Patent Publication Number: US-11383865-B2

Title: Food conveyor and packaging systems and methods

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application a continuation of U.S. application Ser. No. 15/747,745, filed Jan. 25, 2018, which is a U.S. national phase entry of International Application No. PCT/US2016/045743, filed Aug. 5, 2016, which claims the benefit of U.S. Provisional Application No. 62/205,458, filed Aug. 14, 2015, which are incorporated herein by reference in their entirety. 
    
    
     TECHNICAL FIELD 
     The present disclosure generally relates to systems and methods for handling and packaging food products. More specifically, the present disclosure relates to systems and methods for handling baked food products between baking and packaging stations. 
     BACKGROUND 
     Baked food products formed in mass production processes can be transferred from the baking ovens to packaging stations via conveyors. In one such process, baked biscuit products (e.g., biscuits, cookies, crackers, cakes, etc.) are baked in an oven and then transported or moved to one of a series of independent conveyor lanes. 
       FIG. 1  presents an example layout of a system  10  for such a process. As shown in  FIG. 1 , an output of the oven  20  leads to a series of multiple conveyors  40   n , each of which conveyors  40   n  can have multiple lanes. Each of the independent conveyors  40   n  leads to a corresponding dedicated packaging machine  50   n . Thus, in operation, the independent conveyors  40   n  receive biscuits from the oven  20 , and direct a single file stream of biscuits in the lanes to a corresponding packaging machine  50   n.    
     Such an arrangement has several shortcomings. For example, if one packaging machine is inoperable, even for a brief period of time, all of the lanes on the conveyor dedicated to that machine will stop. This can result in inefficiencies because otherwise operable conveyors will go unused. Further, because each packaging machine utilizes its own separate conveyor, the layout for such an arrangement takes up a significant amount of space. For example, the arrangement of  FIG. 1  can occupy 950 m 2  or more of floor space in a packaging facility. 
     Additionally, because the layout of  FIG. 1  includes many conveyors spaced over a large area, each conveyor will require its own set of manual workers to attend to issues that arise on the production line. For instance, workers will need to tend to matters such as inspecting products, removing broken or improperly placed products, and addressing equipment breakdowns. Thus, the worker headcount to operate this system can be significantly high, which can make the process expensive. 
     For at least these reasons, multi-conveyor packaging systems such as those depicted in  FIG. 1  can be can be inconvenient, inefficient, and expensive to operate. 
     SUMMARY 
     The present disclosure presents examples of a food product conveyor and packaging system. In one example, a system includes an upstream conveyor that transports food products. The upstream conveyor has an end portion that transports stacks of food products in a plurality of lanes. The system also includes a bucket conveyor that transports an array of buckets in a direction perpendicular to the lanes of the end portion of the upstream conveyor. The buckets are shaped to hold stacks of the food products. The exemplary system also includes a feeding station that feeds the stacks of food products from the lanes of the second portion of the upstream conveyor into the buckets of the bucket conveyor. The system also includes a transfer device that selectively transfers individual stacks of food products from the buckets to a packaging machine. The transfer device can transfer the stacks without use of an intermediary conveyor. For example, the transfer device can include one or more robotic arms that grab the stacks from the buckets and move them to the packaging machine. 
     The present disclosure also describes methods of conveying and packaging food products. In one example, a method involves conveying stacked food products along a plurality of lanes on an upstream conveyor. The exemplary method feeds the stacked food products into buckets on a second conveyor. The buckets are fed so that each lane of the upstream conveyor feeds into a separate bucket, and so that the individual buckets holding individual stacks of food products. The stacks of food products are then moved along the second conveyor in a direction perpendicular to the lanes of the upstream conveyor. In this way the buckets, or stacks of food products travel in a direction perpendicular to the length of the stacks. The method also includes transferring individual stacks of food products from the second conveyor to an input of a packaging machine using at least one robotic arm. The individual stacks of food products are packaged by the packaging machine. 
     In one example of operation, food products, such as biscuits, crackers, cookies, and the like are baked in an oven and transferred to a receiving end of an upstream conveyor. The food products may be arranged on the conveyor in a flat, non-overlapping manner. 
