Patent Publication Number: US-10766641-B2

Title: Method and apparatus for a product settler

Description:
BACKGROUND OF THE INVENTION 
     Technical Field 
     The present invention relates to an apparatus and method for settling products in a package. 
     Background 
     Many foodstuffs, such as potato chips, are packaged in pillow pouch packages that are made using a form, fill and seal (“FFS”) machine. Typically, a form, fill and seal machine forms the film into a tube, seals the bottom of the tube, fills the partially sealed tube with product, and then seals the top of the tube to form a packaged product. Often, a form, fill and seal machine is oriented so that film travels in a direction that is generally vertical as the film is formed into a tube, filled with product and sealed. Such a machine is an example of a vertical form, fill and seal (“VFFS”) machine. 
     When the product being packaged is an irregularly shaped product such as potato chips, there can be large void spaces between each piece. The void space takes up volume in the package and requires the package to be larger than required for the product alone. This requires more resources, which is less environmentally friendly. It is also more expensive for producers and ultimately consumers. 
     To avoid these and other problems posed by void space, some form, fill and seal machines are fitted with product settlers. These settlers typically shake the product to make it settle into a more compact configuration and thereby reduce void space. 
     In addition to reducing void space in a product, it is desirable to package product more quickly. One way to increase the speed with which product is packaged is to increase the speed with which film is fed to the form, fill and seal machines. Other things being equal, continuously feeding film to a machine is faster than intermittently feeding film. 
     To take advantage of this principle, some machines, called continuous motion machines, are capable of running in a continuous mode in which film is continuously being advanced, as opposed to being paused intermittently. However, running a machine in continuous mode is incompatible with conventional settlers that grab or pinch the film. This is because grabbing or pinching will damage the film unless the film is paused. 
     Examples of conventional settlers that require a film to be paused include settlers with beater bars that grab and shake the film. Another conventional settler that requires film to be paused uses two swinging panels. The two panels are positioned below the product conduit and can rotate together like doors. When the panels come together, they pinch and seal off the film below the product conduit. After product falls on the closed panels, seal jaws come together to form an end seal on the film. This forms the bottom of a partially formed package. Then, the panels rotate open, which releases the film and allows the product to fall to the bottom of the partially formed package. This process of repeatedly dropping and catching the product causes the product to be settled. However, it can also damage the product by causing breakage, for example, of chips. 
     As these examples illustrate, when using conventional settlers, form, fill and seal machines must run in an intermittent mode in which the film is stopped when the settlers grab the film, and the film advances when the settlers release the film. As a result, many continuous motion machines do not even come with a settler. Other machines come with a settler that can be installed by a user, but the machine must then be run in an intermittent mode. Running machines in intermittent mode is inefficient and results in additional wear and tear on the machines and film. Thus, using a conventional settler with a continuous motion form, fill and seal machine can be undesirable. 
     Accordingly, it would be advantageous to have a settler that is compatible with a form, fill and seal machine running in continuous mode. For example, it is desirable to have a settler that does not grab film and can be used with a machine that continuously conveys the film. Such a settler would not require the film to be paused during production of packages. This could, in turn, avoid wear and tear on the machine and film caused by large transient forces that occur when starting and stopping the machine. 
     It would also be advantageous if an inventive settler could be used to produce product-filled packages more quickly than conventional settlers that require packaging film to be paused intermittently. 
     In addition, it would be desirable if the inventive settler reduced the volume that product occupies in a package. For example, it would be desirable if the settler reduced the volume occupied by a product at least as much as a conventional settler. 
     Furthermore, it would be desirable if an inventive settler could increase the head space in a package of a given size. For example, increased head space can help prevent product inside the package from being too close to, or caught in, the end seal of the package. This helps to ensure that the package is properly sealed. Increased head space can also help prevent other manufacturing defects, for example, unintended pleats and unintended tucks. It would be even more desirable if the inventive settler could increase head space and/or reduce manufacturing defects when compared to conventional settlers. 
     Likewise, it would be beneficial if the inventive settler did not break a substantial amount of product by impacting the product. For example, it would be beneficial if the settler were positioned so that it did not impact a substantial amount of the product through the packaging film. It would also be advantageous if the inventive settler could optionally be mounted somewhere besides the seal jaw carriage of a form, fill and seal machine. As another example, it would be beneficial if the inventive settler could operate intermittently or continuously. For example, it would be beneficial if the inventive settler could stop settling while the product is in a position to be damaged by the settler. However, after the product is no longer in such a position, the inventive settler would begin settling again. 
     Similarly, it would be desirable if the inventive settler decreased the amount of film required to package a given amount of product. This could help reduce waste, increase the environmental friendliness of a process, reduce manufacturing costs, and further increase the speed of a manufacturing process. For example, using a settler that can be used with a continuous motion form, fill and seal machine can increase the speed of a manufacturing process. Also, if the inventive settler could decrease the amount of film necessary to package a product, less film would need to be conveyed for a unit of product. This could further reduce the amount of time required to produce each unit. 
     In addition, it would be advantageous if the inventive settler did not interfere with the continuous motion of a package film when the inventive settler stopped. For example, it would be advantageous if the inventive settler had a low torque motor so that if the settler stopped running or even failed while the settler was in contact with a package film, the film could push the settler out of the path of the film, and the film could continue to be advanced. It would also be advantageous if the inventive settler could be stopped in a position where it does not impede the continuous conveyance of packaging film. 
     It would be another benefit if the inventive settler were simple compared to conventional settlers. For example, it would be beneficial if the inventive settler had fewer moving parts than conventional settlers, had a less complicated operating mechanism, and were easier to maintain, repair and/or replace. It would also be beneficial if the inventive settler required minimal training of or input from maintenance personnel. 
     Furthermore, it would be useful if the inventive settler were small compared to conventional settlers. For example, conventional settlers can have components that take up a large amount of space and it would be advantageous to avoid these components. 
     Additionally, it would be desirable if the inventive settler could be easily installed on existing form, fill and seal machines. For example, it would be desirable if the inventive settler were modular and could be easily added to existing continuous motion vertical form, fill and seal machines. It would also be useful if a modular form of the inventive settler were easier to maintain, repair, and/or replace than conventional settlers. For example, it would be desirable if an inventive settler needing maintenance could be easily removed from a continuous motion form, fill and seal machine and replaced with a recently serviced settler. It would also be desirable if the inventive settler were designed so that the form, fill and seal machine could run without needing to be substantially reconfigured if the inventive settler were removed and were not replaced. For example, the machine could be instructed to create bigger packages due to a lack of settling, but the machine would not require other reconfiguration. This could increase the versatility of a product manufacturing line and increase its resilience in the face of maintenance issues. 
     Similarly, it would be advantageous if a form, fill and seal machine were easier to maintain and repair when the inventive settler is used with the machine instead of a conventional settler. It would also be advantageous if the small size and location of the inventive settler made it easier to access and service the machine compared to conventional settlers. For example, the size and location of conventional settlers can block or substantially impede access to the seal jaw carriage of a form, fill and seal machine. In contrast, it would be advantageous if the inventive settler could be installed on one side of a machine making it easy to access the seal jaw carriage even when the inventive settler is installed. It would also be advantageous if the inventive settler could easily be removed in comparison to a conventional settler, for example, if the inventive settler were modular, as this would also increase the ease of servicing of form, fill and seal machine. 
     SUMMARY OF THE INVENTION 
     The present invention is a method and apparatus for settling products. For example, the inventors have developed a new type of settler that can be used in conjunction with a form, fill and seal machine even when the machine is running in continuous mode. 
     In a first aspect, the invention provides a method for settling a product in a package made on a form, fill and seal machine. The method comprises the steps: providing a package material on a product conduit of a form, fill and seal machine; forming a first end seal on the package material to form a partially formed package; filling the partially formed package with product; and settling the product in the partially formed package while continuously conveying the package material along the product conduit. 
