APPARATUS AND PROCESS FOR PACKAGING A PRODUCT

专利摘要:
apparatus and process for packaging a product. The present invention relates to a process for packaging a product (p) comprising driving at least the precursor body in a machine direction along the operating path, forming therein one or more longitudinal rows of tray-shaped elements (8 ) adjacent, loading one or more of said products (p) into a respective cavity of said tray-shaped elements; forming a through opening in corner regions of the tray elements; firmly attaching a plastic film (11) to close the upper opening of said tray-shaped elements (8); transversely separate the closed tray-shaped elements forming closed trays. an apparatus (1) for carrying out the above process is also described.
公开号:BR112015028070B1
申请号:R112015028070-6
申请日:2014-05-06
公开日:2021-08-10
发明作者:Riccardo Palumbo
申请人:Cryovac, Inc；
IPC主号:

专利说明:

Technical Field
[001] The present invention refers to an apparatus and a process for packaging a product. According to certain aspects, the invention relates to an apparatus and method for packaging a product under a controlled atmosphere or under vacuum. According to other aspects, the invention relates to an apparatus and method for packaging the skin of a product. Previous Technique
[002] Plastic containers are commonly used for food packaging and for a wide variety of other items where a plastic lid is attached to the container, for example, by the application of heat.
[003] In order to pack products, in particular food products, vacuum packaging was developed in the past.
[004] Among the known vacuum packaging processes, vacuum skin packaging is commonly employed to package food products such as fresh and frozen meat and fish, cheese, processed meat, ready meals and the like. Vacuum skin packaging is described, for example, in FR 1 258 357, FR 1 286 018, AU 3 491 504, US RE 30 009, US 3 574 642, US 3 681 092 US 3 713 849, US 4 055 672 and US 5 346 735.
[005] Vacuum skin packaging is basically a thermoforming process. In particular, the product is typically placed on a rigid or semi-rigid support (such as a tray, bowl or glass). The holder with the product placed on it is placed in a vacuum chamber where a film of thermoplastic material, held by vacuum in a position above the product placed on the holder, is heated to soften it. The space between the holder and the film is then evacuated and finally a vacuum above the film is released to cause the film to drape down around the product and seal onto the surface of the holder not covered by the product, thus forming a tight skin. around the product and on the stand.
[006] US 2005/0257501 describes a machine for packaging a product arranged in a tray. The machine has a lower tool to support the tray and an upper tool with a cutting device. During operation, the film is held along an edge surrounding the tray and is deformed by the top tool in a direction extending away from the product. The space surrounding the product is then evacuated, the film and tray edge are sealed, and the film is then cut by the cutting device.
[007] As for the machines described by US 2007/0022717 and US2005/0257501, the film is cut to the size of the tray inside the chamber formed by the upper tool and the lower tool, by means of the cutting devices provided in the upper tool. First, this disadvantageously requires providing a rather complex and bulky superior tool. Furthermore, this disadvantageously requires providing an excess of film with respect to the size of the support, which excess film is cut from the package and scraped off during or at the end of the packaging process. In effect, the film is in the form of a continuous sheet wound onto a roll (for example, as shown in Figure 3 of US 2005/0257501). Therefore, an excess of film is required to allow the film to be pulled off the roll and held in place above the supported product. Furthermore, in US 2007/0022717 more than one product-loaded support (namely two) is packed in each cycle, so that an excess of film is also present between adjacent supports.
[008] DE102006022418 describes an apparatus where an unsealing film is cut to size and fixed to the upper rim of a tray within the sealing station. This solution requires a very complex design of the sealing station in order to host and operate the cutting blades. Also, an excess of film is needed to allow sealing and cutting of the film. Furthermore, the description in this reference provides a small tube which operates through a valve in the side wall of the tray or through a gap between the sealing film and the upper rim of the tray.
[009] WO2011 / 012652 shows an apparatus for packaging a product in a tray. The machine comprises a first film transfer plate configured to hold a sheet of film, heat the sheet of film, bring the sheet of film to a position above a tray with the product disposed therein and airtightly secure the film sheet to the tray. A second film transfer plate is also present. As for the first film transfer plate also the second film transfer plate is configured to clamp a film sheet, heat the film sheet, bring the film sheet to a position above a tray with the product disposed on it and airtightly attach the film sheet to the tray. During a first stage of machine operation, the first film transfer plate retains a first film sheet and heats the first film sheet, while the second film transfer plate releases a second film sheet, thereby allowing the second sheet is drawn into a first tray; and during a second stage of machine operation, the second film transfer plate retains a third film sheet and heats the third film sheet, while the first film transfer plate releases the first film sheet, thereby allowing the first sheet of film is drawn into a second tray. The machine further comprises a rotating cylinder suitable for rotating around its X axis, the first film transfer plate and the second film transfer plate being connected to the rotating cylinder so that when the rotating cylinder rotates about its X axis, the positions of the first film transfer plate and the second film transfer plate are swapped. A vacuum arrangement allows air to be removed from inside the tray under the film sheet (positioned by either the first or second film transfer plate) through the hole or holes present in the tray. The film transfer plates are configured to release the film sheet, thereby allowing the film sheet to be drawn into the tray while the vacuum arrangement is removing air from inside the tray. This solution has allowed for significant savings in terms of film material, but requires cutting the film to size before the film is sealed to the tray.
[0010] In addition to the above solutions, the packaging apparatus has been developed in which the trays are formed in-line from a continuous bottom web of plastic material. Trays formed in-line, after being filled with a suitable product, are sealed by a continuous top film. The plurality of sealed trays are then longitudinally and if necessary transversely separated by cutters located downstream of the sealing station. In this type of apparatus, the lower weft is perforated in correspondence with the longitudinal side edges thereof. This is done to create openings that allow air to be removed from the trays in correspondence with the sealing station, before attaching the upper film to the trays. Furthermore, chains provided with gripping means guide the lower web along its path from forming the trays to final separation. The perforated side edges are removed from the trays and cause a non-negligible weft residue and film material.
[0011] EP0293794 B1 describes a packaging apparatus in which a continuous sheet of plastic packaging material carried by a chain is formed into cup-shaped containers loaded with product and arranged in two rows side by side. Evacuation openings are cut through the plastic between successive pairs of containers: the cuts are located in the middle of the transverse rim connecting two consecutive trays and extend in the cross-machine direction. A second continuous web of plastic packaging material is placed over the first web to cover the filled containers and thereby form packages. A proper design of the sealing station allows you to draw gas from the trays via the openings and then completely seal the trays. This solution requires that longitudinally adjacent trays be separated by a sufficiently dimensioned transverse rim, thus causing material waste. Note that if the tray rims involved with the openings are not finally trimmed, the packaged tray may also have rims having a rather irregular shape.
[0012] DE 2161465 shows a packaging apparatus where trays are formed continuously from a continuous plastic web below which is guided to a sealing station. A top sealing film is cut lengthwise and applied to the rows of trays. The longitudinal cuts allow air removal and, after air removal, they are eventually sealed in the packaging assembly. Note that slitting the top film before the actual sealing to the tray can compromise the ability to accurately orient the top film and certainly adds to the complexity of the sealing operation.
[0013] In this situation, it is an object of the present invention to offer a process and an apparatus where trays are formed in-line and at the same time scrap of packaging material is minimized.
[0014] Another objective is that of offering a process and apparatus capable of properly guiding the trays and the sealing film, in order to reduce, if not avoid, problems of poor positioning of the sealing film in the tray.
[0015] Additionally, it is an auxiliary object of the invention to devise a process and an apparatus which can operate flexibly for both skin packaging and modified atmosphere packaging.
[0016] It is yet another object of the invention to design a process and an apparatus for packaging products using either heat shrinkable films or non-heat shrinkable films. Invention Summary
[0017] One or more of the objects specified above are substantially achieved by a process and by an apparatus according to any of the appended claims Aspects of the invention are described herein below.
[0018] A 1st aspect involves an apparatus for packaging a product (P) in a tray, said apparatus comprising: a support structure defining an operating path; a web supply assembly associated with the support structure and configured to provide a plastic precursor body in the form of a plastic web; a drive assembly carried by the support structure and configured to move at least the precursor body in a machine direction (MD) along the operating path; formation positioned in the operating path and configured to receive the precursor body in said plastic web shape and form a series of cavities therein; a film supply assembly configured to supply a plastic film; a packaging assembly also positioned to the along said operating path and configured to receive said plastic film and said precursor body, wherein the packaging assembly is also configured to secure the plastic film to close the upper opening of said tray-shaped elements; a separation assembly positioned along said path downstream of the packaging assembly and configured to at least transversely separate the shaped elements of closed tray and forming closed trays; a cutting tool acting on the precursor body in correspondence with a zone of the predefined path comprised between the web supply assembly and the packaging assembly, the cutting tool being configured to form an opening of passage in the precursor body.
[0019] In a 2nd aspect according to the 1st aspect the deformation station is configured to receive the precursor body in said plastic web form and form therein a series of cavities positioned and formed so that, downstream of the training station, the precursor body comprises: i. one or more longitudinal rows of adjacent tray-shaped elements,ii. longitudinal strips transversely delimiting each row of tray-shaped elements,iii. transverse bands longitudinally delimiting and consecutively joining adjacent tray-shaped elements of the same longitudinal row, the transverse bands and longitudinal bands also delimiting upper openings of the tray-shaped elements and crossing one another in a plurality of transverse regions.
[0020] In a 3rd aspect according to any of the foregoing aspects the cutting tool is configured and positioned to form said through opening or said through openings in said correspondence with a side wall of each of said shaped elements of tray.
[0021] In a 4th aspect according to any of the foregoing aspects 2nd to 3rd the cutting tool is configured and positioned to form said through opening or said through openings in correspondence with a plurality of said transverse regions between the longitudinal and transverse bands.
[0022] In a 5th aspect according to any of the foregoing aspects, the apparatus includes a control unit configured and connected to operate at least said drive assembly, said forming station, said packaging assembly and said tool of cutting.
[0023] In a 6th aspect according to any of the above aspects 2nd to 5th the forming station is configured to form said plastic precursor body with two or more parallel rows of tray-shaped elements.
[0024] In a 7th aspect according to the previous aspect, each of said tray-shaped elements has a substantially rectangular upper opening defined by two longitudinal side walls and two transverse side walls of the tray-shaped elements.
[0025] In an 8th aspect according to the previous aspect, the transverse strips cross perpendicularly the longitudinal strips delimiting said upper openings, so that said transverse regions are located in correspondence with corner zones of the elements in the form of a tray.
[0026] In a 9th aspect according to any of the foregoing aspects 2nd to 8th the cutting tool is positioned to act on said plastic precursor body and is configured to form said through opening in a plurality of said cross regions.
[0027] In a 10th aspect according to the previous aspect, wherein the cutting tool is configured to form said through opening in the form of a cutout portion removed from the plastic precursor body.
[0028] In an 11th aspect according to one of the two aspects above, the cutting tool is configured to form each cutout portion by removing a part of a transverse band in correspondence with a midline between two tray-shaped elements longitudinally adjacent ones of the same row.
[0029] In a 12th aspect according to any of the three foregoing aspects the cutting tool is configured and positioned so that each of said cutout portions is symmetrically located between two adjacent tray-shaped supports.
[0030] In a 13th aspect according to any of the four previous aspects, the cutting tool is configured and positioned so that each of said cutting portions is in the form of one of the following: i. a triangular opening bounded by three sides - straight or arc-shaped, eii. a quadrangular opening bounded by four sides - straight or arch-shaped.
[0031] In a 14th aspect according to any one of the previous five aspects, the cutting tool is configured and positioned so as to form in the center of said transverse regions a corresponding cutout portion in the form of a quadrangular opening delimited by four sides - straight or arc-shaped.
[0032] In a 15th aspect according to any of the foregoing aspects the packaging assembly includes: - a lower tool comprising a pre-set number of seats each intended to receive at least one of said elements in the form of a tray, and - an upper tool facing the lower tool and configured to cooperate with the lower tool to secure said plastic film to at least one tray-shaped element positioned on said seat.
[0033] In a 16th aspect according to any of the foregoing aspects, in which the packaging assembly is also configured to firmly fix the plastic film to close the upper opening of said tray-shaped elements and includes:- lower tool comprising a pre-set number of seats each intended to receive at least one of said tray-shaped elements, e-upper tool facing the lower tool and configured to cooperate with the lower tool to secure said plastic film to the fur. at least one tray-shaped element positioned on said seat and sealingly close the respective upper opening forming one or more closed tray-like elements.
[0034] In a 17th aspect according to either of the two previous aspects the apparatus comprises at least one main actuator active in at least one of said upper and lower tools.
[0035] In an 18th aspect according to the previous aspect, where a control unit is configured to operate the main actuator so that the upper and lower tools are moved between an open position, where the upper tool is moved away from the lower tool and forms a gap that allows positioning of the tray-shaped elements on the seats and the plastic film above the tray-shaped elements, and a closing position, in which the upper tool and the lower tool are in close proximity and they act against each other to sealably secure the plastic film above the one or more tray-like elements located in the packaging assembly.
[0036] In a 19th aspect according to any one of the previous four aspects the upper tool comprises means for retaining a portion of the plastic film in correspondence with an active surface of the upper tool facing the lower tool.
[0037] In a 20th aspect according to the previous aspect said retaining means comprise a vacuum source controlled by/by a control unit, the control unit being configured to activate the means to retain and cause the surface active receives and retains said portion of the plastic film.
