Patent Description:
It is known to provide an apparatus and method for forming packaging material for use with a feedstock of pre-folded paper, as disclosed in UK Patent <CIT>. However, the cutting mechanism used in this machine comprises a single reciprocating blade and a stationary blade, with the packaging material passing between the two blades. An entire width of the packaging material is then crushed and cut with each stroke of the single reciprocating blade. As such, the cutting mechanism is prone to jamming, since the entire width of the packaging material is cut by a single reciprocating blade. This large reciprocating blade also requires a heavy-duty motor, the size of which limits the compactness of the overall machine. Document <CIT> discloses a dunnage forming machine comprising a cutting mechanism which comprises a stationary blade and a first and a second reciprocating blade, which blades are pivotable relative to the stationary blade. The blades being driven by drive cogs which are coupled such that they rotate concurrently, wherein the blades cut the dunnage at the same time. For a business with relatively little space a smaller, lighter and more compact machine which has relatively simple construction and operation is desirable. Furthermore, as the machine may undergo intensive use, it is also desirable to have a machine that is less prone to jamming when cutting the formed packaging material.

In a first aspect, the present invention provides packaging material forming apparatus for use with a feedstock of pre-folded paper having two substantially continuous linear sides provided in the form of a roll, the apparatus comprising a former for partially opening the folded paper into a linear tubular form, and first and second sets of corresponding rollers for moving the tubular paper form through the apparatus, wherein the first set of rollers is arranged to rotate at a speed greater than the second set of rollers to enable the tubular paper form to be partially crushed in a linear direction, the second set of rollers being arranged to crimp the two linear sides of the paper together, and wherein both of the rollers in the second set comprise teeth, the two sets of teeth being arranged to interlock and correspond with one another, the apparatus further comprising a cutting mechanism for cutting the partially crushed linear tubular paper form into desired lengths, wherein: the cutting mechanism comprises a stationary blade, a first reciprocating blade, and a second reciprocating blade; the first reciprocating blade and/or the second reciprocating blade are pivotable relative to the stationary blade; the first reciprocating blade is driven by a first drive cog, and the second reciprocating blade is driven by a second drive cog; the first drive cog and the second drive cog are coupled to one another such that they rotate concurrently; and the coupling of the first drive cog and the second drive cog is achieved via a drive belt, and the drive belt is removable and/or adjustable, such that the first drive cog and the second drive cog may be rotated independently of one another, thereby enabling alteration of a phase difference between movement of the first connecting rod and the second connecting rod, thereby altering a phase difference between movement of the first reciprocating blade and the second reciprocating blade.

The pre-folded paper may have a width of <NUM> (when unfolded), with one edge folded over <NUM> from one linear side and the other edge folded over <NUM> from the other opposite linear side such that the two edges overlap by <NUM>. The paper may be initially folded flat having a width of <NUM>. The roll of paper may be <NUM> long.

The former may be inserted into the folded paper such that as the paper moves across the former, into the apparatus, the portions of paper forming the two side folds are pushed away from the base portion of the paper to create the tubular form.

The first reciprocating blade and the second reciprocating blade may be arranged to cut a first portion and a second portion of a width of the partially crushed linear tubular paper form. In this way, the cutting mechanism may be less prone to jamming, because less force is exerted by the extruded paper form onto the cutting edges of the reciprocating blades. The first reciprocating blade and the second reciprocating blade may be arranged to cut in two distinct strokes. This may render a light duty motor suitable for driving the cutting mechanism, thereby minimising the size and weight of the cutting mechanism and consequently the packaging material forming apparatus.

A portion of the width of the paper form cut by the first reciprocating blade may overlap with a portion of the width of the paper form cut by the second reciprocating blade, such that a portion of the width of the paper form may be cut by both blades.