     In a second aspect, the invention provides an apparatus comprising an improved continuous motion form, fill and seal machine. The machine comprises a product conduit, a conveyor, and seal jaws. The conveyor is positioned to convey a package material that is wrapped around the product conduit, and the conveyor moves the package material along the product conduit. The seal jaws are positioned adjacent to opposite portions of the package material to form a first end seal on the package material, thereby forming a partially formed package. The product conduit is positioned so that a product passing through the product conduit will enter the partially formed package after exiting the product conduit, and the product conduit is positioned above the seal jaws. The improvement comprises a product settler comprising a first object positioned to cause an impact against the package material. The impact agitates the package material and settles the product from an unsettled height to a settled height while the machine continuously conveys the package material along the product conduit. 
     In a third aspect, the invention provides a method for settling a product in a partially formed package. The method comprises the steps: providing a partially formed package; filling the partially formed package with a product; and settling the product in the partially formed package. The settling step comprises rotating a paddle wheel comprising at least one paddle against the partially formed package. 
     In a fourth aspect, the invention provides an apparatus comprising an improved product settler for settling product in a partially formed package. The improved product settler comprises a paddle wheel. The paddle wheel comprises at least one paddle that is positioned to cause an impact against the partially formed package. The impact agitates the partially formed package and thereby settles the product. 
     The invention described herein provides many advantages in its various embodiments. In one aspect, the invention provides a settler that is compatible with a form, fill and seal machine running in continuous mode. For example, it provides a settler that does not grab film and can be used with a machine that continuously conveys the film. Such a settler does not require the film to be paused during the production of packages. This, in turn, avoids large transient forces that occur when starting and stopping the machine and avoids associated wear and tear on the machine. In one embodiment, the inventive settler comprises a rotating paddle wheel with a paddle that impacts the film in substantially the same direction that the film is conveyed. Accordingly, in one embodiment, the inventive settler comprises paddles that intermittently contact the film and scrub the film in the film&#39;s direction of conveyance. 
     The inventive settler also can be used to produce product-filled packages more quickly than conventional settlers, which require packaging film to be paused intermittently. 
     In addition, the inventive settler can reduce the volume that product occupies in a package. For example, the settler reduces the volume occupied by a product at least as much as a conventional settler. 
     Furthermore, the inventive settler increases the head space in a package of a given size. For example, increased head space can help prevent product inside the package from being too close to, or caught in, the end seal of the package. This helps to ensure that the package is properly sealed. Increased head space can also help prevent other manufacturing defects, for example, unintended pleats and unintended tucks. Additionally, the inventive settler can increase head space and/or reduce manufacturing defects when compared to conventional settlers. 
     As another advantage, the inventive settler does not break a substantial amount of product by impacting the product. In one embodiment, the inventive settler causes little or no breakage of product. For example, the settler can be positioned so that the settler does not impact a substantial amount of the product through the packaging film when the settler is in operation. In one embodiment, the inventive settler can be mounted somewhere besides the seal jaw carriage of a form, fill and seal machine. For example, the settler can be positioned just below the product conduit of a form, fill and seal machine so that the settler does not impact a substantial amount of product as the product falls from the product conduit and into the packaging film. The inventive settler can also operate intermittently or continuously. For example, the inventive settler can stop settling while the product is in a position to be damaged by the settler. However, after the product is no longer in such a position, the inventive settler can begin settling again. 
     The inventive settler can also decrease the amount of film required to package a given amount of product. This helps reduce waste, increase the environmental friendliness of the process, reduce manufacturing costs, and further increase the speed of a manufacturing process. For example, the inventive settler can be used with a continuous motion form, fill and seal machine which increases the speed of a manufacturing process relative to using an intermittent machine. Also, although conventional settlers cannot be used with continuous motion machines, the inventive settler can. Accordingly, the inventive settler can decrease the amount of film necessary to package a product on a continuous motion machine. Since less film needs to be conveyed for a unit of product, this further reduces the amount of time required to produce each unit. 
     In addition, the inventive settler does not interfere with the continuous motion of a package film when the inventive settler stops. For example, the inventive settler has a low torque motor so that if the settler stops running or even fails while the settler is in contact with a package film, the film can push the settler out of the path of the film, and the film can continue to be advanced. As another example, the inventive settler can be stopped in a position where it does not impede the continuous conveyance of packaging film. 
     The inventive settler is also simple compared to conventional settlers. For example, compared to conventional settlers, the inventive settler has fewer moving parts, has a less complicated operating mechanism, is easier to maintain, is easier to repair and/or is easier to replace. The inventive settler also requires minimal training of and input from maintenance personnel. 
     Furthermore, the inventive settler is small compared to conventional settlers. For example, conventional settlers can have components that take up a large amount of space and the inventive settler advantageously avoids this. 
     Additionally, the inventive settler can be easily installed on existing form, fill and seal machines. For example, in one embodiment, the inventive settler is modular and can be easily added to existing continuous motion vertical form, fill and seal machines. Also, the inventive settler is easier to maintain, repair, and/or replace than conventional settlers. For example, a modular form of the inventive settler can be installed, uninstalled, and serviced with ease. As another example, the inventive settler can be easily removed from a continuous motion form, fill and seal machine and replaced with another inventive settler. Also, the inventive settler is designed so that the form, fill and seal machine can run without needing to be substantially reconfigured if the inventive settler is removed and is not replaced. For example, the machine can be instructed to create bigger packages due to a lack of settling, but the machine does not require other reconfiguration to continue producing product. Accordingly, the inventive settler increases the versatility of a product manufacturing line and increases its resilience in the face of maintenance issues. 
     Similarly, a form, fill and seal machine is easier to maintain and repair when the inventive settler is used with the machine instead of a conventional settler. In one embodiment, the small size and location of the inventive settler during operation make the machine easier to access and service when compared to machines using conventional settlers. For example, the size and location of conventional settlers can block or substantially impede access to the seal jaw carriage of a form, fill and seal machine. In contrast, the inventive settler can be installed on one side of a machine, rather than, for example, having components that are adjacent to opposite sides of the machine. For example, the inventive settler can comprise a paddle wheel that is positioned adjacent to one side of a product conduit of a form, fill and seal machine. Accordingly, when the inventive settler, as opposed to a conventional settler, is installed on a machine, it is easier to access the components (e.g., seal jaw carriage) of the machine. Furthermore, the inventive settler can easily be removed in comparison to a conventional settler. When the inventive settler is modular, this further increases the ease of servicing a form, fill and seal machine when compared to servicing a machine using a conventional settler. 
     Another benefit of the inventive settler is that it can be used to settle many different kinds of products. For example, the inventive settler is especially useful for settling larger or irregularly shaped products such as tortilla chips or potato chips. The settler is also useful for settling smaller or regularly shaped products such as Cheetos® cheese puffs. Although, when compared to larger or irregularly shaped products, smaller or regularly shaped products may experience less settling. 
     Other aspects, embodiments and features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings. The accompanying figures are schematic and are not intended to be drawn to scale. In the figures, each identical or substantially similar component that is illustrated in various figures is represented by a single numeral or notation. For purposes of clarity, not every component is labeled in every figure. Nor is every component of each embodiment of the invention shown where illustration is not necessary to allow those of ordinary skill in the art to understand the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will be best understood by reference to the following detailed description of illustrative embodiments when read in conjunction with the accompanying drawings, wherein: 
         FIG. 1  is a flow chart depicting one embodiment of a process according to the invention; 
         FIG. 2  is a schematic view of one embodiment of the invention for use with a vertical, form, fill, and seal machine; 
         FIGS. 3A-3C  are a progression of schematic views of one embodiment of the invention depicting a product settler being used to settle product; 
         FIGS. 4A-4B  are schematic depictions of a package for product that can be settled by one embodiment of the invention; 
         FIG. 5A  is a schematic top view of one embodiment of the invention; 
         FIG. 5B  is a schematic side view of the embodiment shown in  FIG. 5A ; 
         FIG. 5C  is a schematic front view of the embodiment shown in  FIG. 5A ; 
         FIGS. 6A-6C  are schematic perspective views depicting one embodiment of a product settler; 
         FIG. 7  is a schematic view of one embodiment of the invention for use with a vertical, form, fill, and seal machine. 
     