     In some examples, during transport along the upstream conveyor the food products can be inspected for problems such as breakage or other damage. The upstream conveyor channels the food products into lanes, and begins to arrange the products into stacks. For example, the upstream conveyor can employ penny stacker features that turns the flat products on edge and stacks them up against each other in the individual lanes. 
     In some examples the upstream conveyor then transports the products around a 90 degree turn so that they are traveling generally perpendicular to the receiving end of the upstream conveyor. The upstream conveyor then slopes downward toward the bucket conveyor, allowing gravity to facilitate transfer of the biscuit stacks between the lanes of the upstream conveyors and the buckets of the bucket conveyor. A feeding station, which may include a feeding device, such as a robotic volumetric feeder, may also ease with this transition to help assure that the food products do not break or become unstacked during the transfer process. The feeding device helps assure that stacks from the lanes of the upstream conveyor are placed into individual buckets in the bucket conveyor. 
     The buckets containing the individual stacks can then be transported in a direction perpendicular to the arrangement of the stacks along the bucket conveyor. As the buckets travel along the bucket conveyor, the sloped portion of the conveyor levels off to horizontal. 
     The buckets then approach a series of transfer devices that can selectively transfer the stacks from the bucket conveyor to the packaging machines. For example, the transfer devices can be robotic arms that grab the stacks and remove them from the buckets, and place them in the input of the packaging machines. 
     The packaging machines can then package the stacks, for example, by applying a flow-wrap packaging around the stacks, and transfer the packaged products to another conveyor. At this point the conveyor may further transport the packaged products to a second packaging station, where a second packaging (e.g., an outer packaging or box) can be applied. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an overhead layout showing a conventional biscuit packaging system that employs individual lanes for each packaging machine. 
         FIG. 2  is an overhead layout showing an example of a food product conveyor and packaging system in accordance with one or more embodiments described herein. 
         FIG. 3  shows a detailed view of an exemplary upstream conveyor area that can be employed in the food product conveyor and packaging system of  FIG. 2 . 
         FIGS. 4 and 4A  shows a more detailed view of an exemplary turning area that can be employed in the food product conveyor and packaging system of  FIG. 2 . 
         FIGS. 5A, 5B, and 5C  demonstrate an example of the operation of a feeding station that can be employed in the food product conveyor and packaging system of  FIG. 2 . 
         FIG. 6  shows a more detailed view of examples of a bucket conveyor area and a packaging station that can be employed in the food product conveyor and packaging system of  FIG. 2 . 
         FIG. 7  shows a more detailed example of a packaging station and secondary conveyor area that can be employed in the food product conveyor and packaging system of  FIG. 2 . 
         FIG. 8  shows a more detailed example of a secondary conveyor area and a secondary packaging station that can be employed in the food product conveyor and packaging system of  FIG. 2 . 
         FIGS. 9A and 9B  show an example of a transfer device interacting with a bucket of a bucket conveyor in accordance with one or more embodiments described herein. 
         FIG. 10A  shows another view of the transfer device of  FIGS. 9A and 9B . 
         FIG. 10B  shows an example of the transfer device of  FIG. 10A  holding a biscuit stack. 
         FIG. 11  is a flow diagram of an example of a method for conveying and packaging food products described herein. 
     
    
    
     DETAILED DESCRIPTION 
     The present disclosure describes examples of conveyor and packaging systems that present solutions to the issues discussed above with respect to the system  10  shown in  FIG. 1 . For example, the presently disclosed systems decouple independent conveyor lanes from dedicated packaging machines so that the operation of each lane does not depend on the continuing operation of a specific packaging machine. Instead, a common conveyor (or conveyor system) having a plurality of lanes transports biscuits independent of any specific packaging machine. A transfer device (e.g., a robotic arm) selectively transfers the biscuits to the packaging machines. In this manner, biscuits can be transferred to packaging machines without requiring specific conveyors to each specific packaging machine. 
       FIG. 2  is an overhead layout of such a conveyor and packaging system  100 . The system  100  includes an upstream conveyor area  110 , which is shown in greater detail in  FIG. 3 , as discussed below. The upstream conveyor area  110  includes an upstream conveyor  111  that leads biscuits to a turning area  120 , which is shown in greater detail in  FIG. 4 . The turning area  120  includes a bend  121  that arranges the biscuits from the lanes of the upstream conveyor  111  into stacks that are generally perpendicular to the lanes of the upstream conveyor  111 . 