[0038] In a 21st aspect according to any one of the six aspects above, the upper tool has a flat active surface facing the lower tool and configured to receive a portion of the plastic film that needs to be attached to the tray-shaped elements hosted in the bottom tool.
[0039] In a 22nd aspect according to any of the previous aspects 15th to 20th the upper tool has a dome-shaped active surface facing the lower tool and configured to receive a portion of the plastic film that needs to be fixed to the tray-shaped elements housed in the lower tool.
[0040] In a 23rd aspect according to either of the two preceding aspects in which the heating means is associated with the upper tool and controlled by/by a control unit, the control unit being configured to control the heating means so that the active surface of the upper tool is brought at least to a temperature comprised between 150°C and 260°C, optionally between 180-240°C, more optionally between 200-220°C.
[0041] In a 24th aspect according to any of the foregoing aspects 15th to 23rd the lower tool presents a series of base wall portions and a series of side wall portions emerging from the respective one of said base wall portions. base for defining said series of seats and wherein one of said side wall portions carries at least one protrusion which is positioned and configured such that, when the tray-like elements are positioned on the respective seats of the lower tool, each protrusion is inserted into a respective through-opening located in one of said transverse regions and projects above the tray-shaped elements towards said active dome-shaped surface.
[0042] In a 25th aspect according to any one of the 15th to 24th previous aspects the apparatus has a vacuum arrangement connected to the lower tool and configured to remove gas from an interior of said tray-shaped elements, the arrangement of vacuum comprising at least one vacuum source and at least one evacuation line connecting said passage opening to the vacuum source.
[0043] In a 26th aspect according to either of the above aspects, or a control unit is configured to control the vacuum arrangement to withdraw gas at least when the upper and lower tools are in said closed position.
[0044] In a 27th aspect according to any of the previous aspects 15th to 26th the apparatus has a controlled atmosphere arrangement connected to the lower tool and configured to inject a gas stream inside said elements in the form of a tray, the controlled atmosphere arrangement comprising at least one injection device and at least one injection line connecting the passage opening to the injection device.
[0045] In a 28th aspect according to either of the aspects above said, or a control unit, is configured to control said controlled atmosphere arrangement to inject said gas stream at least when the upper and lower tools are in said closed position.
[0046] In a 29th aspect according to the previous aspect the controlled atmosphere arrangement is configured to inject gas or gas mixtures including an amount of one or more of N2, O2 and CO2 which is different from the amount of these same gases when present in the atmosphere at 20 °C and at sea level (1 atmosphere of pressure).
[0047] In a 30th aspect according to the previous aspect the apparatus includes both the vacuum arrangement and the controlled atmosphere arrangement and the control unit is configured to control said controlled atmosphere arrangement to begin injecting said gas stream or after a preset delay of activation of said vacuum arrangement or after a preset level of vacuum has been reached within said interior of the tray-shaped elements.
[0048] In a 31st aspect according to the previous aspect said control unit is configured to control said controlled atmosphere arrangement to begin injecting said gas stream while said gas withdrawal is still in progress.
[0049] In a 32nd aspect according to any of the five previous aspects the control unit is configured to operate the vacuum arrangement to remove gas and create a vacuum level with a pressure between 0 and 300 m bar, preferably between 50 and 300 mbar, more preferably between 100 and 250 mbar, within said interior of the tray-like elements.
[0050] In a 33rd aspect according to any of the foregoing aspects each of said seats is delimited by a base wall portion and a side wall portion emerging from the respective base wall portion and wherein the at least one evacuation line and/or the at least one injection line leads to: a first groove defined in the side wall portion of each seat and opening into said seat, and/or a second groove defined in the base wall portion of each seat and opening into said seat.
[0051] In a 34th aspect according to any of the foregoing aspects the drive assembly includes a first active portion positioned downstream of the packaging assembly on both sides of the operating path and configured to grip longitudinal side edges of a portion of the precursor body extending longitudinally downstream of the packaging assembly. In practice, the precursor body is greater in width than the corresponding portion of the plastic film, so that the first active portion surrounds the precursor body, but not directly the longitudinal side edges of the plastic film that is pulled by the body. of precursor by virtue of the fact that downstream the plastic film packaging assembly is attached to the precursor body. The drive assembly is configured so that the longitudinal side edges of the precursor body and the plastic film, in correspondence with the packaging assembly, are free and not engaged by any part of the drive assembly. This means that neither the first active portion nor any other actuation means grip the longitudinal side edges of the precursor body and the plastic film in correspondence with the packaging assembly.
[0052] In a 35th aspect according to the previous aspect the drive assembly is configured so that the longitudinal side edges of the precursor body, in correspondence with the cutting tool, are free and not engaged by any part of the assembly of drive. This means that neither the first active portion nor any other drive means grip the longitudinal side edges of the precursor body in correspondence with the zone where the cutting tool operates.
[0053] In a 36th aspect according to any of the above aspects 1st to 33rd the drive assembly includes a first active portion positioned downstream of the packaging assembly on both sides of the operating path and configured to grip edges longitudinal sides of a longitudinal portion of the plastic film extending longitudinally downstream of the packaging assembly: in practice, the plastic film is greater in width than the corresponding portion of the precursor body so that the first active portion engages with the plastic film, but not directly on the longitudinal side edges of the precursor body. The drive assembly is also configured so that the longitudinal side edges of the precursor body and the plastic film, in correspondence with the packaging assembly, are free and not engaged by any part of the drive assembly. This means that neither the first active portion nor any other actuation means grip the longitudinal side edges of the precursor body and the plastic film in correspondence with the packaging assembly.
[0054] In a 37th aspect according to the previous aspect the drive assembly is configured so that the longitudinal side edges of the precursor body, in correspondence with the cutting tool, are free and not engaged by any part of the assembly of drive. This means that neither the first active portion nor any other drive means grip the longitudinal side edges of the precursor body in correspondence with the zone where the cutting tool operates.
[0055] In a 38th aspect according to any of the above aspects 1st to 33rd the drive assembly includes a first active portion positioned downstream of the packaging assembly on both sides of the operating path and configured to grip edges longitudinal sides of the plastic film and precursor body extending longitudinally downstream of the packaging assembly. In this case, the drive assembly is configured so that the longitudinal side edges of the precursor body and the plastic film, in correspondence with the packaging assembly, are free and not engaged by any part of the drive assembly. This means that neither the first active portion nor any other actuation means grip the longitudinal side edges of the precursor body and the plastic film in correspondence with the packaging assembly.
[0056] In a 39th aspect according to the previous aspect the drive assembly is configured so that the longitudinal side edges of the precursor body, in correspondence with the cutting tool, are free and not engaged by any part of the assembly of drive. This means that neither the first active portion nor any other drive means grip the longitudinal side edges of the precursor body in correspondence with the zone where the cutting tool operates.
[0057] In a 40th aspect according to any of the foregoing aspects 1st to 33rd the drive assembly includes a first active portion positioned on both sides of the operating path and configured to grip: longitudinal side edges of a portion longitudinally of the plastic film extending longitudinally downstream of the packaging assembly, longitudinal side edges of a longitudinal portion of the plastic film extending longitudinally in correspondence with the packaging assembly.
[0058] In practice, the plastic film is greater in width than the corresponding portion of the precursor body so that the first active portion engages the plastic film, but not directly on the longitudinal side edges of the precursor body.
[0059] Thus, the drive assembly is configured so that the longitudinal side edges of the precursor body, in correspondence with the packaging assembly, are free and not engaged by any part of the drive assembly. This means that in this case, neither the first active portion nor any other actuating means grip the longitudinal side edges of the precursor body and that the first active portion only grips the plastic film.
[0060] In a 41st aspect according to the previous aspect the drive assembly is configured so that the longitudinal side edges of the precursor body, in correspondence with the cutting tool, are free and not engaged by any part of the assembly of drive. This means that neither the first active portion nor any other drive means grip the longitudinal side edges of the precursor body in correspondence with the zone where the cutting tool operates.
[0061] In a 42nd aspect according to either of the two previous aspects the drive assembly is configured so that the first active portion also grips the longitudinal side edges of a longitudinal portion of the plastic film that extends between the assembly of supplying film and packaging set; basically in this case the plastic film is only driven from the outlet out of the supply set all the way through the packing set and downstream of the packing set.
[0062] In a 43rd aspect according to any of the foregoing aspects the drive assembly includes a second active portion positioned between the forming station and the packaging assembly on both sides of the operating path and configured to grip longitudinal side edges of a portion of the precursor body extending longitudinally between the forming station and the packaging assembly.
[0063] In a 44th aspect according to the previous aspect the drive assembly is configured so that the longitudinal side edges of the precursor body, in correspondence with the forming station, are free and not engaged by any part of the assembly of drive.
[0064] In a 45th aspect according to any of the foregoing aspects 1st to 42nd the drive assembly includes a second active portion positioned between the supply assembly and the packaging assembly on both sides of the operating path and configured to grip the side edges of a portion of the precursor body extending longitudinally from the forming station, included, and the packaging assembly.
[0065] In a 46th aspect according to any of the foregoing aspects 34th to 45th the drive assembly includes: at least one elongated drive body on each side of the operating path, wherein each elongated drive body is mounted to the support structure defining a closed path having a drive branch and a return branch; a plurality of grippers carried by the elongate drive body and configured to grip opposite longitudinal side edges of the precursor body and/or the plastic film; and at least one motor connected to the drive body and controlled by/by a control unit, the latter being configured to operate the motor so as to move the elongated drive body along said closed path, with the drive branch moving according to the machine direction and the return branch moving opposite the machine direction.
[0066] In a 47th aspect according to the previous aspect each elongated body is configured in said closed path so that the driving branch of the elongated body continuously comprises a first segment extending according to one of the following configurations: parallel to operating path downstream of the packaging assembly; parallel to the operating path in the packaging assembly and downstream of the packaging assembly; transverse to the operating path, between the film supply assembly and the packaging assembly, and parallel to the path operating in the packaging assembly and downstream of the packaging assembly, wherein the first active portion of the drive assembly comprises handle elements carried by said first segment.
[0067] In a 48th aspect according to the previous aspect the grip elements carried by said first segment are adapted to grip the side edges of the precursor body in distribution of the latter longitudinally downstream of the packaging assembly.
[0068] In a 49th aspect according to either of the two foregoing aspects the grip elements carried by said first segment are adapted to grip the side edges of the plastic film or just downstream of the packaging assembly, or in the packaging assembly and downstream of the packaging assembly, or between the film supply assembly and the packaging assembly and in the packaging assembly and downstream of the packaging assembly.
[0069] In a 50th aspect according to any of the three foregoing aspects wherein the elongated body is configured in said closed path, so that the driving branch of the elongated body continuously comprises a second segment extending parallel to the path operating at least downstream of the forming station to upstream of the cutting tool, wherein the grip elements carried by said second segment are adapted to grip the longitudinal side edges of the longitudinally extending precursor body between the cutting station. forming and the packaging assembly; wherein the second active portion of the drive assembly comprises grip elements carried by said second segment.
[0070] In a 51st aspect according to the previous aspect the elongated body drive branch continuously comprises a third segment connecting a downstream end of the second segment to an upstream end of the first segment, the third segment extending along a path which is sufficiently remote from the operating path in correspondence with the packaging assembly and optionally the cutting tool, wherein the grip elements carried by said third segment do not engage the longitudinal side edges of either the precursor body or the plastic film at least in correspondence with the packing set and optionally in correspondence with the cutting tool.
[0071] In a 52nd aspect according to any one of the preceding five aspects the elongated body drive branch continuously comprises a fourth segment extending parallel to the operating path of at least the supply assembly upstream of the forming station, wherein the grip elements carried by said fourth segment are adapted to grip the longitudinal side edges of the precursor body extending longitudinally between the supply assembly and the forming station; wherein the second active portion of the drive assembly comprises the grip elements carried by said fourth segment.
[0072] In a 53rd aspect according to the foregoing aspects the drive assembly includes a fifth segment connecting a downstream end of the fourth segment to an upstream end of the second segment, the fifth segment extending along a path which is sufficiently remote from the operating path in correspondence with the forming station, whereby the handle elements carried by said fifth segment do not engage the longitudinal side edges of the precursor body at least in correspondence with the forming station.
[0073] In a 54th aspect according to any of the foregoing aspects the cutting tool is positioned immediately upstream of the packaging assembly.
[0074] In a 55th aspect according to any of the foregoing aspects including a control unit configured to carry out the following cycle: command the forming station to form said tray-shaped elements for the precursor body from the supply set in the form of a plastic web; commanding the drive assembly to move said precursor body in a step-by-step manner so as to sequentially bring the packaging assembly portions of the precursor body having a preset number of shaped elements trays formed therein; commanding the cutting tool to act on the precursor body in correspondence with a zone of the predefined path comprised between the web supply assembly and the packaging assembly and forming said through opening; commanding the packaging assembly to pass the open position to the closed position, optionally command the vacuum arrangement to remove gas and/or command the controlled atmosphere arrangement to inject a gas or a mixture of gases, command the packaging assembly to securely attach the plastic film to said shaped elements of tray in the packaging assembly command the separation assembly to transversely separate the closed tray-shaped elements and form a series of closed trays.
[0075] In a 56th aspect in accordance with any of the foregoing aspects the film supply assembly is configured to provide a film comprising at least a first gas permeable layer and a second gas permeable layer.
[0076] In a 57th aspect according to the previous aspect the gas-impermeable layer is releasably attached to the underlying gas-permeable layer. The gas-tight layer can then be removed by a user after packaging.
[0077] In a 58th aspect the gas-permeable layer is an oxygen-permeable layer, while the gas-impermeable layer is an oxygen-impermeable layer.