    
    
     DETAILED DESCRIPTION 
     Several embodiments of Applicant&#39;s invention will now be described with reference to the drawings. Unless otherwise noted, like elements will be identified by identical numbers throughout all figures. 
     One embodiment of the invention will now be described with respect to  FIGS. 1, 2, 3A-3C, and 4A-4B . The embodiment is a method for settling a product in a package  404  made on a form, fill and seal machine. The method comprises the following steps. First, in a providing step  102 , a film  202  is provided on a product conduit  204  of a form, fill and seal machine  206  (e.g. a vertical form, fill and seal machine). 
     Second, in a longitudinal sealing step  104 , the film  202  is sealed to form a longitudinal seal  402  (e.g. back seal) on a package  404 .  FIGS. 4A-4B  depict a package  404  with a first face (e.g., first end  414  or a bottom  414 ), a second face (e.g., a second end  416  or a top  416 ), a third face  408  (e.g., a front face), a fourth face  406  (e.g., a back face), a fifth face  410  (e.g., a right face), and a sixth face  412  (e.g., a left face). An example of a longitudinal seal  402  (e.g., a back seal) can be seen on the fourth face  406  (e.g., back side) of the package  404 . The longitudinal seal  402  can be useful to form a tube  210  from a film  202  that has been wrapped around a product conduit  204  (e.g., a hollow former). As shown, the tube  210  has a continuous circumference  218 . Although a longitudinal seal  402  is provided in some embodiments, in other embodiments, a longitudinal seal is not provided. Accordingly, the longitudinal sealing step  104  is optional. When a longitudinal sealing step  104  is not used to provide a tube-shaped film  210 , the tube-shaped film can be provided in other ways, for example, by using a process to produce a blown film, which can have a continuous circumference  218  without using a longitudinal sealing step  104 . 
     Third, in a first end-sealing step  106 , a first end seal  212   a  is formed on the film  202  to form a partially formed package (e.g., partially formed second package  404   b  in  FIG. 2 ). The first end seal  212   a  is located on a first face (e.g., first end  414 ) of the partially formed package. As can be seen in  FIG. 2 , a first package  404   a  has already been formed and a second package  404   b  is a partially formed package. However, before the first package  404   a  was formed, it was also a partially formed package (e.g., partially formed second package  404   b ). 
     Fourth, in a filling step  108 , the partially formed package (e.g., partially formed package  404   b ) is filled with a product  302 . An example of how a package  404   b  can be filled with product is illustrated in  FIGS. 3A-3B . The product  302  enters the package  404   b  through the product conduit  204 . As the product enters the package, it moves in a fill direction  304 , and the product  302  falls under the force of gravity. Accordingly, as shown, the fill direction  304  is downward, although other fill directions are also possible. 
     Fifth, in a settling step  110 , the product  302  in the package (see, e.g., partially formed second package  404   b  in  FIGS. 3A-3B ) is settled while the film  202  is continuously conveyed along the product conduit  204  in a direction of conveyance  306 . In one embodiment, the package material is continuously conveyed at a location where the package material is formed into a package (or partially formed package). Additionally, as shown in  FIG. 2 , the film is continuously conveyed in a direction of conveyance  306  at the product conduit  204 , but the film can also be conveyed in a different direction of conveyance  307  at another location. 
       FIGS. 3A-3C  illustrate how product  302  is settled in a partially formed package  404   b . In one embodiment, the inventive settler includes a paddle wheel that rotates and contacts (e.g., scrubs) a package film in the direction of the film&#39;s conveyance. The contact between the paddle wheel and the film causes the film to shake and thereby settles product inside the film. 
       FIG. 3A  shows a package  404   b  being filled with the product  302  under the force of gravity.  FIG. 3B  illustrates how the product  302  has accumulated at the first end  414  of the partially formed package  404   b . A product settler  308  is actuated to cause the product  302  to settle into a more compact configuration as shown in  FIG. 3C . As shown in  FIG. 3B  the product settler settles the product so that it requires less longitudinal space in the partially formed package  404   b . For example, in one embodiment, before settling, the first end of a package is at a first-end product line  310  and the product is longitudinally distributed (e.g., in a longitudinal direction along central axis  334 ) in the package from the first-end product line  310  to an unsettled second-end product line  314  (e.g., unsettled level or height of the product). However, after settling, the product  302  settles to a settled second-end product line  312  (e.g., settled level or height of the product). Accordingly, the unsettled package film length  316  required for the unsettled product  302  is greater than the settled package film length  318  required for the settled product  302 . For example, as shown in  FIGS. 3A and 3B , the unsettled package film length  316  is the distance from the first-end product line  310  to the unsettled second-end product line  314  of the product  302 . Similarly, the settled package film length  318  is the distance from the first-end product line  310  to the settled second-end product line  312  of the product  302 . Although the settled and unsettled package film lengths indicate the length of film required for a column of product, the overall package length can be greater, for example, to accommodate folds, gussets, seals, and any desired head space. 
     In some embodiments, the settled package film length  318  required for settled product is about 0.5 to about 1.0 inches shorter than the unsettled package film length  316  required for unsettled product. Accordingly, in some embodiment, the settler can reduce overall package lengths for a product by about 0.5 to about 1.0 inches. 
     In some embodiments, the settler  308  settles product  302  while the product is falling. In other embodiments, the settler  308  settles product  302  after the product has fallen. In some embodiments, the settler  308  settles product  302  while the product is falling and after the product has fallen. In some embodiments, the settler  308  comprises a paddle (e.g., one of a plurality of paddles  320   a,b ) that rotates in a rotational direction  322  so that when the paddle contacts the film  202 , the paddle pushes the film generally in the direction of conveyance  306  of the film. 
     Sixth, in a second end-sealing step  112 , a second end seal  212   b  is formed on the partially formed package  404   b  to form a package  404   a . The second end seal  212   b  is located on a second face of the package (e.g., second end  416  of the first package  404   a ). This can be seen, for example, in  FIG. 2 . 
     In the illustration shown in  FIGS. 4A-4B , the first end seal  212   a  is approximately perpendicular to the longitudinal seal  402  (e.g., a back seal). 
     In one embodiment, the settling step  110  comprises the step of intermittently contacting the package (e.g., the partially formed second package  404   b  in  FIG. 2 ) to move the package, thereby moving the product  302  in the package and causing the product to settle. 
     In one embodiment, the settling step further comprises the step of intermittently applying a force to the film (e.g., by impacting or contacting the film) that does not pause the conveyance of the film. For example, the component of the force that is opposed to the conveyance of the film is not sufficient to pause the conveyance of the film. 
     In one embodiment, the settling step  110  further comprises the steps of continuously or intermittently rotating a paddle wheel  326  that comprises a paddle (e.g., paddle  320   a  or paddle  320   b ). The paddle is rotated into contact with the package (e.g., second package  404   b  in  FIG. 3A ), thereby moving the product  302  inside the package. In addition to using a paddle wheel to intermittently contact the package film, other objects and mechanisms (e.g., a single bar that moves into and out of contact with the film) can also be used to intermittently contact the film. 
     In one embodiment, gas is directed into the partially formed package  404   b . For example, some form, fill and seal machines  206  use pressurized gas to maintain positive pressure inside the package  404   b . Such a machine can also be used in conjunction with the inventive settler. For example, when pressured gas is used, it can be directed in the fall direction  304  shown in  FIG. 3A . The gas pressurizes the inside of the package  404   b . This pressure provides some structural rigidity to the package  404   b  and provides resistance to the paddle (e.g., one of a plurality of paddles  320   a,b ) when the paddle impacts the film  202  of the package  404   b . Upon impact, the paddle pushes the film  202  inward. However, after the impact, there is a period of time before the paddle again impacts the film. During the period of time between impacts, the pressure of the gas inside the package  404   b  provides a force (e.g., force  324  in  FIG. 3B ) to push the film  202  out before it is again impacted by a paddle  320   a,b . The cycle of film being pushed in by impact from the paddle and the film being pushed out by the pressure from the gas causes the film to vibrate (e.g., shake or oscillate), which in turn, causes the product  302  inside the partially formed package  404   b  to settle (e.g., in a longitudinal direction along central axis  334 ). This cycle is shown with reference to the partially formed package  404   b  in  FIGS. 3B-3C . Although, this cycle has been described in the context of using a pressurized gas to return the film to an original position after the film is deformed by impact, in other embodiments, the film may be sufficiently elastic to return to an original position even without using the pressurized gas. 
     In one embodiment, gas is directed (e.g., in the fill direction  304 ) into the package (e.g., partially filled second package  404   b  in  FIG. 3A ) in the form of a first jet of gas (e.g., air). In one embodiment, the first jet is directed into the package  404   b  intermittently. For example, in one embodiment, the first jet is activated 520 milliseconds after a first end seal is formed on the package. The first jet is active for 1465 milliseconds and then becomes inactive. Additionally, in one embodiment, a plurality of jets are directed into the package. For example, a second jet of gas (e.g., air) can be directed (e.g., in the fill direction  304 ) into the package  404   b . In some embodiments, the second jet is directed into the package  404   b  intermittently. For example, in one embodiment, the second jet is activated 120 milliseconds after the first jet becomes inactive. The second jet is active for 1465 milliseconds and then becomes inactive. 