The first reciprocating blade and the second reciprocating blade may each have at least one sharp edge. Sharp may mean any profile effective for cutting the partially crushed linear tubular paper form. Sharp may mean that the at least one edge is a right angle. The use of right-angled blades may mean that minimal maintenance and/or sharpening is required, which may therefore increase the longevity of the cutting mechanism. The blades may be made from metal, for example flat ground machine steel.

The second set of rollers may be arranged to produce the crimp along the middle of the partially crushed tubular paper form in the direction of feeding through the machine. This crimp or seal may be effected by the teeth squeezing the paper between them. The seal may be effected between the two linear edges of the paper and the base portion of the paper such that a cross-section of the resultant packaging material is an approximate figure of eight with two cushion-like forms, one either side of a crimped middle section.

The apparatus may further comprise two rotatable rollers upon which the roll of paper may rest and rotate. The rollers may be freely rotatable.

The apparatus may comprise a frame and either or both of the first and second set of rollers may be resiliently mounted to the frame such that they are movable relative to it to accommodate the irregularities of the tubular paper form. The resilience may be achieved by using springs or other such resilient mountings between brackets, retaining a shaft upon which the rollers are mounted, and the frame.

The radial outer surfaces of both of the rollers in the first set may be milled. In this regard, the term "milled" may mean a series of grooves, or a pattern of raised pimples. The milling may aid the initial feeding of the paper into the apparatus as it may more easily "grab" the end of the paper and pull it through. Furthermore, it may assist in maintaining the rate of entry of paper into the apparatus.

The apparatus may further comprise a cowling being arranged to accept the paper after it has been fed through the former and direct it to between the first set of rollers which are located immediately downstream thereof; the cowling having sides which taper inwardly so as to reduce the width of the paper as it passes therethrough.

The sides of the cowling are closer together at the downstream end compared to the upstream inlet to inwardly reduce the width of the tubular paper form to approximately <NUM>. In other words, the cowling may be funnel-shape.

The paper may be cut between the stationary and reciprocating blades.

The stationary blade may have at least one sharp edge. Sharp may mean any profile effective for cutting the partially crushed linear tubular paper form. Sharp may mean that the at least one edge is a right angle. The stationary blade may be made from metal, for example flat ground machine steel.

The first reciprocating blade and/or the second reciprocating blade may be pivotable relative to the stationary blade. In this way, the cutting motion of the reciprocating blades may pivot from an outside edge of the paper form towards the centre of the paper form, thereby resembling a scissor action. Accordingly, each reciprocating blade may incrementally cut the paper form from an outside edge towards the centre, leading to reduced force on the cutting mechanism and a lower likelihood of jamming. In the construction wherein only the first reciprocating blade may be pivotable relative to the stationary blade, it will be appreciated that the second reciprocating blade may move linearly relative to the stationary blade, such that the second reciprocating blade may incrementally cut the paper form from an outside edge of the paper form towards the centre of the paper form. Similarly, in the construction wherein only the second reciprocating blade may be pivotable relative to the stationary blade, it will be appreciated that the first reciprocating blade may move linearly relative to the stationary blade, such that the first reciprocating blade may incrementally cut the paper form from an outside edge of the paper form towards the centre of the paper form.

Motion of the first drive cog may be transferred to the first reciprocating blade via a first crank and first connecting rod, and motion of the second drive cog may be transferred to the second reciprocating blade via a second crank and second connecting rod.

The cutting action of each blade may be staggered by varying degrees. The staggering of the cutting action may be varied to suit the particular type of packaging material being produced. Removable may mean that the drive belt may be partially, or entirely removable from the drive cogs. Adjustable may mean that the drive belt may be extendable, such that the drive cogs may be rotated independently of one another while the drive belt is extended in position. The drive belt may then be retractable such that it retracts back to fitting around the drive cogs once adjustment is complete.

The first reciprocating blade, the second reciprocating blade and the stationary blade may each have a cutting edge, and the cutting edges of the first reciprocating blade and the second reciprocating blade may be arranged immediately adjacent to the cutting edge of the stationary blade. In this way, the movement of the reciprocating blades across the edge of the stationary blade may create a shearing action, thereby effectively cutting the partially crushed linear tubular paper form therebetween.