     In one example, the upstream conveyor  111  equipment arranges the biscuits into arrays in a downstream bucket conveyor  141  at a feeding station  130 . In feeding station  130 , a feeding device  131  (e.g., a robotic volumetric feeder) facilitates the feeding and/or arranging of the biscuit stacks from the upstream conveyor  111  into the array of buckets on a bucket conveyor  141 . A more detailed depiction of the feeding station  130  is shown in greater detail and in operation in  FIGS. 5A-C . 
     The bucket conveyor  141  transports buckets (or trays) filled with stacks of biscuits toward a first packaging station  150 , which can include one or more packaging machines  151   n . A more detailed view of the bucket conveyor area  140  and the first packaging station  150  is shown in  FIG. 6 . 
     In some embodiments, the buckets  144  on the bucket conveyor  141  are linked together such that the movement of one bucket  141  directly corresponds to the movement of the other buckets  144  on the conveyor  141 . That is, in this embodiment, when one bucket  144  moves a first distance along the conveyor  141 , all buckets  144  move the same distance along the conveyor  141 . In another embodiment, the buckets are unlinked and thus configured to move independent of one another. That is, because the buckets are not linked, one bucket  144  may be able to move forward or backward irrespective of the movement of the other buckets  144 . In such a configuration, there may be space between each bucket  144  so that moving one bucket  144  does not necessitate movement of another bucket  144 . An example of such a configuration is the Beckhoff XTS linear transport system. So configured, the buckets  144  may be able to move with different speeds and with different spacing there between. This can provide the ability to buffer buckets between packaging machines, which can help improve the ability to assure most or all buckets are used, thereby improving efficiency of the process. 
     The packaging machines  151  include or are associated with transfer devices  142   n , which can be robotic arms that transfer stacks of biscuits from the buckets into individual packaging machines  151   n  of the first packaging station  150 . In this manner, the system  100  can transfer stacks of biscuits from the conveyors to the packaging machines  151   n  without the use of intermediary conveyors specifically dedicated to each packaging machine  150   n.    
     The transfer devices  142   n  can selectively choose to transfer only stacks of biscuits that are suitable for packaging to the packaging machines  151   n . Unselected stacks may progress along the bucket conveyor  141  and be manually removed by a worker, or simply fall into a waste basket or bin. Moreover, if certain packaging machines  151   n  are inoperable, the system  100  will not need to shut down certain lanes of the conveyor system  100 , as the packaging machines can take biscuits regardless of their conveyor lane or position. 
     As noted, the in some examples, the transfer devices  142   n  can be robotic arms. In general, a variety of types and configurations of robotic arms are available to operate as the transfer devices. One example of such a robotic arm is the UR10 robot, made by Universal Robots. 
       FIGS. 9A and 9B  demonstrates how such a transfer device  142  interacts with a bucket to pick up a stack of biscuits  105 . More specifically,  FIG. 9A  shows a transfer device interacting with an empty bucket  144 , and  FIG. 9B  shows the same diagram with a biscuit stack  105  in the bucket  144 . 
     As shown in  FIGS. 9A-b , a bucket  144  can comprise a pair of vertical support members in between which the cracker stack  105  can be placed. The transfer device  142  can be configured with components that fit in locations with respect to the bucket  144 . 
       FIGS. 10A-B  provide views of the transfer device  142  separate from the bucket. More specifically,  FIG. 10A  shows of the transfer device  142  alone, and  FIG. 10B  shows the transfer device  142  holding a biscuit stack  105 . 
     The transfer device  142  can include a pair of prongs  143  that extend from a base platform  145 . The prongs  143  can be configured to fit into recesses of the bucket  144  so that the biscuit stack  105  can be positioned between the prongs  143  and the base platform. A guide bar  148  can also be used to help keep the biscuit stack  105  within the grip of the transfer device  142  when the stack is rotated. 
     In some examples the transfer device  142  can also include a distal support member  146  to support the distal end of the cracker stack  105 . The distal support member  146  can pivot as controlled by a piston  147 . In this manner, the support member  146  can pivot away from the cracker stack  105  so that the prongs  143  can slide into position with respect to the bucket  144 , and then pivot back up to hold the cracker stack  105  once the transfer device has properly grabbed it. 