     In one embodiment, the paddle wheel  326  rotates continuously. In another embodiment, the paddle wheel  326  rotates intermittently. When the paddle wheel  326  rotates intermittently, the paddle (e.g. paddle  320   a  or paddle  320   b ) also rotates intermittently. In one embodiment, a paddle rotates intermittently in the sense that an actuator (e.g., motor  616  in  FIGS. 6B-6C ) continuously rotates the paddle for a first period of time (e.g., 1500 milliseconds and then the actuator is inactive for a second period of time (e.g., 750 milliseconds). In one embodiment, after the actuator  616  rotates the paddle, the actuator stops the paddle in a desired position (e.g., so that the paddle is not in contact with the film). In one embodiment, the actuator  616  actively accelerates the paddle to increase or decrease its angular velocity. In another embodiment, the actuator only actively accelerates the paddle to increase its angular velocity and the paddle is allowed to decelerate passively (e.g., due to frictional forces). In some embodiments, the paddle wheel rotates at about 600 to 700 revolutions per minute (rpm), at about 660 rpm, or at about 600 rpm. 
     One embodiment of the invention will now be described with reference to  FIGS. 2, 3A-3C, 5A-5C, 6A-6C, and 7 . For example,  FIG. 2  depicts an apparatus comprising an improved product settler  308  for use with a continuous motion form, fill, and seal machine  206 . The form, fill, and seal machine comprising a product conduit  204 , a conveyor (e.g., pull belts  214   a,b ), and seal jaws  216   a - d . The continuous motion form, fill and seal machine is continuous in the sense that a package film  202  is continuously conveyed along a product conduit  204 . For example, the conveyor  214   a,b  is positioned to convey (e.g., positioned to contact) the package film  202  that is wrapped around the product conduit  204 . The conveyor  214   a,b  continuously moves the package film  202  along the product conduit  204 . The seal jaws  216   a - d  are positioned adjacent to opposite portions (e.g., faces  408 ,  406  in  FIGS. 4A-4B ) of the package film  202  to form a first end seal  212   a  on the package film when the seal jaws  216   a - d  move together and the package film is pressed between the seal jaws. This forms a first end seal  212   a  on a first face  414  of a package (e.g., partially formed second package  404   b ). The product conduit  204  is positioned so that a product (e.g., product  302  in  FIGS. 3A-3C ) passing through the product conduit will enter the package (e.g., second package  404   b ) after exiting the product conduit. The product conduit  204  is positioned higher than (e.g., above) the seal jaws  216   a - d.    
     As seen in  FIG. 2  and  FIG. 7 , a first seal jaw  216   a  rotates around a first axis of rotation  220   a , and a second seal jaw  216   b  rotates around a second axis of rotation  220   b . Additionally, a third seal jaw  216   c  rotates around the first axis of rotation  220   a , and a fourth seal jaw  216   d  rotates around the second axis of rotation  220   b . As the first and second seal jaws  216   a,b  rotate, they come together to seal and cut the package film  202  (e.g., to form a first end seal  212   a  on the package film). As shown in  FIG. 7 , as the seal jaws rotate a sealing face  217  of each seal jaw  216   a - d  faces the package film  202  and the package film is pressed between seal jaws  216   a - d  to form a seal. Likewise, as the third and fourth seal jaws  216   c,d  rotate, they come together to seal and cut the package film  202  (e.g., to form a second end seal  212   b  on the package film). In some embodiments, for example, as shown in  FIG. 2 , a second end seal  212   b  for a first package  404   a  is formed simultaneously with a first end seal  212   a  for a second package  404   b.    
     As shown in the embodiment of  FIG. 7 , the first seal jaw  216   a  and third seal jaw  216   c  are fixed to a first rotating seal jaw carriage  220   a . Similarly, the second seal jaw  216   b  and fourth seal jaw  216   d  are fixed to a second rotating seal jaw carriage  220   b . As shown in  FIG. 2 , the seal jaws  216   a - d  rotate in a direction  222   a,b  so that when the seal jaws  216   a - d  contact the package film  202 , the seal jaws have a translational velocity that is generally parallel to a direction of conveyance  306  of the package film. This is advantageous as it permits the package film  202  to continuously move in the direction of conveyance while the seal jaws  216   a - d  seal and cut the package film  202  to form packages (e.g., package  404   a ). This is an example of a continuous form, fill and seal machine  206 . In one embodiment, a form, fill and seal machine produces at least about 25 packages (e.g. package  404  or package  404   a ) per minute. In one embodiment, a form, fill and seal machine produces at least about 40 packages per minute. 
     Generally speaking, because the inventive settler does not pause a package film, the number of packages per minute that a machine produces with the inventive settler is greater than the number of packages per minute that a machine produces when using a conventional settler. For example, the speed at which packages of product are produced can depend on the speed at which a film is conveyed for forming a package, the speed at which the package is filled with product, and any pause in conveying the film that is required to settle a product. If a package can be filled with product faster than the film can be conveyed into position to form a package, the limiting factor for producing a package of product is the speed at which the film is conveyed. Furthermore, if film speed is the limiting factor for the rate at which packages of a product can be manufactured, pausing the film during the activation of a conventional settler will further reduce the number packages per minute produced. Thus, when film speed is the limiting factor for a machine&#39;s rate of package production and settling is desired, settling with the inventive settler will result in an increased rate of package production when compared to settling with a conventional settler. 
     Accordingly, the product settler  308  is especially useful in conjunction with continuous, form, fill and seal machines because the product settler does not require the package film  202  to stop in order to settle product  302  in the package film. Although the product settler  308  has been described with reference to a continuous form, fill and seal machine, the product settler can also be used with machines that intermittently advance the package film  202 . An example is any form, fill and seal machine that that stops or pauses the film  202  of a package  404   a  while the package  404   a  is being formed. Although a partially formed package has been described with reference to a package that has been made on a form, fill and seal machine, this is only an illustrative example. 
     As another example, the product settler can be used to settle product in a package that is open. For example, a partially formed package can be an open package and the formed package can be the closed package. Although using a product settler on a package that is open, but otherwise formed, may not result in savings related to package materials (e.g., film or paper), it can still provide other benefits. For example, it can decrease the size of the package and reduce costs associated with shipping, including secondary packaging costs for items such as shipping crates. 
     With reference to  FIGS. 3A-3C , a product settler  308  is positioned to agitate a product  302  in the package film  202 . The product settler  308  comprises a first object (e.g., paddle  320   a,b ) positioned to cause an impact against the film  202 . The impact agitates the film  202  and settles the product  302  from an unsettled height  314  to a settled height  312  while a form, fill and seal machine  206  continuously conveys the film along the product conduit  204 . The impact against the film can be caused directly or indirectly by the first object. 
     An example of an object directly impacting the film is shown in  FIGS. 3A-3C . As shown, the product settler  308  comprises a rotatable paddle wheel  326  and the paddle wheel comprises a paddle (e.g., one of a plurality of paddles  320   a,b ). The paddle is positioned so that, as the paddle wheel  326  rotates, the paddle causes agitation of the product  302  and thereby settles the product. In the example shown in  FIGS. 3A-3C , the paddle intermittently contacts the package film  202  thereby causing agitation of the product  302 . 
     In some embodiments, a first object (e.g., paddle  320   a ) is positioned to intermittently and directly contact the package film  202  and the first object thereby agitates the product  302 . In other embodiments, the first object (e.g., paddle  320   a ) is positioned to intermittently and directly contact a second object (e.g., the product conduit  204 ), and the second object contacts the product film  202  and thereby agitates the product  302 . 
     As shown in  FIGS. 3B-3C , the product settler  308  can be positioned adjacent to a tube of film  202 , below the product conduit  204 , and above the unsettled second-end product line  314 . For example, this can provide settling of a product without resulting in breakage of the product. The risk of breakage can be further reduced by running the product settler intermittently. For example, the product settler can be paused while product is falling and actuated after the product has fallen past the product settler. 
     In one embodiment, the package film  202  comprises an impact face (e.g., back side  406  in  FIG. 4B ). The impact face  406  is adjacent to the product settler  308 , as shown, for example, in  FIGS. 3A-3C . When the impact face  406  of the package film  202  hangs under the force of gravity (which as shown in  FIGS. 3A-3C  is the same as the direction of conveyance  306 ), the impact face defines a first position of the impact face (e.g., as shown in  FIG. 3A ). The settler  308  is positioned so that as the paddle (e.g., paddle  320   a ) rotates, a first tip  328  of the paddle will reach past the first position by a first distance  330 . In one embodiment, as the paddle (e.g., paddle  320   a ) rotates, the first distance  330  reaches a maximum of about 1 inch. In one embodiment, the first distance  330  reaches a maximum of about 0.5 inch. In one embodiment, the ratio of the first distance to the diameter of the product conduit (e.g., former) is a maximum of about 0.041. In one embodiment, the ratio of the first distance to the diameter of the product conduit (e.g., former) is a maximum of about 0.143. In one embodiment, the settler  308  is positioned so that, as the paddle (e.g., paddle  320   a ) rotates, the paddle will first contact the package film  202  at a first point that is a second distance  332  below the product conduit  204 . In some embodiments the second distance  332  is about 0.5 inch to about 3.6 inches. 