The resultant packaging material may be dispensed via a dispensing chute. This may be located downstream of the cutting mechanism.

The apparatus may further comprise sensing means for sensing the presence or absence of packaging material in the chute, and a PCU for controlling the first and second sets of rollers and the cutting mechanism.

The PCU may control the first and second sets of rollers by controlling a drive motor. The PCU may be programmed to stop the first and second sets of rollers before operating the cutting mechanism.

The PCU may operate the first and second of rollers to produce packaging material when the sensor senses the absence of packaging material in the dispensing chute. In this respect, the apparatus may not be producing packaging material when the sensor senses the presence of packaging material in the chute. In this way, a user may withdraw each length of packaging material, as required, without having to manually control the apparatus and without the apparatus producing more packaging than is immediately necessary. The apparatus may produce packaging material on demand and as required.

The PCU may be programmed to produce a predetermined number of individual lengths of packaging material; the dimension of each length also being predetermined.

The PCU may be programmed and the apparatus arranged such that a user is presented with various lengths to choose from and/or various numbers of lengths to select. The apparatus may include buttons assigned with these choices for ease of operability.

In a second aspect, the invention provides a method of producing packaging material comprising the steps of providing a packaging material forming apparatus according to the first aspect; providing a roll of pre-folded paper; feeding the free end of the paper through the former and between the first set of rollers; the former partially opening the folded paper into a linear tubular form, and operating the apparatus such that the first set of rollers rotate at a speed greater than the second set of rollers to enable the tubular paper form to be partially crushed in a linear direction, the second set of rollers being arranged to crimp the two linear sides of the paper together; and cutting the partially crushed linear tubular paper form into desired lengths.

In this method the two outside corners of the free end of the roll of pre-folded paper may be cut-off prior to being fed through the former and between the first set of rollers such that the free end of the paper is separated into three separate sheets.

A packaging material forming apparatus may be provided for use with a feedstock of pre-folded paper having two substantially continuous linear sides provided in the form of a roll, the apparatus comprising a former for partially opening the folded paper into a linear tubular form, and first and second sets of corresponding rollers for moving the tubular paper form through the apparatus, wherein the first set of rollers is arranged to rotate at a speed greater than the second set of rollers to enable the tubular paper form to be partially crushed in a linear direction, the second set of rollers being arranged to crimp the two linear sides of the paper together, and wherein both of the rollers in the second set comprise teeth, the two sets of teeth being arranged to interlock and correspond with one another, the apparatus further comprising a cutting mechanism for cutting the partially crushed linear tubular paper form into desired lengths, wherein the cutting mechanism comprises a pivotable reciprocating blade and a fixed cutting surface.

It is to be understood that the packaging material forming apparatus may be operated using the same method as described in relation to the second aspect. It will be understood that the features described with regard to the first and second aspects may equally be used with, and/or apply to, the packaging forming apparatus.

The fixed cutting surface may be a planar and/or profiled sheet of material positioned substantially adjacent to the pivotable reciprocating blade, such that the paper form is arranged to pass between the pivotable reciprocating blade and the fixed cutting surface before the paper form is cut. The fixed cutting surface may be a stationary blade.

This description is given for the sake of example only, without limiting the scope of the invention as defined by the claims.

It is to be understood that the terms so used are interchangeable under appropriate circumstances and that operation is capable in other sequences than described or illustrated herein.

Reference throughout this specification to "an embodiment" or "an aspect" means that a particular feature, structure or characteristic described in connection with the embodiment or aspect is included in at least one embodiment or aspect of the present invention. Thus, appearances of the phrases "in one embodiment", "in an embodiment", or "in an aspect" in various places throughout this specification are not necessarily all referring to the same embodiment or aspect, but may refer to different embodiments or aspects.

