured to move the packaging container  14  to the alignment reference plane  28  in the loading location  26 , where the package sensor  32  detects its presence. The conveyor  25  may include features that ensure proper alignment and orientation of the container  14  with respect the alignment reference plane  28 . Once the packaging container  14  is registered at the alignment reference plane  28 , its presence (and registration) may be detected by the package sensor  32 . The package sensor  32  is configured to transmit the package alignment signal to the controller  34  of the packaging system  10  after the package sensor  32  detects the packaging container  14  registered at the alignment reference plane  28 . The package alignment signal is transmitted to inform the controller  34  that the packaging container  14  is registered at the alignment reference plane  28  in the loading location  26 . The controller  34  also may be configured to send a stop signal to the conveyor  25 , upon receipt of which the conveyor  25  is configured to stop. Therefore, the packaging container  14  may be temporarily or permanently stopped in a position and location where it is registered at the alignment reference plane  28  in the loading location  26 . 
     Upon receipt of both the dunnage alignment signal and the package alignment signal, the controller  34  is configured to transmit a dunnage placement signal to a dunnage placement apparatus  22 . In the embodiment depicted in  FIG.  6   , upon receipt of the dunnage placement signal, the dunnage placement apparatus  22  is configured to pivot the at least one gate member  56  from its closed position to its open position, thereby allowing the dunnage product  12  to drop into the packaging container  14 . In an embodiment in which there are at least two gate members  56  pivotable between a closed and open position, upon receipt of the dunnage placement signal from the controller  34 , the dunnage placement apparatus  22  may be configured to pivot only one of the at least two gate members  56  from its closed position to its open position. In another embodiment, the dunnage placement apparatus  22  may be configured to pivot one of the at least two gate members  56  from its closed position to its open position and only partially pivot the other of the at least two gate members  56  from its closed position to a partially open position. In another embodiment, the dunnage placement apparatus may be configured to cooperatively partially pivot each of the at least two gate members from their closed positions to their partially open positions. In each embodiment, a controlled transfer of the dunnage product  12  from the staging location  20  into the packaging container  14  may be achieved, effectively steering the dunnage product  12  into a specific position or location of the packaging container  14 . 
     A method of transferring a dunnage product to a packaging container, using the packaging system  10  described above, will now be described with reference to  FIG.  10   . The method includes the steps of detecting the dunnage product registered at the alignment reference plane in the staging location and detecting the packaging container registered at the alignment reference plane in the loading location. The method further includes the step of transporting the dunnage product from the staging location to the packaging container in the loading location after both the step of detecting the dunnage product registered at the alignment reference plane in the staging location and the step of detecting the packaging container registered at the alignment reference plane in the loading location. 
     The step of detecting the dunnage product registered at the alignment reference plane in the staging location may be performed by the dunnage sensor. The step of detecting the packaging container registered at the alignment reference plane in the loading location may be performed by the package sensor. The step of transporting the dunnage product from the staging location to the packaging container in the loading location may be performed by the dunnage placement apparatus. 
     The method may further include the steps of transmitting the dunnage alignment signal after the step of detecting the dunnage product registered at the alignment reference plane in the staging location, and transmitting the package alignment signal after the step of detecting the packaging container registered at the alignment reference plane in the loading location. The method also may include the step of transmitting, by the controller, upon receipt of both the dunnage alignment signal and the package alignment signal, the dunnage placement signal to the dunnage placement apparatus. The step of transporting the dunnage product may therefore occur upon receipt of the dunnage placement signal by the dunnage placement apparatus. 
     The step of detecting the dunnage product may occur when at least one point, or at least one face, on a periphery of the dunnage product is aligned with the alignment reference plane and the step of detecting the packaging container may occur when at least one point, or at least one face, on a periphery of the packaging container is aligned with the alignment reference plane. The step of detecting the dunnage product may occur when the dunnage product has an orientation aligned with the packaging container registered at the alignment reference plane in the loading location, and the step of detecting the packaging container may occur when the packaging container has an orientation aligned with the dunnage product registered at the alignment reference plane in the staging location. 
     The dunnage placement apparatus also may include at least one gate member pivotably mounted to a staging member, on which the staging location is located, for pivoting between an open and closed position. Accordingly, the step of transporting the dunnage product may include pivoting the at least one gate member from the closed position to the open position. The step of transporting the dunnage product may include dropping the dunnage product from the staging location to the packaging container in the loading location. 
     Although the invention has been shown and described with respect to a certain embodiment, equivalent alternations and modifications will occur to others skilled in the art upon reading and understanding this specification and the annexed drawings. In particular regard to the various functions performed by the above described integers (components, assemblies, devices, compositions, etc.), the terms (including a reference to a “means”) used to describe such integers are intended to correspond, unless otherwise indicated, to any integer which performs the specified function of the described integer (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiments of the invention. In addition, while a particular feature of the invention may have been described above with respect to only one of several illustrated embodiments, such feature may be combined with one or more other features of the other embodiments, as may be desired and advantageous for any given or particular application.