     In one embodiment, the settler  308  is used with a form, fill and seal machine that further comprises a source of pressurized gas (e.g., compressor  224 ). In one embodiment, the source of pressurized gas  224  comprises a nozzle  226  to direct the pressurized gas into the package film  202 . In one embodiment, the source of pressurized gas  224  is selected from the group consisting of a fan, a blower, or a centrifugal compressor. 
     In one embodiment, pressurized gas is used to provide pressure on the inside of the package film  202 . This can be useful when a package film is not resilient enough on its own to move out of a deformed position (e.g., the deformed position illustrated in  FIG. 3B ) that results when the settler  308  impacts the package film  202 . When pressurized gas is used and the impact face  406  of the film  202  is not in a deformed position caused by the settler  308 , the position of the impact face will be different from the position of the impact face when the inside of the package film is not under pressure. In other words, rather than being in a first position as illustrated in  FIG. 3A , the impact face  406  will be in a second position that can be similar to the position illustrated in  FIG. 3A , but can also be further from a central axis  334  of a package (e.g., package  404   b ). 
     As another example, in one embodiment, the package film  202  comprises an impact face  406  that is adjacent to the product settler  308 . When the package film  202  is filled with the pressurized gas and hangs under the force of gravity, the impact face  406  defines a second position of the impact face. This position can be substantially similar to the first position of the impact face  406  described with reference to  FIG. 3A . However, when the impact face  406  is in the second position, the package film  202  is filled with a pressurized gas, and the pressure from the gas can push the surface of the package film, including the impact face  406 , outward. Accordingly, the second position of the impact face  406  can be located further away from a central axis  334  of a package (e.g., the second package  404   b ) than the first position of the impact face. In one embodiment, the settler  308  is positioned so that as the paddle (e.g., paddle  320   a ) rotates, a first tip  328  of the paddle will reach past the second position of the impact face  406  by a third distance. The third distance can be substantially the same as the first distance  330  shown in  FIG. 3B . However, the third distance can also be greater than the first distance  330  when the second position of the impact face  406  is further from the central axis  334  than the first position of the impact face  406 . In one embodiment, as the paddle (e.g., paddle  320   a ) rotates, the third distance reaches a maximum of about 2.5 inches. In one embodiment, the ratio of the third distance to the diameter of the product conduit (e.g., former) is a maximum of about 0.041. In one embodiment, the ratio of the third distance to the diameter of the product conduit (e.g., former) is a maximum of about 0.208. 
     For example, in one embodiment, the distance from the first tip  328  of a paddle  320   a  to the axle  602  of a paddle wheel  326  is about 2.5 inches and the axle of the paddle wheel is positioned about 0.5 inches from the impact face  406  of a package  202 . Accordingly, when the paddle  320   a  rotates, the first tip  328  reaches past the original position of the impact face  406  by about 2.0 inches and the third distance is about 2.0 inches. 
     In one embodiment of an apparatus according to the invention, a package film  202  is wrapped around the product conduit  204 . The apparatus can comprise a plurality of conveyors  214   a,b  positioned to convey the package film  202  along the product conduit  204  at substantially a single speed along a perimeter  218  of the packaging film. The product conduit  204  is selected, for example, from the group consisting of a tube, a chute, a duct, and a pipe. 
     In one embodiment illustrated in  FIG. 5A  the apparatus is a form, fill and seal machine that comprises a positional sensor  614  to determine the position of the paddle wheel  326 . For example, in one embodiment, the machine comprises a product settler  308  and the product settler comprises the positional sensor  614 . 
     The positional sensor  614  can be, for example, a camera or electromagnetic device. The positional sensor  614  can also be a proximity switch. For example, in one embodiment, the positional sensor  614  senses the presence or absence of a sensor target  622  (e.g., a magnet) within a given range of the positional sensor. In another embodiment, the positional sensor  614  senses a distance from the positional sensor  614  to the sensor target  622 . For example, the sensor target  622  can move (e.g. rotate) with the paddle wheel  326  so that the position of the sensor target indicates the position of the paddle wheel. In another example, the position of a portion  624  (e.g., a magnet or discontinuity) of the sensor target indicates the position of the paddle wheel  326 . 
     In one embodiment, the positional sensor  614  is used to position the paddle wheel  326  or a paddle (e.g., paddle  320   a ). For example, when the paddle wheel  326  is stopped, the paddle wheel can be stopped outside the path of a package film  202 . This can be desirable because if the paddle wheel  326  is stopped in the path of the package film  202 , the paddle wheel  326  will increase the resistance that must be overcome to convey the package film. 
     One embodiment of the invention will now be described with reference to  FIGS. 6A-6B . A settler  308  comprises a paddle wheel  326 . The paddle wheel  326  comprises a plurality of paddles (e.g., paddles  320   a,b ). The paddles  320   a,b  rotate around an axle  602 . As shown in  FIGS. 6A and 6B  the paddles  320   a,b  are fixed to the axle  602 , although in other embodiments the paddles  320   a,b  are not fixed to the axle directly, but are instead fixed to another component that rotates around the axle. 
     As shown, for example, in  FIG. 6C , the product settler  308  comprises a first adjustable mount  604  to adjust the position of the product settler in a first direction  606 . The product settler  608  comprises a second adjustable mount  608  to adjust the position of the product settler in a second direction  610 . As shown in  FIG. 6B , the product settler  608  also comprises a third adjustable mount  512  to adjust the position of the product settler in a third direction  620 . 
     With reference to  FIG. 6B , the product settler  308  comprises a controller  612  to set the number of impacts against the package film that the product settler causes. For example, the number of impacts per minute can be calculated by multiplying the number of paddle wheels by the number of rotations or revolutions per minute that the paddle wheel  326  performs. Although, if another object is used to impact the package film, for example, a rod that oscillates into and out of contact with the package film, the number of impacts per minute will need to be calculated differently. For example, one end of the rod can be fixed to a rotating sphere and the other end of the rod can follow an orbital pattern into or out of contact with the package. As another example, the rod can move linearly back and forth between two positions, for example, a first position in contact with the package film and a second position remote from the package film. Regardless of the mechanism used to cause an impact, in some embodiments the number of impacts against a package or package material is greater than about 180 impacts per minute, about 240 impacts per minute, about 300 impacts per minute, about 360 impacts per minute, about 420 impacts per minute, about 480 impacts per minute, about 540 impacts per minute, about 600 impacts per minute, or about 660 impacts per minute. In some embodiments, the number of impacts per minute is about 300 impacts per minute to about 900 impacts per minute. In some embodiments, the number of impacts is about 540 impacts per minute to about 720 impacts per minute. In some embodiments, the number of impacts is about 600 impacts per minute to about 660 impacts per minute. 
     Turning back to  FIG. 6B , the illustrated product settler also comprises a positional sensor  614  (e.g., proximity switch) to determine the position of the paddle (e.g., paddle  320   a ). In one embodiment, the controller  612  uses information from the positional sensor  614  to instruct the actuator  616  to stop the paddle (e.g., paddle  320   a ) when the paddle is in a desired position. 
     As can be seen in  FIG. 6C , the product settler  308  comprises a motor  616  with sufficiently low torque that if the motor turns off while the paddle (e.g., paddle  320   a ) is contacting the package film  202 , as the package film is conveyed, the package film will push the paddle out of the path of the package film. Although the benefits of using a low torque motor have been described with respect to turning off the motor, the similar benefits will be realized if the product settler fails or loses power. In one embodiment, the settler is powered by a small AC/DC drive motor that will rotate the paddle wheel. For example, in one embodiment the actuator (e.g., motor) for the inventive settler requires a maximum of 96 Watts to settle product. 
     As shown in  FIGS. 6A-6C  and  FIGS. 5A-5C , the product settler  308  comprises a frame  618  that fixes the position of the product settler  608  in relation to the path of the package film  202 . For example, as shown in  FIG. 5A , the product settler  608  is adjacent to a package  404   b . The package  404   b  extends on both sides of a center plane  531  that is oriented parallel to a central axis (e.g., central axis  334  in  FIGS. 2 and 3A-3C ) of the package  404   b . In some embodiments the frame  618  comprises adjustable mounts (e.g., the first adjustable mount  604 , the second adjustable mount  608 , and/or the third adjustable mount  512 ) to facilitate changing the position of the product settler  308  relative to the form, fill and seal machine  206 . For example, in one embodiment, the adjustable mounts  604 ,  608 ,  512  can be used to move adjust the position of the product settler  308  in one, two, or three directions. For example, the first adjustable mount  604 , second adjustable mount  608 , and third adjustable mount  512  can be used to move or adjust the position of the product settler  308  in a first direction  606 , second direction  610 , or third direction  620 , respectively. In one embodiment, the adjustable mounts  604 ,  608 ,  512  can be used to move or adjust the position of the product settler  308  in a plurality of mutually perpendicular directions (e.g., two or three). In other embodiments, the frame  618  does not comprise the adjustable mounts  604 ,  608 ,  512  and the frame is positioned in a desired location when it is installed on a form, fill and seal machine  206 . 