Furthermore, while some embodiments described herein include some features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the invention, and form yet further embodiments, as will be understood by those skilled in the art.

In the discussion of the invention, unless stated to the contrary, the disclosure of alternative values for the upper or lower limit of the permitted range of a parameter, coupled with an indication that one of said values is more highly preferred than the other, is to be construed as an implied statement that each intermediate value of said parameter, lying between the more preferred and the less preferred of said alternatives, is itself preferred to said less preferred value and also to each value lying between said less preferred value and said intermediate value.

The use of the term "at least one" may mean only one in certain circumstances.

The principles of the invention will now be described by a detailed description of at least one drawing relating to exemplary features of the invention. It is clear that other arrangements can be configured according to the knowledge of persons skilled in the art without departing from the underlying concept or technical teaching of the invention, the invention being limited only by the terms of the appended claims.

In <FIG>, an apparatus <NUM> for producing packaging material, or dunnage, using a rugation process, from paper or similar material, is shown in schematic form. The figure does not include all of the various elements such as electric motors, instead showing only the key features.

A frame <NUM> includes a support <NUM> at one upper end for holding a pre-folded roll of paper <NUM>. The roll may rotate on an axle (not shown) passing through its centre, the axle being supported by the support <NUM>. Alternatively, the roll of paper may rest on parallel rollers (not shown) without a central axle/spindle. This improves the ease with which the roll of paper may be replaced. An end of the paper <NUM> is led from the roll <NUM> over two individual tensioning rollers <NUM> so that the paper <NUM> may be fed horizontally into the main part <NUM> of the apparatus. Before it enters this main part <NUM> it passes between two further rollers <NUM> acting as guides.

The paper then passes through and around a former <NUM> which expands the pre-folded paper <NUM> from a substantially flat web into a substantially linear tubular form. The former is described with reference to <FIG> and <FIG> in more detail below.

The substantially tubular form has a base <NUM> and two sides <NUM>, <NUM> which extend from the base <NUM> up, around and over the base to form the sides and top of the tubular form.

The linear centre of the tubular form of paper <NUM> then passes between two rollers <NUM> which squeeze together the top and bottom surfaces of the centre of the tubular form to create two cushion-like forms either side of a substantially flat compressed strip running in the direction of the linear length of the paper <NUM>.

The rollers <NUM> may be more wheel-like in form having a thickness in the range of <NUM> to <NUM> and a diameter in the range of <NUM> to <NUM>. The outer circumferential surface of the rollers may be milled or include dimples. The rollers may comprise metal.

The paper <NUM> is propelled through this first set of rollers <NUM> at a speed in the range of <NUM> to <NUM> metres per minute.

The paper <NUM> then passes between a second set of rollers which are rotating at a speed approximately half the speed of rotation of the first set of rollers such that the paper exits the second set of rollers in the range <NUM> to <NUM> metres per minute.

Due to this speed reduction the paper <NUM> is crumpled between the first and second sets of rollers such that its longitudinal linear length is reduced.

Each of the second set of rollers <NUM> includes teeth, the two sets of teeth interlocking during rotation. The teeth are rounded in a sinusoidal manner so that they do not puncture, rip or tear the paper. The interaction of the two sets of teeth help to seal the central, previously compressed, strip such that it does not separate.

The second set of rollers <NUM> may have a thickness in the range of <NUM> to <NUM> and a diameter in the range of <NUM> to <NUM>. The rollers may comprise metal.

The resultant paper form <NUM> is thus comprised of linearly crumpled paper having two cushion-like forms either side of a central compressed and sealed strip.

This dunnage <NUM> may then be cut into required length by a cutting mechanism <NUM>, described in more detail below. The dunnage <NUM> may be used as packaging to prevent goods from being damaged in transit.

The resultant paper may be dispensed via a dispensing chute (not shown) provided downstream of the cutting mechanism.