[0078] In a 59th aspect according to any of the foregoing aspects the apparatus comprises a second packaging assembly operating downstream of the packaging assembly (referred to in this case as first packaging assembly) and configured to apply a second plastic film.
[0079] In a 60th aspect the packaging assembly is configured to apply a first film to form a skin above the products P contained within the tray-shaped elements and the second packaging assembly is configured to apply a second film on top of the tray-shaped elements to create: - a lid with normal atmosphere between the second film and the first film; - a lid with a modified atmosphere between the second film and the first film; - an additional skin formed by the second film and first film.
[0080] In a 61st aspect according to the previous aspect a second cutting tool is active in the tray-shaped elements that received the film, but which did not receive the second plastic film, in order to form an additional passage opening of the similar type to the openings described in any of the aspects 1st to 14th. The second cutting tool would operate downstream of the packaging assembly 20, but upstream, preferably immediately upstream, of the second packaging assembly.
[0081] A 62nd aspect involves a process for packaging products (P), said process optionally using an apparatus according to any of the foregoing aspects, the process comprising the following steps: providing a plastic precursor body in the form of a plastic web; driving at least the precursor body in a machine direction along the operating path; receiving the precursor body in said plastic web shape and forming the same in a series of cavities so that the body of precursor comprise:i. one or more longitudinal rows of adjacent tray-shaped elements,ii. longitudinal strips transversely delimiting each of said rows of tray-shaped elements,iii. transverse bands longitudinally delimiting and consecutively joining adjacent tray-shaped elements of the same longitudinal row, the transverse bands and longitudinal bands delimiting upper openings of the tray-shaped elements and crossing one another in a plurality of transverse regions; load one or more of said products (P) in a respective cavity of said tray-shaped elements; providing a plastic film; fixing, preferably firmly fixing, the plastic film to close the upper opening of said tray-shaped elements of the body of precursor; transversely separating the closed tray-shaped elements, thereby forming separate closed trays or groups of trays; prior to affixing the plastic film to the tray-shaped elements forming a through opening located in correspondence with the precursor body.
[0082] In a 63rd aspect according to the foregoing aspect, forming a through opening located in correspondence with the precursor body comprises forming a through opening in correspondence with at least one of:i. a side wall of each of said tray-shaped elements, eii. a plurality of said transverse regions between the longitudinal and transverse bands.
[0083] In a 64th aspect according to either of the two foregoing aspects comprising forming said plastic precursor body with two or more parallel rows of tray-shaped elements, wherein:- each of said elements in the form of tray has a substantially rectangular upper opening defined by two longitudinal side walls and two transverse side walls of the tray-shaped elements, and the transverse bands perpendicularly cross the longitudinal bands delimiting said rectangular upper openings, so that said transverse regions are located in correspondence with corner zones of the tray-shaped elements.
[0084] In a 65th aspect according to the preceding aspect wherein forming a through opening comprises forming said through opening in a plurality of said transverse regions.
[0085] In a 66th aspect according to any of the three foregoing aspects said through opening is formed in the form of a cut-out portion removed from the plastic precursor body by removing a part of a transverse band in correspondence with a midline between two longitudinally adjacent tray-shaped elements of the same row.
[0086] In a 67th aspect according to the previous aspect each of said cutout portions is symmetrically located between two adjacent tray-shaped supports.
[0087] In a 68th aspect according to either of the two foregoing aspects each of said cutout portions is in the form of one of a triangular opening delimited by three sides - straight or arch-shaped - or a quadrangular opening delimited by four sides - straight or arc-shaped.
[0088] In a 69th aspect according to any one of the foregoing aspects 62nd to 68th comprising: - retaining a portion of the plastic film in correspondence and above a corresponding tray-shaped element, - heating the film portion of plastic at least up to a temperature comprised between 150°C and 260°C, optionally between 180 and 240°C, more optionally between 200 and 220°C, - removing gas from an interior of said tray-shaped elements.
[0089] In a 70th aspect according to any one of the foregoing aspects of the 62nd to the 69th comprising:- injecting a gas or a mixture of gases into said tray-shaped elements to form a controlled atmosphere within said elements in tray shape; in which the gas or gas mixture includes an amount of one or more of N2, O2 and CO2, which is different from the amount of these same gases when present in the atmosphere at 20°C and at sea level (1 pressure atmosphere).
[0090] In a 71st aspect according to any one of the foregoing aspects 62° to 70° comprising firmly affixing the plastic film to the respective tray-shaped element.
[0091] In a 72nd aspect according to any of the foregoing aspects of the 62nd to 71st, driving the precursor body comprises gripping longitudinal side edges of the precursor body in correspondence with a portion where the precursor body has fixedly received the film of plastic, while leaving free the longitudinal side edges of the precursor body in correspondence with a portion of the precursor body where the attachment of the plastic film to the tray-shaped elements takes place.
[0092] In a 73rd aspect according to any one of the foregoing aspects of the 62nd to the 72nd, driving the precursor body comprises gripping longitudinal lateral edges of the precursor body in correspondence with a portion where the precursor body has fixedly received the film of plastic, while leaving free the longitudinal side edges of the precursor body in correspondence with a portion of the precursor body where the fixing of the plastic film to the tray-shaped elements takes place, where the formation of the through openings takes place.
[0093] In a 74th aspect according to any of the above aspects 62° to 71° the plastic film has a measured width perpendicular to the machine direction greater than the width of the underlying portion of the precursor body. In this case, actuating the precursor body comprises gripping longitudinal side edges of the plastic film in correspondence with a portion where the precursor body has fixedly received the plastic film: the precursor body is not gripped and - above all - the side edges longitudinal portions of the precursor body in correspondence with a portion of the precursor body where the attachment of the plastic film to the tray-shaped elements takes place are left free of any grip means which are not attached to the plastic film.
[0094] In a 75th aspect according to the foregoing aspect the longitudinal side edges of the precursor body in correspondence with a portion of the precursor body where formation of the through openings occurs are left free of any grip means.
[0095] In a 76th aspect according to either of the two foregoing aspects in which actuating the precursor body comprises grasping longitudinal side edges of the plastic film in correspondence of: - a portion of the plastic film extending longitudinally where the body of precursor fixedly received the plastic film, - a portion of the plastic film extending longitudinally in the packaging assembly and - optionally, a portion of the plastic film extending longitudinally between the film supply and the plastic film attachment to the body of precursor, while leaving free the longitudinal lateral edges of the precursor body in correspondence with a portion of the precursor body where the fixing of the plastic film to the tray-shaped elements takes place and, optionally, where the formation of the through openings takes place.
[0096] In a 77th aspect according to any one of the preceding aspects of the 62nd to the 71st driving the precursor body comprises gripping longitudinal side edges of the precursor body and the plastic film in correspondence with a portion where the precursor body has received fixing the plastic film, while leaving free the longitudinal lateral edges of the precursor body in correspondence with a portion of the precursor body where the fixing of the plastic film to the tray-shaped elements and optionally where the formation of the through openings occurs.
[0097] In a 78th aspect according to any of the foregoing aspects of the 62nd to the 77th driving the precursor body comprises gripping longitudinal lateral edges of the precursor body in correspondence with a portion where the precursor body has not yet received the formation of the through openings, while leaving free the longitudinal lateral edges of the precursor body in correspondence with a portion of the precursor body where formation of the through openings takes place.
[0098] In a 79th aspect according to any one of the foregoing aspects of the 62nd to the 78th driving the precursor body comprises gripping longitudinal side edges of the precursor body in correspondence with a portion where the precursor body is still in the form of a plastic web prior to formation of the cavities, whilst leaving free the longitudinal side edges of the precursor body in correspondence with a portion of the precursor body where formation of the cavities takes place.
[0099] In an 80th aspect according to any one of the preceding aspects from the 62nd to the 79th the through openings in the side wall of each of said tray-shaped elements are created - after the formation of said number of cavities and of defining the adjacent tray-like elements in the precursor body - by a cutting tool operating upstream of a packaging station configured to securely affix the plastic film to the tray-like elements.
[00100] In an 81st aspect according to any of the previous aspects from the 62nd to the 80th the passage openings in the plurality of said transverse regions between the longitudinal and transverse bands are created - after the formation of said number of cavities and definition of the adjacent tray-like elements in the precursor body - by a cutting tool operating upstream of a packaging station configured to securely affix the plastic film to the tray-like elements.
[00101] In an 82nd aspect the process uses the apparatus according to any of the previous aspects 1st to 61st. Brief description of the drawings
[00102] The present invention will become clearer by reading the following detailed description, given by way of example and not limitation, to be read with reference to the accompanying drawings, in which:
[00103] Figure 1 is a schematic perspective view layout of a first apparatus in accordance with aspects of the invention.
[00104] Figure 2 is a schematic perspective view layout of a second apparatus in accordance with aspects of the invention.
[00105] Figure 3A is a schematic perspective view layout of a third apparatus in accordance with aspects of the invention.
[00106] Figure 3B schematically shows the layout of a fourth apparatus in accordance with aspects of the invention.
[00107] Figure 3C schematically shows the layout of a fifth apparatus in accordance with aspects of the invention.
[00108] Figure 3D is a schematic cross section of a portion of the apparatus of Figure 3C at the exit of the packaging assembly.
[00109] Figure 3E schematically shows a layout of a sixth apparatus in accordance with aspects of the invention.
[00110] Figure 4 is an enlarged view of a feature of the apparatus shown in figure 1.
[00111] Figures 5-7 are perspective views showing a portion of a precursor body with tray-like elements provided with through openings in accordance with aspects of the invention.
[00112] Figures 8-10 schematically show a packaging assembly that can be used in the apparatus shown in any one of figures 1 to 3; the figures refer to sequential steps followed by the packaging assembly in accordance with aspects of the invention.
[00113] Figure 11 is a schematic representation of a variant of the packaging set of figures 8-10.
[00114] Figure 12 is a perspective view of a tray that can be obtained using the apparatus and processes described in this document.
[00115] Figure 13 is a perspective view of clamps carried by a chain that is the drive assembly associated with the apparatus of any one of figures 1 to 3.
[00116] Figure 14 is a side view of the tweezers shown in figure 13.
[00117] Figure 15 is a cross section taken along the XV-XV cutting plane represented in figure 14.
[00118] Figure 16 is a cross section analogous to that of figure 15 showing the chain engaging a sprocket and the collet brought into an open position.
[00119] Figure 17 is a side view of a variant of the clamps that can be used in place of those shown in figure 13.
[00120] Figure 18 is a cross section taken along the cut plane XVIII-XVIII represented in figure 17.
[00121] Figure 19 is a cross section analogous to that of figure 18 showing the chain engaging a sprocket and the collet brought into an open position.
[00122] Figure 20 shows a cross section of a part of the sprocket of the drive assembly according to aspects of the invention.
[00123] Figure 21 is an elevation view of the sprocket of figure 20.
[00124] Figure 22 is a perspective view of the sprocket of figure 20. Definitions and conventions
[00125] It should be noted that in this detailed description corresponding parts shown in the various figures are indicated with the same reference numeral in all figures. Note that the figures are not to scale and thus the parts and components shown in them are schematic representations.
[00126] In the following description and in the claims, the apparatus and the process refer to the packaging of a product inside a support or tray: the product can be a food product or not.
[00127] As used herein:- "tray" means a container of the type having a base wall, a side wall and optionally an upper rim radially emerging from the side wall; the tray has a rectangular shape or any other suitable shape such as round, square, elliptical, etc.; when rectangular or square in shape the corner regions of the tray can be rounded;- "operating path" is the path followed by the plastic precursor body during the packaging process;- "machine direction" is the feed direction of the precursor body along the operating path from the feed assembly to the separation assembly; "machine direction" is identified as MD in the drawings and in the examples described herein is horizontal;- "downstream" and "upstream" refer to the relative position of components or assemblies or apparatus stations with reference to the machine direction; - "bands" refer to transverse or longitudinal strips of plastic material defined in the precursor body and intersecting each other so as to delimit the upper openings of the cavities of the tray-shaped elements formed in the precursor body; the strips are elongated in shape and, depending on the shape of the cavities, may or may not have a substantially constant width (the width of the longitudinal strips is measured perpendicular to the machine direction, while the width of the transverse strips is measured parallel to the machine direction). For example, if the cavities have a perfectly rectangular top opening, then the longitudinal and transverse bands would be substantially straight stripes of constant width. In the case where the cavities have upper openings of substantially rectangular or substantially square shape with rounded corners (as in the examples of the attached drawings), then the bands show an increase in width in transverse regions where the transverse bands cross the longitudinal bands. The trays or supports
[00128] The trays described and claimed in this document can be made of a single layer or, preferably, of a multilayer polymeric material formed in-line before loading the product or products into the tray cavity.
[00129] In the case of a single layer material suitable polymers are, for example, polystyrene, polypropylene, polyesters, high density polyethylene, poly(lactic acid), PVC and the like, or foamed or solids.
[00130] Tray material can be provided with gas barrier properties. As used herein, this term refers to a film or sheet of material that has an oxygen transmission rate of less than 200 cm3/m2 dia bar, less than 150 cm3/m2 dia bar, less than 100 cm3/m2 dia-bar as measured in accordance with ASTM D-3985 at 23°C and 0% relative humidity.
[00131] Suitable materials for gas barrier monolayer thermoplastic trays are, for example, polyesters, polyamides and the like.
[00132] In case a multilayer material is used to form the tray, suitable polymers are, for example, ethylene homo and copolymers, propylene homo and copolymers, polyamides, polystyrene, polyesters, poly(lactic acid), PVC and the like. Some of the multilayer material can be solid and some can be foamed.