     As shown in  FIGS. 5A-5C , the first adjustable mount  604  comprises a first mechanism (e.g., bolts  528   a,b ) to fix the product settler  308  in a desired vertical position relative to the form, fill, and seal machine  206 . The second adjustable mount  608  comprises a second mechanism (e.g., bolt  530 ) to fix the product settler  308  at a desired proximity to the form, fill, and seal machine  206 . The third adjustable mount  512  comprises a third mechanism (e.g., bolts  532   a,b ) to fix the product settler  308  in a desired horizontal position relative to the form, fill, and seal machine  206 . 
     One embodiment of the invention will now be described with reference to  FIGS. 5A-5C  and  FIG. 8 . As shown, the product settler  308  is modular. For example, besides connecting the product settler  308  to a form, fill, and seal machine, no assembly is required for the product settler. Accordingly, in one embodiment, the product settler  308  is operable after being electronically connected to a power source and placed in a desired position relative to the form, fill and seal machine  206 . In one embodiment, this is accomplished by mounting a module in the form of a product settler  308  on the form, fill and seal machine  206  using a machine mount  502 . For example, the machine mount  502  can connect the frame  618  of the product settler  608  (see, e.g.,  FIGS. 5A-5C ) to the frame  702   a,b  of the form, fill and seal machine  206  (see, e.g.,  FIG. 7 ). In one embodiment, the machine mount  502  is fixed to controller  612  using a mechanism  534  such as screws or bolts (see, e.g.,  FIGS. 5A-5C ). The same mechanism  534  or an additional mechanism can also be used to fix the machine mount  502  to the form, fill and seal machine  206 . 
     In one embodiment shown in  FIGS. 5A-5C , a modular product settler  308  is linked to a form, fill, and seal machine through a line of communication (e.g., one of a plurality of lines of communication  504   a,b ). The line of communication can be electronic, pneumatic, or some other manner of conveying power and/or information. For example, a line of communication (e.g.,  504   a,b ) can provide an electronic line of communication between the product settler  308  and the form, fill and seal machine  206 . In turn, the form, fill and seal machine  206  can provide a power source  508  for the product settler  308 . Although, the product settler  308  can also be connected to a power source  508  (e.g., power outlet or battery) that is separate from the form, fill and seal machine  206 . Similarly, a line of communication (e.g.,  504   a,b ) can connect the product settler  308  to a controller  612  for the product settler. In turn, the controller  612  can be used to control the position of the paddle wheel  326  in conjunction with a positional sensor  614 . Furthermore, the controller  612  can be used to control the angular velocity or rotational speed of the paddle wheel  326 . In some embodiments, a plug  506  is provided to facilitate connecting and disconnecting a line of communication between the product settler  308  and a component (e.g. the controller  612 ) or the form, fill and seal machine  206 . In some embodiments, the line of communication between the product settler  308  and the form, fill and seal machine  206  goes through the controller  612 . In some embodiments, the controller  612  for the product settler  308  is in communication with the form, fill and seal machine  206  through an auxiliary port  510  of the form, fill and seal machine  206 . Accordingly, in some embodiments a line of communication (e.g.,  504   a,b ) exists between the form, fill and seal machine  206  and the product settler  308  so that a control system of the form, fill and seal machine  206  can be used to control the controller  612  of the product settler  308 , and thereby control the product settler  308 . 
     The product settler  308 , shown in  FIGS. 5A-5C  also comprises a timing belt  514  which is used to actuate the product settler  308 . The timing belt  514  is wrapped around a rotor  516  and an axle  602 . When that the rotor  516  is rotated by motor  616 , it causes the timing belt  514  to travel around the axle  602 . This, in turn, causes the axle  602  to rotate, which rotates the paddle wheel  326 . 
     In the embodiment shown in  FIGS. 5A-5C , the product settler  308  comprises a timing belt guard  518 . The timing belt guard protects the timing belt from being caught on an object, for example, product  302  or film  202 . Similarly, as shown in  FIGS. 6A-6C , the frame  618  of the product settler  308  can comprise a paddle guard that protects the paddle (e.g., on one side or a plurality of sides) from being obstructed by objects other than the package film  202 . 
     As can be seen in  FIG. 7 , the product settler  308  is unobtrusive. The product settler is fairly small, lightweight, and located to one side of the seal jaw carriage  704   a,b  so it does not obstruct access to the carriage for repair or maintenance. For example, as shown in  FIGS. 5B-5C , one embodiment of the product settler has a length  522  of about 24 inches, a width  524  of about 16, and a height  526  of about 8 inches. In some embodiments, the product settler has a length  522  of about 6 to about 30 inches, a width  524  of about 6 to about 30 inches, and a height  526  of about 4 to about 12 inches. In one embodiment, the product settler, excluding the machine mount  502  and third adjustable mount  512 , weighs a maximum of about 12 lbs. In comparison, conventional product settlers, excluding mounting plates, typically weight about 50 lbs. 
     Additionally, the product settler can be easily installed or uninstalled. For example, with reference to the embodiment shown in  FIGS. 5A-5C , a portion of the product settler can be uninstalled by removing a plug  506  and detaching the portion from the machine mount  502 , which can be left attached to a form, fill, and seal machine  206 . Alternatively, the machine mount  502  can be detached from the form, fill and seal machine  206 . This can be done without (or in addition to) removing the plug  506  and detaching a portion of the product settler  308  from the machine mount  502 . 
     Although the inventive product settler has been described by reference to use of a package made from film. The package material can be made from a film or some other form of material. For example, the inventive settler can be used with packages made from package materials of varying thicknesses. Furthermore, the package material can be, for example, paper, metal, metal oxides, polymer, or some combination thereof. 
     EXAMPLES 
     Illustrative examples of the inventive settler and experiments involving the inventive settler will now be described. 
     Example 1 
     An experiment was conducted to measure certain benefits of using the inventive product settler  308  described herein. A continuous motion vertical form, fill and seal machine  206  was fitted with the inventive settler  308 . Then, the machine  206  was used to produce 13.0 oz packages  202  containing TOSTITOS® Restaurant Style Tortilla Chips. The machine  206  ran at a speed of about 26 packages per minute. The packages  202  were produced on a product conduit  204  (e.g., former) with a circular cross-section. The cross-section of the product conduit  204  had a diameter of about 10.5 inches, and accordingly the packages  202  had a diameter of about 10.5 inches while wrapped around the product conduit. The packages  202  had a length of about 15.75″ from the tip of a first end seal  212   a  to the opposite tip of a second end seal  212   b . Each end seal  212   a,b  was approximately ⅜ inches long providing a total usable package length of about 15 inches. In other words, the length of the package  202  that could be filled with product was approximately 15 inches. 
     A first set of five packages  202  were produced on a machine  206  without using the inventive settler  308 . The average package head space was about 1.3 inches and the average unsettled height  314  of the product was about 13.7 inches. A second set of five packages  202  were produced on the machine  206  with the inventive settler  308  activated. Using this set up, the average package head space was about 2.9 inches and the average settled height  312  of the product was about 12.1 inches. As can be seen, the inventive settler resulted in an average settling of about 1.6 inches, which is a settling fraction of at least about 0.116 relative to the unsettled height  314  of the product. 
     Additionally, the inventive settler reduced the average length of film required to package each unit of product by about 1.6 inches. For example, rather than increasing the head space in a package, the product settler could also have been used to maintain a given head space while decreasing the length of film required for the package. In this example, the length of film required to package each unsettled unit of product was 15.75 inches. Since the product settler resulted in settling of about 1.6 inches, the product settler could have reduced the length of film required by 1.6 inches. This is a film reduction fraction of at least 0.101 relative to the length of film required if no settler is used. 
     Breakage of product occurring with and without the inventive settler activated was substantially the same. The use of the inventive settler did not result in any statistically significant increase in the ratio of broken product to non-broken product in a package. In other words, any increase in breakage was within the margin of error for the experiment. 
     Table 1 
     Table 1 provides speeds in packages per minute at which an illustrative form, fill and seal machine can produce packages with a clamp on. All information in the table corresponds to a seal time of 70 milliseconds. In other words, the seal jaws press against the film for approximately 70 milliseconds to form package end seals. The table shows how package production speeds vary with bag length. As can be seen, increased package lengths result in lower package production speeds. This is because, given a fixed speed for conveying packages, longer packages require more time to be convey. 
     