With the roll of paper <NUM> located above the frame <NUM> and the apparatus <NUM> being relatively simple; it is possible to produce packaging material with equipment that occupies a relatively small space.

<FIG>, shows the main part <NUM> of the apparatus comprising a frame <NUM>. The paper <NUM> enters the apparatus in the direction <NUM> on the right and exits on the left in the direction <NUM>. The frame supports a lower first roller 100A and a lower second roller 120A. A support <NUM> extends from approximately the centre of the lower part of the frame <NUM> upwardly and a pivot point is provided towards the top thereof. From this pivot point <NUM>, two arms <NUM> extend one rearwardly towards the first set of rollers <NUM> and one forwardly towards the second set of rollers <NUM>. At the end of the rearwardly extending arm <NUM>, the upper first roller 100B is pivotally connected. Similarly, at the end of the forwardly extending arm <NUM>, the upper second roller 120B is pivotally connected.

These upper first 100B and second 120B rollers may thus move up and down relative to the fixed lower first 100A and second 120A rollers. This movement allows for the crumpled paper <NUM> to pass through the second set of rollers 120A, 120B without blocking occurring.

The upper first 100B and second 120B rollers are biased downwardly against the upper side of the frame <NUM> by individual coil springs <NUM> the force of each being adjustable via a threaded bar <NUM> as will be understood by the skilled person. This ensures good traction between the upper and lower rollers.

Although not shown, it will be understood that a motor is used to drive the rollers. A gear system may be employed to drive the first and second sets of rollers at different speeds.

<FIG> shows a cross-section of the pre-folded paper <NUM>. It comprises a single laminar sheet wherein the two longitudinal edges have been folded over the central portion <NUM>. One edge has been folded over initially and then the other folded over such that an upper portion <NUM> overlies a middle portion <NUM> which, in turn, overlies the lower portion <NUM>. The figure shows the paper slightly opened for the sake of clarity. In reality the paper <NUM> will feed off the roll <NUM> with tight folds such that the upper portion <NUM> will be substantially immediately above and on the middle portion <NUM> which will be substantially immediately above and on the lower portion <NUM>.

With the initial paper roll <NUM> being provided in this way the amount of space required is minimised.

<FIG> and <FIG> show the former <NUM> which is used to open the folded paper into an approximate tubular form. The former <NUM> comprises two lobes <NUM>, <NUM>, located one at either end of a first rectilinear bar <NUM>. The lobes <NUM>, <NUM> each comprise a cylinder with a dome shape at either longitudinal end. A second rectilinear bar <NUM> is provided extending from one lobe <NUM> towards the other lob <NUM>, parallel with, but slightly spaced from the first rectilinear bar <NUM>. This second bar <NUM> does not extend all the way to the lobe <NUM>. Rather, it turns through <NUM> degrees and extends upwardly <NUM>. This upwardly extending bar is only partially shown in <FIG>. The direction of its extent is indicated by broken lines. It is used to affix the former to the apparatus <NUM>. The upwardly extending bar <NUM> is located closer to the lobe <NUM> than the lobe <NUM> from which it extends. This allows for upwardly extending bar <NUM> to be located approximately at the position of the longitudinal edge of the upper portion <NUM> of paper.

In use, the former <NUM> is arranged such that the direction of the movement of the paper <NUM> as it passes past the former <NUM> is substantially perpendicular to the axis of the two rectilinear bars <NUM>, <NUM>.

The paper <NUM> passes the former such that the lower portion <NUM> passes underneath the first rectilinear bar <NUM>, the middle portion <NUM> passes between the first and second rectilinear bars <NUM>, <NUM>, and the upper portion <NUM> passes over the upper second rectilinear bar <NUM>.

The former is positioned inside the folded paper <NUM> such that as the paper passes past the former <NUM> the two lobes move the paper into an approximate tubular form <NUM>. The upwardly extending bar <NUM> allows the paper to pass it by extending beyond the longitudinal edge of the upper portion <NUM> as may be more clearly seen in <FIG>.