     In one example of a conveyor and packaging system  100 , the packaging machines  151  place the stacks of biscuits into packaging (e.g., flow wrap packaging, boxes, wrappers, etc.), and move the packaged stacks to a secondary conveyor  161  in a secondary conveyor area  160 .  FIG. 7  provides another detailed view of the first packaging area  150 , as well as the secondary conveyor area  160 . 
     Upon being loaded with packaged stacks of biscuits, the secondary conveyor  161  moves the packaged stacks toward a secondary packaging area  170  with one or more secondary packaging machines  171   n .  FIG. 8  shows another view of the secondary conveyor area  160  and the secondary packaging area  170  in greater detail. In the secondary packaging area, secondary packaging machines  171   n  place a secondary or outer package around the already-packaged stacks. For example, the secondary packaging machines  171  place the wrapped stacks into boxes, secondary wrappers, bags, or the like. It should be noted that not all products will have secondary packages, and thus not all systems falling within the scope of the present disclosure will include such secondary conveyor areas  160  or secondary packaging areas  170 . 
     As noted above,  FIGS. 3-8  show various areas and stations of the system  100  in greater detail.  FIG. 3  shows a more detailed view of an example of an upstream conveyor  111  that can be employed in the system  100  of  FIG. 2 . It should be noted that some examples of the upstream conveyor  111  may employ a single conveyor line that uses a single conveyor belt or platform from beginning to end. In other examples, however, the upstream conveyor  111  may comprise components or portions, each of which may be individually considered a separate conveyor. For example, as shown in  FIG. 3 , the upstream conveyor  111  includes a receiving portion  118 , an inspection area  113 , and a penny stacker portion  115 , each of which may be considered separate conveyors that employ separate conveyor belts. 
     The upstream conveyor  111  includes a receiving portion  118  that receives biscuits. In some examples, the receiving portion  118  is adjacent an oven so that biscuits are transferred to the receiving portion  118  upon discharge from the oven. In some examples the biscuits received in the receiving portion  118  will generally lie flat on the conveyor  110  and will not overlap one another. That is, in some examples, the biscuits on the receiving portion  116  of the upstream conveyor will not be stacked. 
     In some approaches, the upstream conveyor includes a first dribbleboard  112  that moves the biscuits down a slope. The first dribbleboard  112  moves the biscuits to an inspection area  113 . In the inspection area  113 , biscuits can be inspected for damage or other issues. This inspection can be performed by a camera and/or a manual worker assigned to inspect the products. Biscuits that are broken, damaged, or otherwise unsuitable for packaging can be removed from the conveyor  111 . 
     Downstream from the inspection area  113  on the upstream conveyor  111  is a second dribbleboard  114 . The second dribbleboard  114  can provide lane balance so that the biscuits are arranged to flow into individual lanes  117 . That is, in this portion of the upstream conveyor  111 , the biscuits can move from one lane to another so that each generally contains the number of biscuits therein. 
     Downstream of the second dribbleboard  114  is a gap closing, or penny stacker portion  115 . In the penny stacker portion  115 , the lanes can narrow to ensure that the biscuits are arranged to begin the stacking process. In this portion, the biscuits may begin to overlap with one another, for example, such that an edge of one biscuit rests upon an edge of an adjacent biscuit. Biscuits passing through the penny stacker portion  115  pass to a straight vibratory portion  116  that leads to the turning area  120 . 
       FIG. 4  shows a more detailed view of an exemplary turning area  120 . To reduce clutter in the drawings, the individual biscuits in stacks are not shown, however the view in  FIG. 4A  shows the biscuit stacks in more detail to show the individual biscuits. Figure In some examples, the upstream conveyor  111  includes a straight vibratory portion  116  that leads to the turning area  120 . In some formats, the straight vibratory portion  116  starts to stack the biscuits in the lanes  117  of the conveyor  111 . For example, the straight vibratory portion  116  may vibrate the lanes  117 , thereby causing the biscuits to vibrate, which can initiate the stacking process. That is, the biscuits may begin to tilt up on their sides so that they are no longer lying flat on the conveyor. 
     The upstream conveyor  111  moves biscuits from the straight vibratory portion  116  through a bend  121 . The bend  121  can also be a vibratory portion that continues to vibrate the biscuits to facilitate the stacking process. For example, while passing through the bend  121 , the biscuits can begin or continue to turn from lying flat to vertical, short side leading. 