       
         
           
               
               
               
             
               
                   
                 TABLE 1 
               
               
                   
                   
               
               
                   
                 Package length 
                 Production Speed 
               
               
                   
                 (inches) 
                 (packages/minute) 
               
               
                   
                   
               
             
            
               
                   
               
            
           
           
               
               
               
            
               
                   
                 27.99 
                 19 
               
               
                   
                 27.5 
                 19 
               
               
                   
                 27 
                 19 
               
               
                   
                 26.5 
                 19 
               
               
                   
                 26 
                 20 
               
               
                   
                 25.5 
                 20 
               
               
                   
                 25 
                 21 
               
               
                   
                 24.5 
                 21 
               
               
                   
                 24 
                 22 
               
               
                   
                 23.5 
                 22 
               
               
                   
                 23 
                 23 
               
               
                   
                 22.5 
                 23 
               
               
                   
                 22 
                 24 
               
               
                   
                 21.5 
                 24 
               
               
                   
                 21 
                 25 
               
               
                   
                 20.5 
                 25 
               
               
                   
                 20 
                 26 
               
               
                   
                 19.5 
                 27 
               
               
                   
                 19 
                 27 
               
               
                   
                 18.5 
                 28 
               
               
                   
                 18 
                 29 
               
               
                   
                 17.5 
                 30 
               
               
                   
                 17 
                 31 
               
               
                   
                 16.5 
                 32 
               
               
                   
                 16 
                 33 
               
               
                   
                 15.5 
                 34 
               
               
                   
                 15 
                 35 
               
               
                   
                   
               
            
           
         
       
     
     Although the inventive settler is described herein as being installed on specific embodiments of vertical form, fill, and seal machines, the inventive settler is not limited to being used with these machines. Rather, the inventive settler can be used, for example, with essentially any process where a product can be settled in a package. Although, the inventive settler is especially useful with processes where a film is being continuously advanced to form a package that is filled with product and then sealed. When used with such a process, the inventive settler can settle product within the film while the film is being continuously advanced. This is a substantial improvement over conventional settlers that require a film to pause intermittently for settling. 
     Additionally, while the product settler has generally be described in the form of a paddle wheel, some embodiments of the product settler for use with a form, fill and seal machine are also possible. For example, the product settler can be in the form of an object such as a rod that is positioned and actuated to intermittently impact a partially formed package and thereby settle product in the package. In some embodiments, the object can provide settling by contacting the partially formed package on one and only one face. In some embodiments, the object impacts the partially formed package more than 300 times per minute. In some embodiments, the object impacts the partially formed package more than 600 times per minute. 
     Furthermore, while the steps for particular embodiments of the invention have been described herein, a person skilled in the art would understand from the disclosure that the steps can be modified. For example, as appropriate, steps can occur at different times, steps can occur simultaneously or sequentially, the order of steps can be swapped or varied, certain steps can overlap even if they start at different times, and steps can be added or removed. 
     While this invention is particularly shown and described herein with reference to preferred embodiments, it will be understood by those skilled in the art that various changes in form and detail can be made therein without departing from the spirit and scope of the invention. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the elements described herein, in all possible variations thereof, is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context. For example, various advantages of the invention can still be realized if additional elements are added to provide additional advantages or if certain elements are omitted because a particular feature is unnecessary or undesirable for a given application. 
     ADDITIONAL DISCLOSURE 
     The following clauses are offered as further description of the disclosed invention. 
     1. A method for settling a product in a package made on a form, fill and seal machine, the method comprising the steps: 
     
         
         
           
             a. providing a package material on a product conduit of a form, fill and seal machine; 
             c. forming a first end seal on the package material to form a partially formed package; 
             d. filling the partially formed package with the product; and 
             e. settling the product in the partially formed package while continuously conveying the package material along the product conduit.
 
2. The method of clause 1 further comprising the step:
 
             f. forming a second end seal on the partially formed package to form a package from the partially formed package.
 
3. The method of clause 1 further comprising the step:
 
             b. sealing the package material to form a longitudinal seal.
 
4. The method of clause 3, wherein the first end seal is approximately perpendicular to the longitudinal seal.
 
5. The method of clause 1, further comprising the step:
 
             directing a gas into the partially formed package.
 
6. The method of clause 5, wherein the gas is directed into the partially formed package as a first jet of gas.
 
7. The method of clause 5, wherein the gas pressurizes an interior of the partially formed package.
 
8. The method of clause 1, wherein the settling step further comprises the steps:
 
             pressurizing an interior of the partially formed package to provide resistance; and 
             intermittently contacting the partially formed package to move the partially formed package, thereby moving the product.
 
9. The method of clause 1, wherein the settling step further comprises the steps:
 
             rotating a paddle wheel comprising a paddle; 
             intermittently rotating the paddle into contact with the partially formed package, thereby moving the product while the product is inside the partially formed package.
 