The resultant tubular form of paper <NUM> includes enlarged cushion like forms <NUM>, <NUM> each around the lobes <NUM>, <NUM>.

For an initial feeding of the paper <NUM> into the apparatus <NUM>, the longitudinal end of the paper <NUM> is trimmed with scissors such that a substantially triangular shape is formed. In other words the two outer corners are cut off. This leaves the three leaves (upper <NUM>, middle <NUM>, and lower <NUM>) substantially separate with no connecting folds at the sides. This allows the three separate leaves <NUM>, <NUM>, <NUM> to be fed under, between and over the two rectilinear bars <NUM>, <NUM> without having to pull the folded paper open so as to fit around the lobes <NUM>, <NUM>. The paper is then fed manually to the first set of rollers <NUM> which when rotating pull the paper into the apparatus <NUM>. The paper is then automatically pulled around the lobes as it progresses into the apparatus such that the folded flat paper form is opened into the approximate tubular form.

In <FIG>, a partial view of one example of the apparatus including a cutting mechanism <NUM> is shown. The cutting mechanism <NUM> comprises a first reciprocating blade <NUM>, a second reciprocating blade <NUM> and a stationary blade <NUM>. The stationary blade <NUM> extends substantially horizontally across an upper portion of the cutting mechanism <NUM>, from a left-hand side of the cutting mechanism <NUM> to a right-hand side of the cutting mechanism <NUM>. The first reciprocating blade <NUM> is pivotally mounted adjacent to the stationary blade <NUM> at a pivot point <NUM> located near the left-hand edge of the stationary blade <NUM>. The second reciprocating blade <NUM> is pivotally mounted adjacent to the stationary blade <NUM> at a pivot point <NUM> located near the right-hand edge of the stationary blade <NUM>.

The first <NUM> and second <NUM> reciprocating blades each include a pivot point <NUM>, <NUM>, thereby pivotally mounting them to the pivot points <NUM>, <NUM>. Each blade comprises a cutting edge <NUM>, <NUM> on its upper surface arranged to pass over the stationary cutting blade <NUM>. The stationary blade <NUM> has a cutting edge <NUM> along its lower edge.

Below the cutting edge <NUM> of the stationary blade <NUM>, an outward facing surface of the interlocking teeth of the second <NUM> set of rollers can be seen. The finished paper form would therefore pass out of the figure, towards the direction of the viewer. The first reciprocating blade <NUM> and second reciprocating blade <NUM> may move toward and away from the stationary blade <NUM> such that the finished crumpled dunnage which passes between the blades parallel to the cutting edge <NUM> of stationary blade <NUM> is cut into desired lengths.

Towards the base of the cutting mechanism <NUM> are arranged two drive cogs <NUM>, <NUM>. Each drive cog includes a crank, arranged as a pin <NUM>, <NUM>, extending from the face of each drive cog <NUM>.

Connecting rods <NUM>, <NUM> are arranged to connect each drive cog <NUM>, <NUM> via their respective cranks <NUM>, <NUM> to each respective blade <NUM>, <NUM>. Each connecting rod <NUM>, <NUM> is pivotably attached to each blade. Accordingly, in use, as each drive cog rotates, each connecting rod is driven up and down reciprocatively to thus move each blade <NUM>, <NUM> up and down reciprocatively so that they partially rotate back and forth about their pivot points <NUM>, <NUM>. This movement ensures that the cutting edge <NUM>, <NUM> of each pivotable blade <NUM>, <NUM> moves across, and against, the cutting edge <NUM> of the stationary blade to thereby cut the paper emerging from withing the apparatus. It will be understood that the cut starts at both outer edges of the crimped paper and travels towards the centre. The cutting edge <NUM>, <NUM> of each pivotable blade <NUM>, <NUM> has a length that is at least as long, or longer, than half the width of the paper at the point of being cut such that the cutting edges <NUM>, <NUM> may overlap, in use. The speed of reciprocation of the blades is arranged such that the blades do not impede the flow of crimped paper from the machine. However, it is also contemplated that the motion of the paper may be stopped briefly while it is cut.