     The turning area  120  turns the individual lanes  117  through bend  121  toward an end portion  122  of the upstream conveyor  111 . In some approaches the bend  121  is be a 90 degree bend that turns the lanes  123  of the end portion  122  generally perpendicular to the lanes  117  in the upstream area  110  of the upstream conveyor  111 . The angle of the bend  121  can vary depending on the layout of the equipment; in particular, the angle can vary depending on the location of the oven or the receiving portion  118  of the upstream conveyor  111  with respect to the bucket conveyor  141 . In some examples, the bend  121  will be configured so that the lanes  123  of the end portion  122  of the upstream conveyor  111  are generally perpendicular to the bucket conveyor  141 . In this manner, the lanes  123  of the end portion  122  can align to fill the buckets  144  of the bucket conveyor  141 . 
     In some examples the process of stacking the biscuits (i.e., turning the biscuits from flat and non-overlapping to a stacked orientation) will be generally complete as biscuits enter the end portion  122  of the upstream conveyor  111 . The lanes  123  of the end portion  122  of the upstream conveyor  111  can thus feed the stacks of biscuits into buckets  144  in the bucket conveyor  141  at the feeding station  130 . 
     In some examples, the end portion  122  of the upstream conveyor slopes downward from a higher elevation to a lower elevation so that gravity can facilitate the stacks of biscuits moving toward the feeding station  130  and the bucket conveyor  141 . In some examples the end portion  122  is also vibratory to facilitate the stacking process or the movement of the stacks of biscuits toward the feeding station  130 . 
       FIGS. 5A-C  show a more detailed view of the feeding station  130  at various stages of the feeding process. In some approaches, the feeding station  130  includes a feeding device  131  to facilitate guiding the biscuits into the buckets  144  of the bucket conveyor. For example, the feeding device  131  can include a robotic volumetric feeder that feeds and/or arranges of the biscuits from the upstream conveyor  111  into the array of buckets on a bucket conveyor  141 . In some examples the lanes  123  of the end portion  122  of the upstream conveyor  111  align with the buckets  144  of the bucket conveyor  141  at the feeding station such that each lane  123  can supply a bucket  144  with a stack  105  of biscuits. 
       FIGS. 5A, 5B, and 5C  each present an example of the feeding station  130  at various stages of the feeding process. The feeding device  131  is shown as a robotic volumetric feeder that includes a robotic arm  135  and a platform  136 . The platform supports the biscuit stacks in the lanes  123  of the end portion  122 . As the robotic arm  135  lowers the platform  136 , the biscuit stacks arrange themselves into buckets  144  of the bucket conveyor  141 . 
     The buckets  144  can be sleeves, or channels that are designed to hold a single stack  105  of biscuits. The buckets  144  can have a variety of cross sectional shapes depending on the shape of the biscuit that it is intended to hold. For example, in some examples the buckets  144  will have a rounded bottom to hold round biscuits, an angled v-shaped bottom to hold triangular or diamond shaped biscuits, or a squared bottom to hold square shaped biscuits. Other shaped buckets  144  can also be employed where biscuits of other shapes are used. 
       FIG. 5A  shows the feeding device at an initial position  132 . Here, the platform  136  is positioned near the top of the bucket conveyor  141 , and thus the biscuit stacks  105  have not yet entered into the buckets  144 .  FIG. 5B  shows the feeding device  131  in an intermediary position so that the buckets  144  of the bucket conveyors are approximately half-way filled.  FIG. 5C  shows the feeding device  131  at an end position  135 , whereby the buckets have been allowed to fill the buckets  144  to the desired capacity. 
     Because the upstream conveyor  111  is generally at a higher elevation than the bucket conveyor  141 , the end portion  122  of the upstream conveyor  111  slopes downhill to the bucket conveyor  131 . In this manner, gravity facilitates transfer of the stacks of food products from the upstream conveyor to the bucket conveyor. The feeding device  131  controls the lowering of the stacks of food products from the lanes of the upstream conveyor into buckets. The feeding device  131  helps assure that the biscuits are properly placed into the buckets in a controlled manner to help prevent damage to the biscuits during this process. 