[00133] For example, the tray material may comprise at least one layer of a foamed polymeric material selected from the group consisting of polystyrene, polypropylene, polyesters and the like.
[00134] The multilayer material can be produced either by co-extrusion of all layers using co-extrusion techniques or by glue or hot lamination of, for example, a rigid foamed or solid substrate with a thin film, commonly called "liner ".
[00135] The thin film can be laminated either on the side of the tray in contact with product P or on the side facing away from product P or on both sides. In the latter case, the laminated films on both sides of the tray can be the same or different. A layer of an oxygen barrier material, eg copolymer (ethylene-covinyl alcohol), is optionally present to increase the shelf life of the packaged product P.
[00136] Gas barrier polymers that can be employed for the gas barrier layer are PVDC, EVOH, polyamides, polyesters and mixtures thereof. The thickness of the gas barrier layer will be defined in order to provide the tray with an appropriate oxygen transmission rate for the specific packaged product.
[00137] The tray material may also comprise a heat sealable layer. Generally, the heat sealable layer will be selected from polyolefins such as ethylene homo or copolymers, propylene homo or copolymers, ethylene/vinyl acetate copolymers, ionomers and homo and copolyesters, for example PETG, a polyethylene terephthalate modified with glycol.
[00138] Additional layers, such as adhesive layers, to better adhere the gas barrier layer to adjacent layers, may be present in the gas barrier material for the tray and are preferably present depending in particular on the specific resins used for the gas barrier layer.
[00139] In the case of a multilayer material used to form the tray, part of this structure may be foamed and part may be unfoamed. For example, the tray may comprise (from the outermost layer to the innermost food contact layer) one or more structural layers, typically of a material such as foamed polystyrene, foamed polyester or foamed polypropylene, or a sheet. molded from, for example, polypropylene, polystyrene, poly(vinyl chloride), polyester or cardboard; a gas barrier layer and a heat sealable layer.
[00140] The tray or trays described in this document can be obtained from a sheet of foamed polymeric material having a film comprising at least one oxygen barrier layer and at least one surface sealing layer laminated on the side facing the packaged product , so that the surface sealing layer of the film is the food contact layer of the tray. A second film, either barrier or non-barrier, can be laminated to the outer surface of the tray.
[00141] Specific tray material formulations are used for food products that require heating in a conventional or microwave oven prior to consumption. The surface of the container in contact with the product, i.e. the surface involved in forming the seal with the lid film, comprises a polyester resin. For example, the container can be made of cardboard coated with a polyester or it can be made entirely of a polyester resin. Examples of suitable containers for the packaging of the invention are CPET, APET or APET/CPET containers. Such a container can be either foamed or unfoamed.
[00142] Tray materials used for lid or skin applications containing foamed parts have a total thickness of less than 8 mm and, for example, may be between 0.5 mm and 7.0 mm and, more often, between 1 .0mm and 6.0mm.
[00143] In the case of rigid tray containing no foamed parts, the total thickness of the single-layer or multi-layer thermoplastic material is preferably less than 2 mm and, for example, may be between 0.1 mm and 1.2 mm mm and, more often, between 0.2 mm and 1.0 mm. The plastic film
[00144] The plastic film described and claimed here can be applied to form a lid on the tray (eg for MAP - modified atmosphere packaging) or a skin associated with the tray and matching the contour of the product.
[00145] The film for skin applications can be made of a flexible multilayer material comprising at least an external heat sealable first layer, an optional gas barrier layer and an external heat resistant second layer. The outer heat-sealable layer may comprise a polymer capable of welding to the inner surface of the supports carrying the products to be packaged such as, for example, ethylene homo or copolymers such as LDPE, ethylene/alpha-olefin copolymers, ethylene copolymers /acrylic acid, ethylene/methacrylic acid copolymers and ethylene/vinyl acetate copolymers, ionomers, copolyesters, eg PETG. The optional gas barrier layer preferably comprises oxygen-impermeable resins such as PVDC, EVOH, polyamides and blends of EVOH and polyamides. The external heat resistant layer can be made of ethylene homo or copolymers, ethylene/cyclic olefin copolymers, such as ethylene/norbornene copolymers, propylene homo or copolymers, ionomers, (co)polyesters, (co)polyamides. The film can also comprise other layers, such as adhesive layers or raw layers, to increase the film's thickness and improve its abuse and deep drawing properties. Crude layers used particularly are ionomers, ethylene/vinyl acetate copolymers, polyamides and polyesters. In all film layers, the polymer components can contain appropriate amounts of additives normally included in such compositions. Some of these additives are preferably included in the outer layers or one of the outer layers, while some others are preferably added to the inner layers. These additives include slip and antiblock agents such as talc, waxes, silica and the like, antioxidants, stabilizers, plasticizers, fillers, pigments and dyes, crosslink inhibitors, crosslink enhancers, UV absorbers, odor absorbers, oxygen scavengers , bactericides, antistatic agents and the like additives as known to those skilled in the art of packaging films.
[00146] One or more film layers can be crosslinked to improve the film strength and/or its heat resistance. Crosslinking can be achieved using chemical additives or subjecting the film layers to an energetic radiation treatment. Skin packaging films are typically manufactured in order to show low shrinkage when heated during the packaging cycle. These films generally shrink less than 15% at 160°C, more often less than 10%, even more often less than 8%, both in the longitudinal and transverse directions (ASTM D2732). Films are generally between 20 microns and 200 microns thick, more often between 40 and 180 microns and even more often between 50 microns and 150 microns.
[00147] Skin packages are generally "easy to open", i.e. they are easily opened by manually pulling out two webs, usually starting from a point such as a corner of the package where the upper web was not purposely sealed to the support. To achieve this feature, either the film or the tray can be provided with a suitable composition, allowing easy opening of the package, as is known in the art. Typically, the sealing composition and/or the composition of the adjacent layer of the tray and/or the film are adjusted in order to achieve the easy-open characteristic.
[00148] Various mechanisms can occur while opening an easy-to-open package.
[00149] In the first one ("peelable easy opening") the package is opened separating the film and the tray at the sealing interface.
[00150] In the second mechanism ("adhesive failure") the opening of the packaging is achieved through an initial break, through the thickness of one of the sealing layers followed by delamination of this layer from the support or underlying film.
[00151] The third system is based on the mechanism of "cohesive failure": the easy opening feature is achieved by internal rupture of a sealing layer that, during opening of the package, breaks along a plane parallel to the layer itself.
[00152] Specific mixtures are known in the art to obtain such opening mechanisms, ensuring the peeling of the film from the surface of the tray, such as those described in EP1084186.
[00153] On the other hand, in case the film is used to create a lid on the tray, the film material can be obtained by co-extrusion or lamination processes. Cover films can have a symmetrical or asymmetrical structure and can be monolayer or multilayer.
[00154] Multilayer films have at least 2, more often at least 5, even more often at least 7 layers.
[00155] The total film thickness can often vary from 3 to 100 microns, in particular from 5 to 50 microns, even more often from 10 to 30 microns.
[00156] Films can be optionally crosslinked. Crosslinking can be effected by irradiation with high energy electrons at a suitable dosage level as known in the art. The cover films described above can be heat shrink or heat cure. Heat shrink films typically show free shrinkage value at 120°C measured according to ASTM D2732 in the range 2 to 80%, more often 5 to 60%, even more often 10 to 40%, both in the longitudinal direction and transversal. Heat-curable films typically have free shrinkage values lower than 10% at 120°C, preferably lower than 5%, in both the longitudinal and transverse directions (ASTM D 2732). Lid films typically comprise at least one heat sealable layer and an outer skin layer which is generally composed of heat resistant polymers or polyolefin. The sealing layer typically comprises a heat-sealable polyolefin which, in turn, comprises a single polyolefin or a mixture of two or more polyolefins, such as polyethylene or polypropylene or a mixture thereof. The sealing layer can further be provided with anti-fog properties by incorporating one or more anti-fog additives into its composition or by coating or spraying one or more anti-fog additives onto the surface of the sealing layer by techniques well known in the art. The sealing layer can further comprise one or more plasticizers. The skin layer can comprise polyesters, polyamides or polyolefins. In some structures, a blend of polyamide and polyester can be advantageously used for the skin layer. In some cases, cover films comprise a barrier layer. Barrier films typically have an OTR (assessed at 23°C and 0% RH according to ASTM D-3985) below 100 cm3/(m2^dia^atm) and more often below 80 cm3/(m2^day ^atm). The barrier layer is generally made of a thermoplastic resin selected from a saponified or hydrolyzed ethylene-vinyl acetate (EVOH) copolymer product, an amorphous polyamide and a vinyl-vinylidene chloride and mixtures thereof. Some materials comprise an EVOH barrier layer, sandwiched between two layers of polyamide. The skin layer typically comprises polyesters, polyamides or polyolefin.
[00157] In some packaging applications, cover films do not comprise any barrier layer. Such films generally comprising one or more polyolefins are defined herein.
[00158] Non-barrier films typically have an OTR (assessed at 23°C and 0% RH according to ASTM D-3985) of 100 cm3/(m2^dia^atm) to 10000 cm3/(m2^day^ atm), more typically up to 6000 cm3/(m2^dia^atm).
[00159] Peculiar compositions based on polyester are those used for ready-meal packaging tray covers. For these films, polyester resins can make up at least 50%, 60%, 70%, 80%, 90% by weight of the film. These films are typically used in combination with polyester based supports.
[00160] For example, the container can be made of a cardboard coated with a polyester or it can be made entirely of a polyester resin. Examples of suitable containers for packaging are CPET, APET or APET/CPET containers, either foamed or non-foamed.
[00161] Generally, biaxially oriented PET are used as the cover film due to their high thermal stability at standard food heating/baking temperatures. Often biaxially oriented polyester films are heat curable, i.e. not heat shrinkable. To improve the heat sealability of the PET lid film to the container a heat sealable layer of a lower melt material is generally provided on the film. The heat sealable layer can be co-extruded with the PET base layer (as described in EP-A-1,529,797 and WO2007/093495) or it can be coated with solvent or by extrusion onto the base film (as described in US 2,762,720 and EP-A-1.252.008).
[00162] Particularly in the case of fresh red meat packaging, double-lid film comprising an inner, oxygen-permeable lid film and an outer, oxygen-impermeable, is advantageously used. The combination of these two films significantly prevents discoloration of the meat also when the wrapped meat extends upwards with respect to the height of the tray walls, which is the most critical situation in fresh meat barrier packaging.
These films are described, for example, in EP1848635 and EP0690012, the disclosures of which are incorporated herein by reference.
[00164] The cover film can be monolayer. The typical composition of monolayer films comprises polyesters as defined herein and blends thereof, or polyolefins as defined herein and blends thereof.
[00165] In all film layers, the polymer components may contain appropriate amounts of additives normally included in such compositions. Some of these additives are preferably included in the outer layers or one of the outer layers, while some others are preferably added to the inner layers. These additives include slip and antiblock agents such as talc, waxes, silica and the like, antioxidants, stabilizers, plasticizers, fillers, pigments and dyes, crosslink inhibitors, crosslink enhancers, UV absorbers, odor absorbers, oxygen scavengers , bactericides, antistatic agents, anti-fogging agents or compositions and the like additives as known to those skilled in the art of packaging films.
[00166] Films suitable for application of cap may advantageously be perforated in order to allow the packaged food to breathe. These films can be perforated using different technologies available in the art, by means of laser or mechanical means, such as rollers equipped with various needles. The number of perforations per unit area of the film and their dimensions affect the gas permeability of the film. Microperforated films are generally characterized by OTR value (assessed at 23°C and 0% RH according to ASTM D-3985) of 2500 cm3/(m2^dia^atm) to 1000000 cm3/(m2^dia^atm) . Macroperforated films are generally characterized by OTR (assessed at 23°C and 0% U.R. according to ASTM D-3985) higher than 1,000,000 cm3/(m2^day atm).
[00167] Furthermore, the films described herein for lid applications can be formulated to provide strong or peelable seals on the support. A method for measuring the strength of a peelable seal, referred to herein as "peel strength" is described in ASTM F-88-00. Acceptable peel strength values are in the range 100g/25mm to 850g/25mm, 150g/25mm to 800g/25mm, 200g/25mm to 700g/25mm.
[00168] The desired seal strength is achieved by specifically designing the tray and lid formulations.
[00169] In general, one or more layers of cover film may be printed in order to provide useful information to the consumer, a pleasing image and/or trademark information or other advertising information to enhance the retail sale of the product packed.
[00170] The film can be printed by any suitable method, such as by rotary screen, engraving or flexographic techniques, but known in the art. Definitions and conventions involving materials
[00171] PVDC are any vinylidene chloride copolymers in which a major amount of the copolymer comprises vinylidene chloride and a minor amount of the copolymer comprises one or more unsaturated monomers copolymerizable therewith, typically vinyl chloride and alkyl acrylates or methacrylates ( for example, methyl acrylate or methacrylate) and mixtures thereof in different proportions. Generally, a PVDC barrier layer will contain plasticizers and/or stabilizers as is known in the art.
[00172] As used herein, the term EVOH includes saponified or hydrolyzed ethylene-vinyl acetate copolymers and refers to ethylene/vinyl alcohol copolymers having an ethylene comonomer content preferably comprised from about 28 to about 48% in mole, more preferably from about 32 to about 44% by mole of ethylene and even more preferably a degree of saponification of at least 85%, preferably at least 90%.