Either or both of the drive cogs <NUM>, <NUM> are driven by a motor (not shown), which may be the same motor as which drives the first <NUM> and second <NUM> sets of rollers. The drive cogs <NUM>, <NUM> are shown coupled together via drive belt <NUM>, although it is to be understood that if both drive cogs are driven no drive belt is required.

The drive belt <NUM> includes an interior ribbed profile corresponding to an exterior toothed profile on each of the drive cogs <NUM>, <NUM>. In this way, the drive belt <NUM> connects the two drive cogs <NUM>, <NUM> such that they may rotate in unison. The rotation of the drive cogs <NUM>, <NUM>.

The relative rotational position of the drive cogs <NUM>, <NUM> may be varied by removing the drive belt <NUM>, rotating one or both of the drive cogs <NUM>, <NUM>, and replacing the drive belt <NUM>. In this way, an offset may be introduced between the pivoting cutting action of the first reciprocating blade <NUM> and the second reciprocating blade <NUM>. Alternatively, the drive belt <NUM> may be extendable, thereby allowing for adjustment of the offset between the rotational position of the drive cogs <NUM>, <NUM> by extending the drive belt <NUM> to separate its ribs from the teeth on the drive cogs <NUM>, <NUM>, and rotating one or both of the drive cogs <NUM>, <NUM> to a different relative position. The drive belt <NUM> may then be retractable such that it retracts back so its ribs again engage with the teeth on the drive cogs <NUM>, <NUM> once adjustment is complete. The drive belt <NUM> is supported at its lower edge by a support roller <NUM>.

The first <NUM> and second <NUM> sets of rollers may be stopped when the cutting mechanism is required to cut the paper.

Claim 1:
Packaging material forming apparatus for use with a feedstock of pre-folded paper having two substantially continuous linear sides provided in the form of a roll, the apparatus comprising a former (<NUM>) for partially opening the folded paper into a linear tubular form, and first and second sets of corresponding rollers (<NUM>, <NUM>) for moving the tubular paper form through the apparatus, wherein the first set of rollers (<NUM>) is arranged to rotate at a speed greater than the second set of rollers (<NUM>) to enable the tubular paper form to be partially crushed in a linear direction, the second set of rollers (<NUM>) being arranged to crimp the two linear sides of the paper together, and wherein both of the rollers (<NUM>, <NUM>) in the second set comprise teeth, the two sets of teeth being arranged to interlock and correspond with one another, the apparatus further comprising a cutting mechanism (<NUM>) for cutting the partially crushed linear tubular paper form into desired lengths, wherein:
the cutting mechanism (<NUM>) comprises a stationary blade (<NUM>), a first reciprocating blade (<NUM>), and a second reciprocating blade (<NUM>);
the first reciprocating blade (<NUM>) and the second reciprocating blade (<NUM>) are pivotable relative to the stationary blade (<NUM>);
the first reciprocating blade (<NUM>) is driven by a first drive cog (<NUM>), and the second reciprocating blade (<NUM>) is driven by a second drive cog (<NUM>);
the first drive cog (<NUM>) and the second drive cog (<NUM>) are coupled to one another such that they rotate concurrently; and
the coupling of the first drive cog (<NUM>) and the second drive cog (<NUM>) is achieved via a drive belt (<NUM>), and the drive belt (<NUM>) is removable and/or adjustable, such that the first drive cog (<NUM>) and the second drive cog (<NUM>) may be rotated independently of one another, thereby enabling alteration of a phase difference between movement of the first connecting rod (<NUM>) and the second connecting rod (<NUM>), thereby altering a phase difference between movement of the first reciprocating blade (<NUM>) and the second reciprocating blade (<NUM>).