     Once the stacks  105  of biscuits are fed into the buckets  144 , the bucket conveyor transports the stacks toward the feeding station  150 .  FIG. 6  provides a more detailed view of the bucket conveyor area  140  of the system  100 . In some formats, the bucket conveyor  141  is arranged to transport the buckets  144  in a direction perpendicular to the lanes  123  of the end portion  122  of the upstream conveyor  111 . Put another way, the bucket conveyor  141  transports the buckets  144  in a direction perpendicular to the length of the buckets  144 , or the stacks  105  within the buckets  144 . 
     In some examples, the bucket conveyor  141  at the feeding station  130  is sloped at an angle as shown in  FIGS. 4-6 . That is, the feeding station  130  may generally share the same slope as the end portion  122  of the upstream conveyor  111  to facilitate the feeding process. Accordingly, the bucket conveyor  141  may be arranged to bring the conveyor surface back to horizontal as the bucket conveyor  141  approaches the packaging station  150  as shown in  FIGS. 4-6 . 
     The bucket conveyor  141  transports the buckets to a feeding station  150 , where transfer devices  142   n  load stacks  105  of biscuits into individual packaging machines  151   n . In some examples, the packaging system  150  will include a plurality of packaging machines  151   n  as shown in  FIGS. 2 and 6 . 
     The packaging machines  151   n  may include or operate in association with one or more transfer devices  142   n  that selectively load biscuit stacks  105  from the bucket conveyor  141  to the packaging machine  151   n . For example, each transfer device  142   n  may be specifically associated with individual packaging machines  151   n  such that each transfer device (e.g.,  141   a ) loads stacks  105  of biscuits into one and only one packaging machine (e.g.,  151   a ). 
     In other examples, the system  100  may employ transfer devices  142  that are associated with more than one packaging machine  151 . That is, in some examples, one transfer device  142  can be configured to load biscuit stacks  105  into two, three, or more different packaging machines. In still other examples, packaging machines  151  can be configured to be loaded from more than one transfer device  142 , or to share multiple transfer devices  142  with multiple packaging machines  151 . 
     Generally speaking, the transfer devices  142  selectively load biscuit stacks  105  from the bucket conveyor  141  to the packaging machines  151  without employing an intermediary conveyor. In some examples, the transfer devices  142  comprise a robotic arm that selectively grabs the biscuit stacks  105  from the bucket conveyor  141  and transfers the stacks  105  to the packaging machines  151 . The robotic arms can be lightweight and flexible and have a low profile so as to reduce floor space that they occupy. 
     In some embodiments the transfer devices  142   n  are operated by a control module that controls operation of the transfer devices  142 . The control module may include a computer processor that communicates with various components of the system  100  to facilitate control of the packaging process. The control module may be in communication with various inspection related equipment so that the control module can determine which biscuit stacks  105  in the buckets  144  are suitable for packaging. For instance, the control module may learn that a certain bucket  144  comprises an insufficient number of biscuits, broken biscuits, or other problems rendering the corresponding biscuit stack  105  unsuitable for packaging. In such a situation, the control module may control the transfer devices to skip or dispose the problematic biscuit stack. 
     In other examples, the control module may be in communication with the equipment of the system so that the control module can determine which packaging machines  151  are operating properly. For example, where a certain packaging machine  151   n  is not working properly, the control module may disable the transfer device  142   n  associated with that machine, or assign that transfer device  142   n  to another packaging machine  151 . 
     In some aspects, the transfer devices  142   n  will load cracker stacks into an input  152   n  of a packaging machine  151   n . The input  152   n  can be a vibratory flowpack feeder that includes, for example, a channel that flows into packaging lanes of the packaging machine  151   n . In some examples, each packaging machine  151   n  may include a plurality of inputs  152   n  so that the packaging machine  151   n  can package multiple biscuit stacks at a time. 
       FIG. 7  shows a more detailed example of a packaging station  150  having a plurality of packaging machines  151   n . As shown, each packaging machine has an input  152   n , or a plurality of inputs. The inputs  152   n  feed the corresponding packaging machines with a biscuit stack  105 , whereby the packaging machine  151  packages the stack  105 . The packaging machines  151  can apply packaging in a variety of forms. For example, the packaging machines can package the stacks  105  paper or plastic sleeves, bags, boxes, tubes, cans, flow wrap packages, etc. 