The term "polyamides" as used herein is intended to denote both homo and co or to have polyamides. This term specifically includes aliphatic polyamides or copolyamides, for example, polyamide 6, polyamide 11, polyamide 12, polyamide 66, polyamide 69, polyamide 610, polyamide 612, copolyamide 6/9, copolyamide 6/10, copolyamide 6/12, copolyamide 6 /66, copolyamide 6/69, aromatic and partially aromatic polyamides or copolyamides, such as polyamide 6I, polyamide 6I/6T, polyamide MXD6, polyamide MXD6/MXDI and mixtures thereof.
[00174] As used herein, the term "copolymer" refers to a polymer derived from two or more types of monomers and includes terpolymers. Ethylene homopolymers include high density polyethylene (HDPE) and low density polyethylene (LDPE). Ethylene copolymers include ethylene/alpha-olefin copolymers and ethylene/unsaturated ester copolymers. Ethylene/alpha-olefin copolymers generally include copolymers of ethylene and one or more comonomers selected from alpha-olefins having from 3 to 20 carbon atoms, such as 1-butene, 1-pentene, 1-hexene, 1-octene, 4 - methyl-1-pentene and the like.
[00175] Ethylene/alpha-olefin copolymers generally have a density in the range of about 0.86 to about 0.94 g/cm3. The term linear low density polyethylene (LLDPE) is generally understood to include that group of ethylene/alpha-olefin copolymers which fall in the density range of about 0.915 to about 0.94 g/cm3 and particularly about 0.915 to about 0.925 g/cm3. Sometimes linear polyethylene in the density range of about 0.926 to about 0.94 g/cm3 is referred to as linear medium density polyethylene (LMDPE). Low density ethylene/alpha-olefin copolymers can be referred to as very low density polyethylene (VLDPE) and ultra low density polyethylene (ULDPE). Ethylene/alpha-olefin copolymers can be obtained by either heterogeneous or homogeneous polymerization processes.
[00176] Another useful ethylene copolymer is an ethylene/unsaturated ester copolymer which is the copolymer of ethylene and one or more unsaturated ester monomers. Useful unsaturated esters include vinyl esters of aliphatic carboxylic acids, where the esters have 4 to 12 carbon atoms, such as vinyl acetate and alkyl esters of acrylic or methacrylic acid, where the esters have 4 to 12 atoms of carbon.
[00177] Ionomers are copolymers of an ethylene and an unsaturated monocarboxylic acid having the carboxylic acid neutralized by a metal ion such as zinc or, preferably, sodium.
[00178] Useful propylene copolymers include propylene/ethylene copolymers which are copolymers of propylene and ethylene having a weight percent content of majority propylene and propylene/ethylene/butene terpolymers which are copolymers of propylene, ethylene and 1-butene .
[00179] As used herein, the term "polyolefin" refers to any polymerized olefin that may be linear, branched, cyclic, aliphatic, aromatic, substituted or unsubstituted. More specifically, included within the term polyolefin are olefin homopolymers, olefin copolymers, copolymers of an olefin and a non-olefinic comonomer copolymerizable with the olefin, such as vinyl monomers, modified polymers thereof, and the like. Specific examples include polyethylene homopolymer, polypropylene homopolymer, polybutene homopolymer, ethylene alpha-olefin copolymer, propylene alpha-olefin copolymer, butene-alpha-olefin copolymer, ethylene-unsaturated ester copolymer, ethylene-unsaturated acid copolymer , (eg ethylene-ethyl acrylate copolymer, ethylene-butyl acrylate copolymer, ethylene-methyl acrylate copolymer, ethylene-acrylic acid copolymer and ethylene-methacrylic acid copolymer), ethylene-methacrylic acid copolymer. vinyl, ionomer resin, polymethylpentene, etc.
[00180] The term "polyester" is used herein to refer to both homo and copolyesters, wherein homopolyesters are defined as polymers obtained from the condensation of a dicarboxylic acid with a diol and copolyesters are defined as polymers obtained from the condensation of one or more dicarboxylic acids with one or more diols. Suitable polyester resins are, for example, polyesters of ethylene glycol and terephthalic acid, i.e. poly(ethylene terephthalate) (PET). Preference is given to polyesters which contain ethylene units and comprise, based on the dicarboxylate units, at least 90% by mole, more preferably at least 95% by mole, of terephthalate units. The remaining monomer units are selected from other dicarboxylic acids or diols. Other suitable aromatic dicarboxylic acids are preferably isophthalic acid, phthalic acid, 2,5-, 2,6- or 2,7-naphthalenedicarboxylic acid. Of cycloaliphatic dicarboxylic acids, mention should be made of cyclohexanedicarboxylic acids (in particular cyclohexane-1,4-dicarboxylic acid). Of the aliphatic dicarboxylic acids, (C3 -C19 )alkanedioic acids are particularly suitable, in particular, succinic acid, sebacic acid, adipic acid, azelaic acid, suberic acid or pimelic acid. Suitable diols are, for example, aliphatic diols such as ethylene glycol, diethylene glycol, triethylene glycol, propylene glycol, 1,3-butane diol, 1,4-butane diol, 1,5-pentane diol, 2,2- dimethyl-1,3-propane diol, neopentyl glycol and 1,6-hexane diol and cycloaliphatic diols, such as 1,4-cyclohexanedimethanol and 1,4-cyclohexane diol, optionally heteroatom-containing diols having one or more rings .
Copolyester resins derived from one or more dicarboxylic acid(s) or their lower alkyl diesters (up to 14 carbon atoms) with one or more glycols, particularly an aliphatic or cycloaliphatic glycol may also be used as the polyester resins for the base film. Suitable dicarboxylic acids include aromatic dicarboxylic acids such as terephthalic acid, isophthalic acid, phthalic acid or 2,5-, 2,6- or 2,7-naphthalenedicarboxylic acid and aliphatic dicarboxylic acids such as succinic acid, sebacic acid, adipic acid, acid azelaic, suberic acid or pimelic acid. Suitable glycol(s) include aliphatic diols such as ethylene glycol, diethylene glycol, triethylene glycol, propylene glycol, 1,3-butane diol, 1,4-butane diol, 1,5-pentane diol, 2,2-dimethyl- 1,3-propane-diol, neopentyl glycol and 1,6-hexane diol and cycloaliphatic diols such as 1,4-cyclohexanedimethanol and 1,4-cyclohexane diol. Examples of such copolyesters are (i) copolyesters of azelaic acid and terephthalic acid with an aliphatic glycol, preferably ethylene glycol; (ii) adipic acid and terephthalic acid copolyesters with an aliphatic glycol, preferably ethylene glycol; and (iii) copolyesters of sebacic acid and terephthalic acid with an aliphatic glycol, preferably butylene glycol; (iv) copolyesters of ethylene glycol, terephthalic acid and isophthalic acid. Suitable amorphous copolyesters are those derived from an aliphatic diol and a cycloaliphatic diol with one or more dicarboxylic acids, preferably an aromatic dicarboxylic acid. Typical amorphous copolyesters include copolyesters of terephthalic acid with an aliphatic diol and a cycloaliphatic diol, especially ethylene glycol and 1,4-cyclohexanedimethanol. Detailed DescriptionAppliance 1
[00182] Figures 1 to 3 show variants of an apparatus 1 for packaging a product P. The apparatus 1 is adapted for modified atmosphere packaging, in which a plastic film is applied to the upper rim of a support or a tray after a modified gas atmosphere has been created within the tray and/or for vacuum skin packaging of product P, in which a thin film of plastic material is draped over the product and intimately adheres to an upper rim and the inner surface of the holder, as well as the surface of the product, thus leaving a minimal amount, if any, of air inside the package. Apparatus 1 can also be used in case a plastic film is applied to the tray and no vacuum or modified atmosphere is created.
[00183] The apparatus 1 comprises a support structure 2 (schematically represented in phantom lines) which defines, for example, in an upper portion thereof, an operating path which in the example shown is horizontal. A web supply assembly 3, preferably carried by the support structure 2, comprises a roll 4 of plastic web 5 which is then used to form the trays in-line; in practice the plastic web 5 is unwound from the roll 4 and defines a plastic precursor body 6 in which the pockets 7 of tray-shaped elements 8 are then formed in-line as is further described hereinafter. A film supply assembly 9, preferably carried by said supporting structure 2, comprises a respective roller 10 configured to supply a plastic film 11 to be fixed on top of the tray-shaped elements 8. The plastic film can include at least one gas permeable layer and at least one gas (in particular, oxygen) impermeable layer.
[00184] A training station 12 is mounted on the support structure 2 and positioned in the operating path. The forming station 12 is configured to receive from the roll 4 the precursor body 6 when the latter is still in the form of a plastic web and create the cavities therein 7. In practice, the forming station 12 comprises at least an upper portion. 13a and at least one lower portion 13b which are movable relative to each other so that, in an open condition where the two portions 13a, 13b are spaced apart from each other, a longitudinal section of the web-shaped precursor body 6 can be positioned in correspondence with the forming station and, in a closed position, where the two portions 13a, 13b are moved against each other, the two portions define one or more mold cavities 14, wherein the tray-shaped elements are formed in the precursor body. In this regard, at least one of the upper and lower portions 13a, 13b has one or more molding portions defining said formed mold cavities as the tray-shaped elements to be formed; the forming station may include molding portions (e.g. male and female elements) which - when the forming station is in the closed position - mechanically force the weft material of the precursor body into the desired shape; alternatively the forming station may include one or more gas injection devices to blow mold the web material against the mold cavities 14 and form the tray-shaped elements; in another alternative the forming station may include one or more gas withdrawal devices to suck web material into the mold cavities. Of course, other molding techniques can be adopted to form the web material. In order to facilitate the formation of the web material the upper and/or lower portions of the precursor body may be heated to an appropriate temperature.
[00185] In any case, the forming station 12 is configured so that upon leaving the forming station, the precursor body 6 comprises one or more longitudinal rows 15 of adjacent tray-shaped elements 8 (in the example shown in the figures 1-4 two horizontal rows 15 of tray-shaped elements 8 are progressively formed by forming station 12), each of the rows 15 of tray-shaped elements is transversely delimited by longitudinal strips 16, while transverse strips 17 longitudinally delimit and consecutively join adjacent tray-shaped elements in the same longitudinal row.
[00186] As can be seen from figures 1 to 4, the transverse strips and the longitudinal strips delimit the upper openings 18 of the tray-shaped elements 8 and intersect with each other in a plurality of transverse regions 19: in the examples shown the upper openings are substantially rectangular and are defined by two longitudinal side walls and two transverse side walls of the tray-shaped elements; consequently, the transverse strips cross perpendicularly the longitudinal strips delimiting said rectangular upper openings 18, so that said transverse regions are located in correspondence with corner zones of the tray-shaped elements. In the examples shown the upper openings are formed to have rounded corners, thus the transverse and longitudinal strips 16, 17 have a substantially straight conformation with widening in the transverse regions 19.
[00187] A packaging assembly 20, also positioned in frame 2 along said operating path, is configured to receive said plastic film 11 and said precursor body 6. Packaging assembly 20 is configured to securely attach the plastic film 11 for closing the upper openings 18 of the tray-shaped elements 8 and comprises at least one lower tool 21 defining a preset number of seats 21a (in the example shown four seats 21a, two per row). Each seat 21a is designed to receive a respective one of said tray-like elements 8. An upper tool 22, also part of the packaging assembly, faces the lower tool 21 and is configured to cooperate with the lower tool to secure said plastic film 11 to the tray-shaped elements 8 positioned on said seats 21a and sealingly close the respective upper openings 18 forming one or more closed tray-shaped elements 8a hosting one or more of the product P which is, for example, loaded - either automatically or manually - in the cavities of the tray-shaped elements downstream of the forming station 12 (note that in figures 1 to 4, the product P within the tray-shaped elements has sometimes been omitted for reasons of clarity of the drawing).
[00188] Downstream the packaging assembly operates a separation assembly 23 positioned along said path and configured to at least transversely separate the closed tray-shaped elements and form closed trays 8b. Separator assembly 23 may include a transverse blade 24 positioned on frame 2 perpendicular to the MD machine direction and configured to longitudinally separate adjacent closed tray-shaped elements 8a by cutting transverse bands 17 in correspondence with a midline 17a; the separator assembly 23 may also include a longitudinal blade 25 positioned on the frame 2 parallel to the MD machine direction and configured to transversely separate adjacent rows of tray-shaped elements by cutting a series of longitudinal strips 16 in correspondence with a midline 16a of the (midlines 16a and 17a are visible in figure 4).
[00189] According to an aspect of the invention, a cutting tool 26 can be carried by the support structure 2 and can be configured to be active to form cuts in the precursor body 6 in correspondence with a zone of the predefined path comprised between the weft supply assembly 3 and packaging assembly 20; a tool actuator 126 (eg hydraulic, pneumatic or electric type) can act on the cutting tool 26: the tool actuator is controlled by the control unit 100 so as to lower and raise the cutting tool and obtain the formation of through openings 27 and 28; according to a further aspect the cutting tool 26 can operate immediately upstream of the packaging assembly 20, so that - when as the precursor body has been processed by the cutting tool 26 and moves in the direction of the MD machine - it immediately enter the packing set. The cutting tool 26 is configured to form in the precursor body a through opening 27 located in correspondence with a side wall of each of said tray-shaped elements (see figures 5 and 7) or a through opening 28 located in correspondence with a plurality of said transverse regions 19 between the longitudinal and transverse bands (see figures 5 and 6). In one example, a through opening 27 may be formed through horizontal ribs 29 formed in the corner regions of each of the tray-shaped elements 8 (Figure 7); in another example a through-opening 28 may be formed in each of the transverse regions 19 between said longitudinal band and said transverse band (Figure 6); in yet another example a through opening 27 may be formed in horizontal ribs 29 defined in the corner regions of the tray-shaped elements and a through opening 28 may be formed in the transverse regions 19 between said longitudinal and transverse bands (Figures 5 and 6).