10. The method of clause 9, wherein an actuator rotates the paddle and stops the paddle in a desired position.
 
11. The method of clause 1 wherein the package material is a film.
 
12. An improved continuous motion form, fill and seal machine, said machine comprising a product conduit, a conveyor, and seal jaws; wherein the conveyor is positioned to convey a package material that is wrapped around the product conduit; wherein the conveyor moves the package material along the product conduit; wherein the seal jaws are positioned adjacent to opposite portions of the package material to form a first end seal on the package material, thereby forming a partially formed package; wherein the product conduit is positioned so that a product passing through the product conduit will enter the partially formed package after exiting the product conduit; and wherein the product conduit is positioned above the seal jaws; wherein the improvement comprises:
 
             a product settler comprising a first object positioned to cause an impact against the package material; 
             wherein the impact agitates the package material and settles the product from an unsettled height to a settled height while the machine continuously conveys the package material along the product conduit.
 
13. The machine of clause 12, wherein the machine comprises a source of pressurized gas.
 
14. The machine of clause 13, wherein the machine comprises a nozzle to direct the pressurized gas into the package material.
 
15. The machine of clause 12, wherein the product settler comprises a controller to set a number of impacts per minute that the first object causes on the package material.
 
16. The machine of clause 12, wherein the product settler comprises a positional sensor to determine a position of the first object.
 
17. The machine of clause 12, wherein the impact occurs on one and only one face of the partially formed package.
 
18. The machine of clause 12, wherein the first object directly contacts the package material to cause the impact.
 
19. The machine of clause 12, wherein the impact against the package material occurs below the product conduit and above the unsettled height.
 
20. The machine of clause 12, wherein the product settler comprises a motor with sufficiently low torque that if the motor turns off while the first object is in contact with the package material, as the package material is conveyed, the package material will push the first object out of a path of the package material.
 
21. The machine of clause 12, wherein the product settler is modular.
 
22. The machine of clause 12, wherein the product settler comprises a frame that spatially fixes the product settler in relation to a path of the package material.
 
23. The machine of clause 12, wherein the product settler comprises a first adjustable mount to move the product settler in a first direction.
 
24. The machine of clause 12, wherein the settler is positioned so that, as the first object moves into contact with the package material, the first object will first contact the package material at a first point that is a second distance below the product conduit.
 
25. The machine of clause 12, wherein the product settler is positioned adjacent to the package material so that, as the first object moves into contact with the package material, the first object will contact the package material below the product conduit and above the unsettled height of the product.
 
26. The machine of clause 12:
 
             wherein the seal jaws comprise a first seal jaw and a second seal jaw; 
             wherein the first seal jaw rotates around a first axis of rotation; 
             wherein the second seal jaw rotates around a second axis of rotation; 
             wherein the first seal jaw, the first axis of rotation, the second seal jaw and the second axis of rotation are positioned so that, as the first seal jaw and the second seal jaw rotate, the first seal jaw and the second seal jaw come together to form the first end seal.
 
27. The machine of clause 12:
 
             wherein the seal jaws comprise a third seal jaw and a fourth seal jaw; 
             wherein the third seal jaw rotates around a first axis of rotation; 
             wherein the fourth seal jaw rotates around a second axis of rotation; 
             wherein the third seal jaw, the first axis of rotation, the fourth seal jaw and the second axis of rotation are positioned so that, as the third seal jaw and the fourth seal jaw rotate, the third seal and the fourth seal jaw come together to form a second end seal on the package material thereby forming a package.
 
28. The machine of clause 12, wherein the package material is a film.
 
29. The machine of clause 12, wherein the machine is a vertical form, fill and seal machine.
 
30. The machine of clause 12:
 
             wherein the first object is a rotatable paddle wheel; 
             wherein the paddle wheel comprises a paddle; and 
             wherein the paddle is positioned so that, as the paddle wheel rotates, the paddle causes agitation of the package material and thereby settles the product.
 
31. The machine of clause 30:
 
             wherein the package material comprises an impact face; 
             wherein the impact face is adjacent to the product settler; 
             wherein, when the impact face of the package material hangs under a force of gravity, the impact face defines a first position; 
             wherein the settler is positioned so that as the paddle wheel rotates, a first tip of the paddle will reach past the first position by a first distance; and 
             wherein the first distance reaches a maximum of about 2.5 inches while the paddle wheel rotates.
 
32. The machine of clause 30, wherein the paddle wheel comprises a plurality of paddles.
 
33. A method for settling a product in a partially formed package, the method comprising the steps:
 
             a. providing a partially formed package; 
             b. filling the partially formed package with a product; and 
             c. settling the product in the partially formed package; 
             wherein the settling step comprises:
           rotating a paddle wheel comprising at least one paddle against the partially formed package.
 
34. The method of clause 33, further comprising the step:
   
         
             g. closing the partially formed package to form a package.
 
35. The method of clause 33, further comprising the step:
 
             h. directing a pressurized gas into the partially formed package.
 
36. The method of clause 33, wherein the paddle wheel rotates intermittently.
 
37. The method of clause 33, wherein the paddle wheel rotates continuously.
 
38. The method of clause 33, wherein the at least one paddle intermittently contacts the partially formed package.
 
39. The method of clause 33, wherein the partially formed package is provided on a form, fill and seal machine that intermittently conveys a package material along a product conduit.
 
40. The method of clause 33, wherein the partially formed package is provided on a form, fill and seal machine that continuously conveys a package material along a product conduit.
 
41. The method of clause 33, wherein the providing step further comprises the steps:
 
             i. providing a package material on a product conduit of a form, fill and seal machine; 
             iii. forming a first end seal on the package material to form the partially formed package.
 
42. The method of clause 41, wherein the providing step further comprises the step:
 
             ii. sealing the package material to form a longitudinal seal.
 
43. The method of clause 41, further comprising the step:
 
             f. forming a second end seal on the partially formed package to form a package from the partially formed package.
 
44. The method of clause 33, further comprising the step:
 
             e. settling the product in the partially formed package while continuously conveying a package material along a product conduit.
 
45. The method of clause 42:
 
             wherein the first end seal is approximately perpendicular to the longitudinal seal.
 
46. An apparatus comprising an improved product settler for settling product in a partially formed package; wherein the improved product settler comprises:
 
             a paddle wheel; 
             wherein the paddle wheel comprises at least one paddle that is positioned to cause an impact against the partially formed package; 
             wherein the impact agitates the partially formed package and thereby settles the product.
 
47. The apparatus of clause 46, wherein the apparatus further comprises a source of pressurized gas.
 
48. The apparatus of clause 47, wherein the apparatus comprises a nozzle to direct the pressurized gas into the partially formed package.
 
49. The apparatus of clause 46, wherein the product settler comprises a controller to set a number of impacts per minute that the paddle wheel causes on the partially formed package.
 
50. The apparatus of clause 46, wherein the product settler comprises a positional sensor to determine the position of the paddle wheel.
 
51. The apparatus of clause 46, wherein the apparatus comprises a positional sensor to determine the position of the paddle wheel.
 
52. The apparatus of clause 46, wherein the impact occurs on one and only one face of the partially formed package.
 
53. The apparatus of clause 46, wherein the paddle wheel directly contacts the partially formed package to cause the impact.
 
54. The apparatus of clause 46, wherein the product settler comprises a motor with sufficiently low torque that if the motor turns off while the paddle wheel is in contact with the partially formed package, as the partially formed package is conveyed, the partially formed package will push the paddle wheel out of a path of the partially formed package.
 
55. The apparatus of clause 46, wherein the product settler is modular.
 
56. The apparatus of clause 46, wherein the product settler comprises a frame that spatially fixes the product settler in relation to a path of the partially formed package.
 
57. The apparatus of clause 46, wherein the product settler comprises a first adjustable mount to move the product settler in a first direction.
 
58. The apparatus of clause 46, wherein the paddle wheel comprises a plurality of paddles.
 
59. The apparatus of clause 46, wherein the apparatus comprises a form, fill and seal machine.
 
60. The apparatus of clause 46, wherein the apparatus comprises a form, fill and seal machine that advances film continuously along a product conduit.