     It should be noted that  FIG. 2  shows a system  100  that employs four packaging machines  151 , each with a separate transfer device  142 ; however, certain embodiments and implementations of the presently disclosed systems and methods can employ more or fewer machines as appropriate for the process. 
       FIG. 7  also shows a secondary conveyor area  160  that can be employed in the food product conveyor and packaging system of  FIG. 2 . The packaging machines  151   n  include a secondary collation station  163   n  where packaged stacks  108  are discharged from the packaging machines  151   n . Other transfer devices  162   n , which can be robotic arms, feed the packaged stacks  108  from the packaging machines  151   n  to the secondary conveyor  161 . The secondary conveyor  161  then transports the packaged stacks toward the secondary packaging station  170 . 
       FIG. 8  shows a more detailed example of a secondary conveyor area  160  and a secondary packaging station  170 . As shown, the secondary packaging station can include a plurality of secondary packaging machines  171   n . It is noted that  FIG. 2  depicts two secondary packaging machines  171  while  FIG. 8  shows three secondary packaging machines  171 . Indeed, the secondary packaging station  170  may employ fewer or more secondary packaging stations as driven by the demands of the packaging process. The secondary packaging machines  171   n  each employ a feeding mechanisms  172   n , which can be robots, that feed the secondary packaging machines  171   n  with the once-packaged stacks  108  of biscuits from the secondary conveyor  161 . The secondary packaging machines  171  apply a secondary package to the packaged stacks  108 . For example, the secondary packaging machines  171  can put the packaged stacks  108  in bags, boxes, wrappers, trays, cartons, or the like. 
     An example of the operation the conveyor and packaging system  100  is as follows. Biscuits are discharged from an oven are placed on the receiving portion  118  of the upstream conveyor  111 . The biscuits lie generally flat and non-overlapping on the conveyor and traverse downstream along the conveyor  111  towards a turning area  120 . At or around the turning area  120 , the biscuits are channeled into lanes. 
     While in lanes  117 , the biscuits begin to arrange into stacks. For example the biscuits may be vibrated along the conveyor so that the biscuits begin to overlap and turn vertical. The biscuit stacks approach the end portion  122  of the upstream conveyor  111  traveling in a direction perpendicular to the bucket conveyor  141 . In this way the biscuit stacks  105  align with the buckets  144  so that the stacks  105  can be fed therein. A feeding device  131  facilitates the feeding of the biscuit stacks  105  into the buckets at a feeding station  130 . 
     The buckets  144  then proceed along the bucket conveyor  141  in a direction generally perpendicular to the length of the stacks  105 . As the buckets  144  approach a packaging station  150 , transfer devices  142  (e.g., robotic arms), pick up the stacks  105  and feed the stacks  105  into inputs  152  of individual packaging machines  151 . Thus, the stacks  105  can be transferred to the packaging machines  151  without passing along a separate, dedicated conveyor. 
     The packaging machines  151  package the stacks and place the stacks onto a secondary conveyor  161 , which transports the packaged stacks  108  to a secondary packaging station  171 . The secondary packaging station  171  can apply a secondary, or outer, package to the packaged products  108 . 
     The presently described system provides several efficiencies and advantages over other conveying and packaging systems. One example of such an advantage is a reduction in the number of manual workers to facilitate efficient operation of the system. Because the biscuits travel together on a single conveyor as opposed to separate conveyor lanes dedicated to each packaging machine, the process is more compact. Thus, individual workers can oversee a larger portion of the process, thereby minimizing the headcount. 
     Another advantage that the presently disclosed system  100  provides is the ability to skip biscuit stacks that are not suitable for packaging. For instance, if one of the buckets has an irregular stack or broken biscuits, then the feeding devices can simply skip that bucket. Further, if one of the packaging machines is inoperable, then all of the buckets can be still processed using the other packaging machines. 
     Still another advantage of the presently disclosed system includes the ability to effectively function while occupying reduced floor area. Because the system  100  does not employ dedicated conveyor lanes for each packaging machine, the size of the equipment employed, and the floor space it occupies, can be much smaller. For example, in some settings the system  100  of  FIG. 2  may occupy 120 m 2  as compared to the 950 m 2  or more of floor space occupied by the conventional system of  FIG. 1 . 