[00190] The cutting tool 26 can be configured to form the through openings 28 in the corner regions 19 in the form of a cutout portion removed from the plastic precursor body: in particular, the cutting tool 26 can be configured to forming each cut-out portion by removing a portion of said corner regions 19 in correspondence with the midline between two longitudinally adjacent tray-shaped elements of a same row; in practice, the cutaway portions create passages for gas communication to the interior of each of the adjacent tray-shaped portions during the application of the plastic film; furthermore, due to the shape and position of the cut-out portions defining the through openings 28, the continuity of the horizontal rim of each forming tray is not compromised and thus the formation of large horizontal tray rims is not necessary.
[00191] According to a specific aspect the cutting tool 26 is configured and positioned so that each of said cutout portions is symmetrically located between two adjacent tray-shaped supports and form a triangular opening delimited by three sides - straight or arch-shaped - or a quadrangular opening bounded by four sides - straight or arch-shaped. In the example shown in figure 1, the cutting tool comprises a plurality of cutters 26a configured to be incident on the corner regions 19 of said strips: each cutter has a cutting edge 26b which is formed as the opening 28 to be formed in the precursor body: as can be seen from figure 4 certain cutting edges are substantially triangular in shape and form triangular openings 28, while certain cutting edges are quadrangular in shape and form quadrangular openings.
[00192] Going now to a detailed description of the packaging assembly 20 and with reference to figures 8 to 11, it should be noted that the packaging assembly comprises at least one main actuator 29 (which may be a pneumatic, electrical or hydraulic) active in at least one of said upper and lower tools 22, 21, so that the upper tool and the lower tool are moved between an open position, wherein the upper tool 22 is spaced from the lower tool 21 and forms a gap which allows positioning of the tray-shaped elements 8 on the seats 21a and the plastic film 11 above the tray-shaped elements, and a closed position, in which the upper tool and the lower tool are in close proximity and act against each other. another, so as to sealably secure the plastic film above the one or more tray-like elements located in the packaging assembly. In practice, the plastic film material and that of the precursor body are interposed between abutment portions 30 of the upper tool 22 and the corresponding abutment portions 31 of the lower tool 21, as shown in Figures 9 and 10. The abutment portions 30 and 31 at least surround the periphery of the upper openings of the tray-shaped elements 8. The control unit 100 controls the main actuator 29 so as to move the upper and lower tool between the upper and lower positions.
[00193] The upper tool comprises means 33 for retaining a portion of the plastic film 11 in correspondence with an active surface 32 of the upper tool facing the lower tool. The means for retaining 33 may comprise a vacuum source 34, for example a vacuum pump, controlled by the control unit 100 and a tubing 35 connected or connectable to the vacuum source and leading to a series of suction openings 36 present in the active surface 32 of upper tool 22. Alternatively, or in addition, the means for retaining 33 may include a mechanical retainer (e.g., comprising tongs configured to hold the plastic film in place). In another alternative, or in addition, the means for retaining may comprise a heater capable of heating the active surface of the upper tool, thereby heating the plastic film 11, so as to increase adhesiveness to the active surface 32 of the same plastic film. plastic. According to yet another alternative, or in addition, the means for retaining may include adhesive portions of the active surface. In another alternative, or in addition, the means for retaining may include an electrical retainer configured to change the polarity of the active surface of the upper tool so as to create electrical forces between said active surface and the plastic film. in one embodiment, the control unit 100 is configured to activate the means to retain, for example, activating said vacuum source 34 or having a valve 37 connecting the tubing to the vacuum source 34 and causing the active surface to receive and retain the said portion of the plastic film in a suitable position above the tray-shaped elements located in the packaging assembly.
[00194] Going in more detail, it should be noted that the top tool 22 can have a flat active surface or a dome-shaped active surface (this second variant is shown in figure 11). Heating means are associated with the upper tool and controlled by the control unit 100 so that the active surface of the lower tool is brought at least to a temperature comprised between 150°C and 260°C, optionally between 180 and 240°C, plus optionally between 200 and 220°C. As a heating means, electrical resistances within the upper tool 22 or located in correspondence with the active surface 32 can, for example, be used.
[00195] The lower tool 21 presents a series of base wall portions 39 and a series of side wall portions 40 emerging from respective ones of said base wall portions to define said number of seats 21a. In the event that the upper tool has a dome-shaped active surface, then one or more of the side wall portions on the lower tool may carry at least one protrusion 41 which is positioned and configured so that when the tray-shaped elements 8 are located on the respective seats 21a of the lower tool, each protrusion 41 is inserted into a respective through-opening located in one of said transverse regions and projects above the tray-shaped elements towards said active dome-shaped surface. In other words, the protrusion which may comprise a pin passes through the openings 28 and emerges above the tracks of the precursor body towards the dome-shaped active surface 32, so as to prevent the plastic film from closing the openings 28 before any possible step of removing and/or injecting gas into the cavities of the tray-shaped elements 8. The presence of the protrusion is not strictly necessary as the means to retain 33, for example, applying a vacuum to the active surface of the upper tool, may be sufficient to keep the film away from the openings 27, 28 during the application of a vacuum to the lower tool.
[00196] In fact, the apparatus 1 may further comprise a vacuum arrangement 42 connected to the lower tool 21 and configured to remove gas from an interior of said tray-shaped elements; the vacuum arrangement 42 has at least one vacuum source 43 (eg a pump) and at least one evacuation line 44 connecting said through openings 27, 28 to the vacuum source. Control unit 100 can be configured to control vacuum arrangement 42 to withdraw gas at least when the upper and lower tools are in the closed position. The control unit 100 may also inactivate the means for retaining 33 of the plastic film 11, for example, by inactivating the vacuum pump 33 and/or connecting the suction openings 36 to atmosphere, for example, via an auxiliary line 45 open to the outside atmosphere is selectively connectable to the openings 36 by valve 37 so that the plastic film can drape down onto the tray and onto product P hosted in each tray (figure 10). This together with adequate heating of at least portions of the plastic film and/or the precursor body, for example in the strips, causes sealing of the tray-shaped elements and the skin package of the product P with the plastic film. In the case of skin packaging the film may include a gas permeable layer (eg oxygen) which adheres to the product and a gas impermeable layer (eg oxygen impermeable) removablely adhering to the gas permeable layer, so that - when the tray is in use - the gas-impermeable layer may be removed allowing oxygen to come into contact with the product, while keeping liquids and solids confined within the package due to the presence of the gas-permeable layer.
[00197] The apparatus may alternatively, or in addition, include a controlled atmosphere arrangement 46 (shown in Figure 10) connected to the lower tool 21 and configured to inject a gas stream into said tray-shaped elements. The controlled atmosphere arrangement comprises at least one injection device 47 (for example an injection pump or valve) and at least one injection line 48 connecting a gas source 49 to the through openings 27, 28 via the injection device 47: the control unit 100 acts on said controlled atmosphere arrangement to inject said gas stream at least when the upper and lower tools are in said closed position. Also in the case of modified atmosphere packaging (MAP), adequate heating of at least portions of the plastic film or of precursor body strips causes the tray-shaped elements to be sealed with the plastic film. In particular, in the case of MAP applications, the upper tool may include a heating bar which - after injecting the gas into the cavities of the tray elements - lowers and abuts against the film portions overlapping the upper rim of the elements in tray shape, to thermally seal the film to the upper rim(s). The controlled atmosphere arrangement can be configured to inject gas or gas mixtures including an amount of one or more of N2, O2 and CO2 that is different from the amount of these same gases when present in the atmosphere at 20°C and at sea level ( 1 atmosphere of pressure). Control unit 100 may also be configured to control the composition of the modified atmosphere generated within the packaging assembly. For example, the control unit 100 can regulate the composition of the gas stream injected into the packaging chamber. The gas mixtures injected into the packaging chamber to generate a modified atmosphere can vary depending on the nature of the product P. In general modified atmosphere mixtures include a volumetric amount of one or more of N2, O2 and CO2 that is different from the amount of these same gases as present in the atmosphere at 20°C and at sea level (1 atmosphere of pressure). If product P is a product such as meat, poultry, fish, cheese, bakery or pasta the following gas mixtures can be used (quantities are expressed as percentages by volume at 20°C, 1 atm pressure):- Meat red, Skinless poultry: O2=70%, CO2=30%- Skinned poultry, Cheese, Pasta, Bakery products: CO2=50%, N2=50%- Fish CO2=70%, N2=30% or CO2 =40%, N2=30%, O2%=30 - Processed meat CO2=30%, N2=70%
[00198] In one embodiment, the apparatus includes both the vacuum arrangement and the controlled atmosphere arrangement. Furthermore, the control unit 100 in this case may be configured to control said controlled atmosphere arrangement to start injecting said gas stream either after a pre-set delay of activation of said vacuum arrangement or after a pre-set vacuum level has been reached within said interior of the tray-shaped elements.
[00199] According to an aspect the control unit is configured to control said controlled atmosphere arrangement to begin injecting said gas stream while said gas withdrawal is still in progress.
[00200] In a further aspect the control unit is configured to operate the vacuum arrangement to remove gas and create a vacuum level with a pressure of between 100 and 300 m bar, optionally between 150 and 250 mbar, within said interior of the tray-shaped elements.
[00201] Going into detail on other structural aspects, the lower tool 21 has one or more seats 21a for receiving the tray-like elements 8: each seat 21a is delimited by a base wall portion 39 and a side wall portion 40 emerging from the respective base wall portion. In the embodiment shown, for example, in Figures 8 to 11 the evacuation line 44 of the vacuum arrangement leads to a first slot 50 defined in the side wall portion 40 of each seat and a second slot 51 defined in the base wall portion 39 of each seat; the first and second grooves are obtained in the respective wall portions and are open to the interior of the respective seat 21a: the grooves allow adequate gas communication between the through openings 27, 28 in the tray-shaped elements and a pipe obtained in the tool bottom connecting said grooves to said evacuation line. Similarly, the injection line 48 of the controlled atmosphere arrangement 46, if present, leads to the first groove 50 defined in the side wall portion 40 of each seat and the second groove 51 defined in the base wall portion 39 of each seat. ; a tubing (which may be the same tubing used by the vacuum arrangement) in the lower tool may be present to connect said grooves to said injection lines. Alternatively, the injection line can directly lead to matching openings 27, 28 or it can lead to nozzles passing through said openings 27 or 28, so as to prevent the pressure outside the tray-shaped elements from being higher than the pressure generated within the tray-shaped elements.
[00202] According to aspects of the invention, a drive assembly 60 is associated with frame 2 and drives precursor body 6 and plastic film 11 as will be described hereinafter. Figures 1 to 3 schematically show possible alternative modalities of the drive assembly.
[00203] The drive assembly 60 includes a first active portion 61 positioned downstream of the packaging assembly 20 on both sides of the operating path. The first active portion 61 can be configured to grip the two longitudinal side edges of a longitudinally extending longitudinal portion of the precursor body downstream of the package assembly 20 (this is visible in all embodiments of Figures 1 to 3E). The drive assembly and particularly the first active portion can contemporarily also engage with the side edges of the plastic film 11, as downstream of the packaging assembly the plastic film and precursor body overlap and may have substantially or exactly the same width. In any case, the plastic film 11 is at least pulled by the precursor body by virtue of the fact that the plastic film, in the packaging assembly, has been attached to the precursor body; as mentioned, if the plastic film has substantially the same width as the precursor body, the plastic film portion extending downstream of the packaging assembly is gripped and pulled by the first active portion 61 along with the precursor body. In certain embodiments (see, for example, figures 1, 2 and 3A), in correspondence with the packaging assembly 20 and preferably also in correspondence with the cutting assembly 26, both the plastic film 11 and the body of precursor 6 are laterally (ie, across the machine direction) free of engagement with the first active portion or other drive mechanism. In practice, as shown in Figures 1, 2 and 3A the longitudinal edges of the plastic film 11 and the precursor body 6, in correspondence with the packaging assembly 20 and the cutting assembly 26, are left free. This solution allows the plastic film to be exactly sized to match the size of the upper openings of the tray 8 elements. Furthermore, the absence of any drive portion acting on the side edges of the precursor body in the packaging assembly allows for minimizing the size of the longitudinal strips 16 that will form the upper rims of the end trays without compromising the efficient sealing of the plastic film.
[00204] Alternatively (see, for example, figures 3C and 3D), the first active portion 61 can be configured to grip only the two longitudinal side edges of a longitudinal portion of the plastic film 11. In this case, the plastic film 11 would have a width (measured perpendicular to the MD) greater than the width of the precursor body: see the cross section of the 3D figure where it is shown that the plastic film is wider than the underlying precursor body in order to allow for clamps associated with the first active portion 61 engage the longitudinal edges of the plastic film 11 without engaging the longitudinal side edges of the precursor body.
[00205] In a variant, see Figure 3A, the first active portion 61 is configured to grip the two longitudinal side edges of a portion of the plastic film 11 extending longitudinally downstream of the packaging assembly 20 (in this case the first portion active can also grip the longitudinal side edges of the precursor body).
[00206] In a second variant, see fig. 3B, the first active portion 61 is configured to grip the two longitudinal side edges of a portion of the plastic film 11 extending longitudinally within the packaging assembly and by a downstream tract of the packaging assembly 20. In this case, the first active portion preferably just grip the plastic film.
[00207] In a third variant (figure 3C and figure 3D), the first active portion 61 is configured to grip the two longitudinal side edges of a portion of the plastic film 11 extending from the film supply assembly 9 and longitudinally within of the packaging assembly and by a downstream tract of the packaging assembly 20.
[00208] In these last two variants (figures 3B and 3C) the drive assembly and particularly the first active portion preferably do not engage the precursor body 6 which is basically just pulled by the plastic film which, in the packaging assembly, has been fixed to the precursor body.
[00209] The first active portion 61 can release the plastic film 11 in or downstream of the separation assembly 23 and two lateral stripes of excess material can then be removed from the plastic film 11. Also note that the apparatus can comprising a preheat plate 110 (shown only in Figure 3C, but which could also be present in other embodiments shown) active downstream of supply assembly 10 and positioned immediately upstream of the packaging assembly. For example, the preheat plate 110 may be located in correspondence with the vertical film tract 11 extending between the film supply assembly 9 and the packaging assembly 20: the preheat plate faces towards the sheet of film and is configured to heat it to a suitable temperature to intensify the elasticity of the film before the film arrives within the packaging assembly; this aspect combined with the first active portion 61 gripping the longitudinal side edges of film 11 within the packaging assembly 20 allows reaching the product packaging by projecting vertically out of the cavity of the tray-shaped elements (in such case an upper tool in dome shape is normally used). In correspondence with both the packaging assembly and the cutting assembly, precursor body 6 is laterally (i.e., transversely to the machine direction) free of engagement with the first active portion or other drive mechanism.
[00210] The three variants above allow to minimize, if not cancel, the scrap of material forming the body of precursor. In the variant where also the plastic film is not gripped while inside the packaging assembly, it allows the plastic film to be exactly sized to match the size of the upper openings of the tray-shaped elements 8. Moreover, the absence of any drive portion acting on the lateral edges of the precursor body in the packaging assembly allows to minimize the size of the longitudinal strips 16 that will form the upper rims of the end trays without compromising the efficient sealing of the plastic film. In the variant where the plastic film is gripped while inside the packaging assembly, there may be some scrap of plastic film material 11, but also the possibility of laterally controlling the plastic film during application thereof to the tray-shaped elements , with the possibility of packing emerging P products vertically above the tray-shaped elements (in this case with the use of a dome-shaped top tool, as shown in figure 11).
[00211] In a further variant, the first active portion can be configured to grip both the longitudinal side edges of the longitudinal portion of the plastic film and the longitudinal side edges of the precursor body. In more detail, in accordance with this additional variant, when the plastic film and precursor body exit the packaging assembly, the first active portion engages longitudinally extending side edge portions downstream of the packaging assembly. In this variant too, the drive assembly is configured so that the longitudinal side edges of the precursor body and the plastic film, in correspondence with the packaging assembly and preferably also the cutting assembly, are free and not engaged by any part of the drive assembly.
[00212] In the example of Figures 1 and 2, the drive assembly includes a second active portion 62 positioned between the forming station 12 and the packaging assembly 20 on either side of the operating path and configured to grip longitudinal side edges of a portion of the precursor body 6 extending longitudinally between the forming station 12 and the packaging assembly 20. In a first variant, shown in Figure 1, the drive assembly is configured so that the longitudinal side edges of the body precursor, in correspondence with the forming station 12, are laterally engaged by said second active portion 62, although in a second variant, shown in figure 2, the drive assembly is configured so that the longitudinal side edges of the precursor body, in correspondence with the forming station 12, are laterally free and not engaged by any part of the drive assembly. Engaging the drive assembly in the form station can help keep the precursor body in the correct position while forming the tray form elements. On the other hand, leaving the edges free can reduce scrap material and still be suitable for certain types of easily deformable materials.
[00213] In Figure 1, the first and second active portions 61 and 62 are, on each side of the structure, part of the same elongated body. In figure 2, the first and second active portions are, on each side of the frame, part of two respective elongated bodies. Figure 3 shows an embodiment in which the drive assembly has no second active portions, but only the first active portions in the variants described above.
[00214] From a constructive point of view and as shown in Figures 13 to 22, the drive assembly 60 includes at least one elongated drive body 63 (e.g., a drive chain or a drive belt) on each side of the path of operation. In the case of Figure 2 two elongated bodies 63 are present on each side of frame 2. Each elongate drive body 63 is mounted on support frame 2 defining a respective closed path having a drive branch engaging at least one of the plastic film. and the elongated body and a return branch; each drive assembly 60 also includes a plurality of tongs 66 carried by the elongated drive body 63 and configured to grip opposite longitudinal side edges of the precursor body 6 and/or the plastic film film 11 as described above and at least one motor 67 connected, for example, via a sprocket 68 to the drive body 63 and controlled by the control unit 100. The control unit 100 is configured to operate the motor 67 so as to move the elongated drive body 63 along said path closed, with the drive branch moving in accordance with the machine direction and the return branch moving opposite the machine direction to close the circuit. The elongated body 63 is configured in closed path, so that the actuating branch continuously comprises a first segment 64 which extends, parallel to the operating path, downstream of the package assembly 20: in practice the first active portion 63 described above is defined, on each side of the frame 2, by grip elements 66 carried by the first segment 64 which are adapted to grip the side edges of the precursor body and/or the plastic film positioned longitudinally downstream of the packaging assembly.
[00215] In the embodiment of Figure 1 an elongated body 63 is configured in a closed path on each side of the frame 2, so that the actuating branch of the continuously elongated body comprises a second segment 65 extending parallel to the operating path at least from downstream of forming station 12 to upstream of cutting tool 26. Handle elements 66 carried by said second segment 65 are adapted to grip the longitudinal side edges of precursor body 6 extending longitudinally between forming station 12 and the packaging assembly 26. In the embodiment of Figure 2 two elongated bodies are configured in a respective closed path on each side of the frame 2 so that the actuating branch of the continuously elongated body comprises the first segment in one of said elongated bodies. and, on the other of said elongated bodies, a second segment 65 extending parallel to the operating path by the at least from downstream of forming station 12 to upstream of cutting tool 26. Handle elements 66 carried by said second segment 65 are adapted to grip the longitudinal side edges of precursor body 6 extending longitudinally between the station. formation 12 and the packaging assembly 26. In practice, the second active portion 62 of the drive assembly 60 is defined, on each side of the frame, by grip elements 66 carried by said second segment 65 which are adapted to grip the side edges. of the precursor body portions positioned longitudinally upstream of the cutting assembly 26.
[00216] As mentioned, in Figure 2 two distinct elongated bodies on each side of the frame 2 are used. In contrast, in the example of Figure 1, the single elongated body drive branch 63 present on each side of frame 2 continuously comprises a third segment 69 connecting a downstream end of the second segment to an upstream end of the first segment, the third segment 69 extends along a path which is sufficiently remote from the operating path in correspondence with the packaging assembly and, optionally, the cutting tool, whereby the grip elements 66 carried by said third segment do not engage the side edges longitudinals of neither the precursor body nor the plastic film at least in correspondence with the packaging assembly and optionally (as shown in figure 1) in correspondence with the cutting tool.
[00217] In the examples of figures 1 and 2 the driving branch of the continuously elongated body 63 may comprise a fourth or additional segment 70 extending parallel to the operating path of at least the supply assembly upstream of the forming station 12. handle elements carried by said fourth segment are adapted to grip the longitudinal side edges of the precursor body extending longitudinally between the supply assembly and the forming station. In a variant not shown the fourth segment can be obtained in an elongated body other than the one carrying the first or second segment. The second active portion of the drive assembly in the case of figures 1 and 2 also comprises the grip elements carried by said fourth segment. Finally, an optional fifth segment 71 connecting a downstream end of the fourth segment 70 to an upstream end of the second segment 65 may be present: the fifth segment extends along a path that is sufficiently far from the operating path in correspondence with the forming station 12 (see figure 2), whereby the handle elements 66 carried by said fifth segment 71 do not engage the longitudinal side edges of the precursor body at least in correspondence with the forming station.
[00218] In order for the grip elements 66 to engage/disengage from the precursor body 6 and/or the plastic film 11, each of the grip elements 66 comprises at least two opposing claws 72, 73 which are normally held in position closed, for example, by an elastic element 74. The grip elements 66 are mounted on the elongated body 63 so that a deflection surface 75 carried, for example, by the sprocket 68, pushes the claws in an open condition allowing to release the precursor body 6 and/or plastic film 11. Note that the apparatus may include sprockets positioned along the closed path of the elongated body for the trajectory of the elongated body and thus the grip elements (e.g. to define the third and fifth segments 69 and 71). The sprockets comprise the deflection surface 75 which is defined, for example, by a pulley 76 coaxially mounted on the sprockets. Control unit 100 of the apparatus 1
[00219] The apparatus according to the invention has at least one control unit.
[00220] The control unit 100 (schematically represented in Figure 1) may comprise a digital processor (CPU) with memory (or memories), an analog type circuit or a combination of one or more digital processing units with one or more circuits Analog processing tools. In the present description and in the claims it is indicated that the control unit 100 is "configured" or "programmed" to carry out certain steps: this can be achieved in practice by any means allowing to configure or program the control unit. For example, in the case of a control unit 100 comprising one or more CPUs, one or more programs are stored in a suitable memory: the program or programs containing instructions which, when executed by the control unit, cause the control unit 100 to execute the steps described and/or claimed in connection with the control unit. Alternatively, if the control unit 100 is of an analog type, then the control unit circuits are designed to include circuits configured, in use, to process electrical signals in order to carry out the control unit steps described herein. .
[00221] The control unit can be configured to control the apparatus 1 in order to carry out any of the packaging processes described below or claimed in the appended claims. In particular, the control unit 100 can be configured to control the drive assembly, the forming station, the cutting tool and the packaging assembly so as to synchronize the movement of the precursor body in a step-by-step manner with forming the cavities of the tray-shaped elements in the forming station, forming the through opening in the cutting tool and sealing the tray-shaped elements in the packaging assembly. The control unit can also operate the vacuum and controlled atmosphere arrangements, if present.
[00222] For example, note that the operation of the apparatus is controlled by the control unit 100. The control unit 100 is configured to carry out the following cycle: command the forming station to form said elements in the form of a tray for the body of precursor from the supply assembly in the form of a plastic web; commanding the drive assembly to move in a stepwise manner said precursor body and said plastic film so as to sequentially bring the portions of the packaging assembly of the precursor body having a preset number of tray-shaped elements formed therein and the corresponding portions of plastic film; commanding the cutting tool to act on the precursor body in correspondence with a zone of the predefined path comprised between the weft supply assembly and the packaging assembly and forming said through opening; commanding the packaging assembly to pass the pos. tion open to the closed position, optionally command the vacuum arrangement to remove gas and/or command the controlled atmosphere arrangement to inject a gas or a mixture of gases, command the packaging assembly to securely attach the plastic film to said elements tray-shaped in the packaging assembly, command the separation assembly to separate transversely, and if necessary longitudinally, the closed tray-shaped elements and form a series of closed trays.
[00223] Once the cycle is complete, it is possible to obtain a closed tray of the type shown in figure 12, in which the corners of the plastic film overlap and protrude out of the rounded corners of the upper rim of the tray, thus allowing an easy peeling, while at the same time minimizing the scrap of plastic material.Packaging processes
[00224] Packaging processes according to aspects of the invention are now described.
[00225] The following processes can be carried out by the apparatus according to any of the above modalities and variants under the supervision of the control unit 100. According to one aspect of the invention, it is the control unit 100 that is controlled and programmed to execute the processes described below using an apparatus 1 as described in one of the above embodiments or as claimed in any one of the appended claims.
[00226] A process of packaging products (P) according to aspects of the invention includes the following steps.
[00227] A plastic precursor body 6 in the form of a plastic web is provided from the roll 4. The precursor body 6 is driven in one direction of the MD machine along an operating path and is received at a forming station 12 where a series of cavities are formed in the precursor body such that the precursor body comprises: i. one or more longitudinal rows of adjacent tray-shaped elements 8,ii. longitudinal strips 16 transversely delimiting each of said rows of tray-shaped elements, iii. transverse bands 17 longitudinally delimiting and consecutively joining adjacent tray-shaped elements of the same longitudinal row, the transverse bands and longitudinal bands delimiting upper openings of the tray-shaped elements and crossing one another in a plurality of transverse regions.
[00228] Downstream of the training station, one or more of said products (P) are loaded manually or automatically into a respective cavity of said elements in the form of a tray.
[00229] After the formation of the tray-shaped elements, through openings 27 and/or 28 as described above can be created by the cutting tool 26 operating upstream of the packaging assembly 20. The openings of 27 and/or 28 can be positioned and formed as already described when describing the cutting tool 26. As the precursor body is moved a plastic film is also provided so that the plastic film and precursor body are received in a packaging assembly 20 wherein the plastic film is attached to the tray-like elements 8 to close the upper opening of said tray-like elements of the precursor body. At this point a vacuum can be created within the tray-shaped element cavities, for example by activating the vacuum arrangement as described here above. Alternatively, or in addition, a controlled atmosphere can be created within the tray-shaped element cavities by activating the controlled atmosphere arrangement as described herein above. Thanks to the watertight closure and thanks to the openings 27 or 28 present in the tray-shaped elements, gas can be efficiently injected and/or withdrawn as desired.