     The present disclosure also presents methods for conveying and packaging food products.  FIG. 11  is a flow diagram of an example of a method  500  for conveying and packaging food products described herein. 
     At step  510 , biscuits are delivered onto an upstream conveyor. At step  510  biscuits can be delivered directly from an oven, or from another device. The biscuits received can be generally flat and non-overlapping. The biscuits are conveyed into a plurality of lanes, where the biscuits are turned into stacks on the upstream conveyor. In some examples, the biscuits and/or biscuit stacks can turn through a bend such that the biscuits at the end of the conveyor travel in a direction perpendicular to the direction biscuits travel at the receiving end of the conveyor. In some examples, at step  510 , the previously flat and non-overlapping biscuits are turned onto their sides and stacked within the lanes of the upstream conveyor. 
     At step  520 , biscuits are transferred to buckets in a bucket conveyor. Step  520  may include feeding the stacked food products into a plurality of buckets on a second conveyor (e.g., a bucket conveyor) so that each lane of the plurality of lanes feeds into a separate bucket. In some examples, each individual bucket will hold an individual stack of biscuits. Also at step  520 , the biscuit stacks are conveyed along the second conveyor in a direction perpendicular to the lanes at the end of the upstream conveyor. 
     Next, at step  530 , individual stacks of biscuits are selectively transferred from the second conveyor to a packaging station. For example, at step  530 , biscuits can be transferred by a robotic arm to an input of a packaging machine using at least one robotic arm. Notably, at step  530 , the individual stacks of biscuits can be transferred from the secondary conveyor—which is a common conveyor conveying all biscuits regardless of the packaging machine destination—to individual packaging machines without employing an intermediary conveyor. 
     In some examples, at step  530 , a first robotic arm selectively transfers a first biscuit stack to a first packaging machine associated with the first robotic arm, while a second robotic arm transfers a second biscuit stack to a second packaging machine associated with the second robotic arm. The first robotic arm may then selectively grab a third stack of biscuits and transfer that biscuit stack to the first packaging machine, while the second robotic arm transfers a fourth biscuit stack to the second packaging machine. That is, the robotic arms can repeatedly and selectively transfer independent stacks of biscuits from a common conveyor (e.g., the second or bucket conveyor) to separate independent packaging machines. 
     In some approaches, the method can include, at step  530 , determining which of the individual stacks of food products conveying along the second conveyor are suitable for packaging. In such an approach, at least one of the transfer machines/robotic arms may bypass or dispose of certain biscuit stacks that are deemed to be unsuitable for packaging. 
     At step  540 , biscuits are flow wrapped at a first wrapping or packaging station. For example, at step  540 , biscuits can be packaged into packaged stacks by packaging machines. 
     At step  550 , the wrapped/packaged biscuit stacks are transferred to a third conveyor, such as secondary conveyor  161  described herein with respect to  FIGS. 2-8 . 
     The secondary conveyor then transfers the wrapped stack of biscuits to a secondary wrapping station at step  560 . The secondary wrapping station can employ one or more secondary packaging machines that use robotic arms to transfer the wrapped or packaged biscuit stacks from the third conveyor to the second wrapping station. 
     At step  570 , the secondary wrapping station applies a second wrapper or package to the once-packaged biscuit stack. For example, the secondary wrapping station can apply an outer package around one or more of the once-packaged biscuit stacks. 
     The present disclosure refers to food products, and more specifically baked food products. For convenience, this disclosure refers to general baked food products generally as biscuits. Thus, it should be understood that such general references to biscuits are not intended to exclusively apply to biscuits alone. That is, the references to biscuits in the present are intended to refer to any baked food products capable of being manufactured in the described production processes, including but not limited to cookies, crackers, muffins, cakes, bread products, wafers, or the like. 
     The present disclosure describes preferred embodiments and examples of the present technology. It is contemplated that certain aspects described herein with respect to specific embodiments could be included in other embodiments even if not specifically described with respect to those embodiments. Those skilled in the art will recognize that a wide variety of modifications, alterations, and combinations can be made with respect to the above described embodiments without departing from the scope of the invention as set forth in the claims, and that such modifications, alterations, and combinations are to be viewed as being within the ambit of the inventive concept. All references cited in the present disclosure are hereby incorporated by reference in their entirety.