[00230] Then, the closed tray-shaped elements proceed to a separation assembly where they are transversely separated, thereby forming separate closed trays or groups of trays.
[00231] The actuation of the precursor body and/or the plastic film can be done in different ways.
[00232] According to a first variant of the invention, the precursor body is driven along the operating path by gripping the longitudinal side edges of the precursor body in correspondence with a portion of the precursor body of the precursor body already firmly receiving the plastic film, whilst leaving free the longitudinal lateral edges of the precursor body in correspondence with a portion of the precursor body where the fixing of the plastic film to the tray-shaped elements takes place, i.e. in the packaging assembly. According to this first variant only the precursor body is gripped at the side edges thereof, while the plastic film is pulled by the precursor body by virtue of the fact that the plastic film downstream of the packaging assembly is attached to the body. of precursor. If the precursor body and the plastic film have the same width, then both the precursor body and the plastic film are simultaneously gripped at the side edges thereof downstream of the packaging assembly.
[00233] According to a second variant of the invention only the plastic film is actuated directly by gripping the longitudinal side edges of the plastic film at least in correspondence with a portion of the plastic where the precursor body and the plastic film have been firmly coupled. The longitudinal side edges of the precursor body in correspondence with a portion of the precursor body where the fixing of the plastic film to the tray-shaped elements takes place, i.e. in the packaging assembly, are left free. The side edges of the precursor body are also not gripped downstream of the packaging assembly and the precursor body is basically pulled by the plastic film only by virtue of the fact that the plastic film, downstream of the packaging assembly, is attached to the precursor body. Note that the plastic film, in an additional variant, can also be actuated by exclusively gripping the plastic film and not the precursor body, in the packaging assembly or even upstream of the packaging assembly, for example, in correspondence with a film tract 11 extending between the film supply assembly 9 and the packaging assembly 20. This allows control of the width of the plastic film and thus gives skin packaging possibility to a wide variety of products, including products projecting vertically above the contour of the tray-shaped elements.
[00234] According to a third variant, the precursor body can be actuated along the operating path by gripping the longitudinal side edges of both the plastic film and the precursor body in correspondence with a portion of the precursor body and the film of plastic where the precursor body has already firmly received the plastic film (namely, downstream of the packaging assembly). The longitudinal side edges of the precursor body in correspondence with a portion of the precursor body where fixing of the plastic film to the tray-shaped elements takes place, i.e. in the packaging assembly, are left free of grip.
[00235] According to a fourth variant, which can be combined with any of the three variants described herein above in relation to the process for driving the precursor body, driving the precursor body comprises gripping longitudinal side edges of the precursor body in correspondence with a portion where the precursor body has not yet received formation of the through openings, while leaving free the longitudinal side edges of the precursor body in correspondence with a portion of the precursor body where formation of the through openings occurs (this is, in cutting tool 26).
[00236] According to a fifth variant, which can be combined with any of the four variants described in this document above in relation to the process for driving the precursor body, driving the precursor body comprises gripping longitudinal side edges of the precursor body in correspondence with a portion where the precursor body is still in the form of a plastic web before the formation of the cavities, while leaving free the longitudinal side edges of the precursor body in correspondence with a portion of the precursor body where the formation of the cavities occurs (ie, at training station 12).
[00237] Although the invention has been described in connection with what is currently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not limited to the described embodiments, but rather is intended to cover various modifications and equivalent provisions included within the spirit and scope of the appended claims.
[00238] For example, the specific nature of the described actuators is exemplary and alternative types of actuators can be used as long as the type of movement imposed on the moving parts in which said actuators are operating is the same.
[00239] Also note that although the described modalities show a single packaging set, multiple packaging sets can be used in parallel in order to optimize productivity.
[00240] Furthermore, as shown schematically in Figure 3E, the apparatus 1 can allow the application of a second plastic film 11' in a second packaging assembly 20' operating downstream of the packaging assembly 20 (denoted in this case as the first set of packaging). For example, the first film 11 can be applied to form a skin above the products P contained within the tray-shaped elements. Then, the tray-shaped elements proceed to a second packaging assembly 21' having an upper and a lower tool 22', 21'. A second film supply assembly 9' provides second film 11 which can be applied on top of the tray-like elements to create:- a lid with normal atmosphere between the second film 11' and the first film 11;- a lid with modified atmosphere between second film 11' and first film 11;- an additional skin formed by second film 11' and first film 11.
[00241] Note that the second film supply set and the second packaging set may have the same structure and operation respectively as the film supply set 9 (first film supply set) and packaging set 20 (first packaging set) and thus are not described again.
[00242] Also note that a second cutting tool, for example, identical to cutting tool 26, may be present and active in the tray-shaped elements that received film 11, but which did not receive the additional openings of the second film of plastics 11' analogous to openings 27 or 28 that have been closed by the application of plastic film 11. The second cutting tool would operate downstream of the packaging assembly 20, but upstream, preferably immediately upstream, of the second packaging assembly. 20'.

权利要求:
Claims (18)
[0001]
1. Apparatus for packaging a product (P) in a tray, said apparatus comprising: - a support structure (2) defining an operating path; - a web supply assembly (3) associated with the support structure ( 2) and configured to provide a plastic precursor body (6) in the form of a plastic web; - a drive assembly (60) carried by the support structure (2) and configured to move at least the precursor body ( 6) in a machine direction (MD) along the operating path; - a forming station (12) positioned in the operating path and configured to receive the precursor body (6) in said plastic web shape and form in it a series of cavities so that, downstream of the forming station (12), the precursor body (6) comprises:- one or more longitudinal rows of adjacent tray-shaped elements (8), - transversely delimiting longitudinal strips each row of tray-shaped elements (8),- transverse strips longitudinally delimiting and consecutively joining adjacent tray-shaped elements (8) of the same longitudinal row, the transversal strips and longitudinal strips also delimiting upper openings of the tray-shaped elements (8) and crossing a to the other in a plurality of cross-sectional regions; and - a film supply assembly (9) configured to supply a plastic film (11), - a packaging assembly (20) also positioned along said operating path and configured to receive said plastic film (11) and said precursor body (6), wherein the packaging assembly (20) is also configured to securely attach the plastic film (11) to close the upper opening of said tray-shaped elements (8) and includes; - a lower tool (21) comprising a pre-set number of seats each intended to receive at least one of said tray-shaped elements (8), and - an upper tool (22) facing the lower tool (21) and configured to cooperate with the lower tool (21) to secure said plastic film (11) to at least one tray-shaped element (8) positioned on said seat and sealingly close the respective upper opening forming one or more ban-shaped elements deja closed (8); - a separation assembly (23) positioned along said path downstream of the packaging assembly (20) and configured to at least transversely separate the closed tray (8) elements and form closed trays ;characterized by the fact that it further comprises:- a cutting tool (26) acting on the precursor body (6) in correspondence with a predefined path zone comprised between the web supply assembly (3) and the packaging assembly ( 20), the cutting tool (26) being configured to form a through-opening located in correspondence with at least one of:- a side wall of each of said tray-shaped elements (8); and - a plurality of said transverse regions between the longitudinal and transverse bands; and - a control unit (100) configured and connected to operate at least said drive assembly (60), said forming station (12), said packaging assembly (20) and said cutting tool (26 ).
[0002]
2. Apparatus according to claim 1, characterized in that the forming station (12) is configured to form said plastic precursor body (6) with two or more parallel rows of tray-shaped elements ( 8), wherein: - each of said tray-shaped elements (8) has a substantially rectangular upper opening defined by two longitudinal side walls and two transverse side walls of the tray-shaped elements (8), and - the bands transversals cross perpendicularly the longitudinal strips delimiting said upper rectangular openings, so that said transverse regions are located in correspondence with corner zones of the elements in the form of tray (8).
[0003]
3. Apparatus according to claim 1 or 2, characterized in that the cutting tool (26) is positioned to act on said plastic precursor body (6) and is configured to form said through opening in a plurality of transverse regions, further wherein the cutting tool (26) is configured to form said through opening in the form of a cutout portion removed from the plastic precursor body (6), wherein the cutting tool ( 26) is configured to form each cut-out portion by removing a part of a transverse band in correspondence with a midline between two longitudinally adjacent tray-shaped elements (8) of a same row;4. wherein the cutting tool (26) is positioned immediately upstream of the packaging assembly (20) and is configured so that:5. each of said cutout portions is symmetrically located between two adjacent tray-shaped supports, e6. each of said cutout portions is in the form of one of the following:7. a triangular opening bounded by three sides - straight or arch-shaped, e8. a quadrangular opening bounded by four sides - straight or arch-shaped.
[0004]
4. Apparatus according to any one of the preceding claims, characterized in that the packaging assembly (20) comprises at least one main actuator operated by the control unit (100) and active in at least one of said upper and lower (22, 21), the control unit (100) being configured to operate the main actuator such that the upper and lower tools (22, 21) are moved between an open position, where the upper tool (22) is away from the lower tool (21) and forms a gap that allows positioning of the tray-shaped elements (8) on the seats and the plastic film (11) above the tray-shaped elements (8), and a closing position, wherein the upper tool (22) and the lower tool (21) are in close proximity and act against each other so as to sealably secure the plastic film (11) above the one or more tray-shaped elements (8) located in the set of packaging (20).
[0005]
5. Apparatus according to any one of the preceding claims, characterized in that the upper tool (22) comprises means for retaining a portion of the plastic film (11) in correspondence with an active surface of the upper tool (22) facing to the lower tool (21), wherein said means for retaining comprises a vacuum source controlled by the control unit (100), the control unit (100) being configured to activate the means for retaining and making the surface the active surface receives and retains said portion of the plastic film (11), wherein the upper tool (22) has a flat or dome-shaped active surface facing the lower tool (21) and configured to receive a portion of the plastic film. plastic (11) which needs to be attached to the tray-like elements (8) housed in the lower tool (21) and in which the heating means are associated with the upper tool (22) and controlled by the counter unit. roll (100), the control unit (100) being configured to control the heating means so that the active surface of the upper tool (22) is brought at least to a temperature comprised between 150°C and 260°C; that said lower tool (21) has a series of base wall portions and a series of side wall portions emerging from the respective one of said base wall portions to define said series of seats; side wall carries at least one protrusion which is positioned and configured so that when the tray-like elements (8) are positioned on the respective seats of the lower tool (21), each protrusion is inserted into a respective through opening located at one of said transverse regions and projects above the tray-shaped elements towards said dome-shaped active surface, and wherein the apparatus further comprises at least s one of: - a vacuum arrangement connected to the lower tool (21) and configured to remove gas from an interior of said tray-shaped elements (8), the vacuum arrangement comprising at least one vacuum source and at least one evacuation line connecting said passage opening to the vacuum source, said control unit (100) being further configured to control the vacuum arrangement for withdrawing gas at least when upper and lower tools (22, 21) are in said closed position; and - a controlled atmosphere arrangement connected to the lower tool (21) and configured to inject a gas stream into said tray-shaped elements (8), the controlled atmosphere arrangement comprising at least one injection device and at least an injection line connecting the through opening to the injection device, said control unit (100) being further configured to control said controlled atmosphere arrangement to inject said gas stream at least when the upper and lower tools (22 , 21) are in said closed position; wherein the controlled atmosphere arrangement is configured to inject gas or gas mixtures including an amount of one or more of N2, O2 and CO2 that is different from the amount of these same gases when present in the atmosphere at 20°C and at sea level (1 atmosphere of pressure).
[0006]
6. Apparatus according to claim 5, characterized in that each of said seats is delimited by a base wall portion and a side wall portion emerging from the respective base wall portion and wherein at least one evacuation line and/or the at least one injection line leads to: - a first groove defined in the side wall portion of each seat and opening into said seat and/or - a second groove defined in the side wall portion of each seat. base of each seat and opening to the interior of said seat.
[0007]
7. Apparatus according to any one of the preceding claims, characterized in that the drive assembly (60) includes a first active portion positioned downstream of the packaging assembly (20) on both sides of the operating path and configured to grasp longitudinal side edges of a longitudinal portion of at least one of the precursor body (6) and the plastic film (11), said grasped longitudinal portion extending longitudinally downstream of the packaging assembly (20), wherein the assembly drive (60) is configured so that the longitudinal side edges of the precursor body (6) and the plastic film (11), in correspondence with the packaging assembly (20), are free and not engaged by any part of the drive assembly (60).
[0008]
8. Apparatus according to claim 7, characterized in that - the drive assembly (60) includes a first active portion positioned downstream of the packaging assembly (20) on both sides of the operating path and configured to grasp longitudinal side edges of a longitudinal portion of only the precursor body (6), said longitudinal portion extending longitudinally downstream of the packaging assembly (20), wherein the drive assembly (60) is configured so that the longitudinal side edges of the precursor body (6) and the plastic film (11), in correspondence with the packaging assembly (20), are free and not engaged by any part of the drive assembly (60); or- the drive assembly (60) includes a first active portion positioned downstream of the packaging assembly (20) on both sides of the operating path and configured to grip longitudinal side edges of a longitudinal portion only of the plastic film (11 ), said longitudinal portion extending longitudinally downstream of the packaging assembly (20), wherein the drive assembly (60) is configured so that the longitudinal side edges of the precursor body (6) and the plastic film ( 11), in correspondence with the packaging assembly (20), are free and not engaged by any part of the drive assembly (60); or- the drive assembly (60) includes a first active portion positioned downstream of the packaging assembly (20) on both sides of the operating path and configured to grip longitudinal side edges of a longitudinal portion of the plastic film (11) and the precursor body (6) extending longitudinally downstream of the packaging assembly (20), wherein the drive assembly (60) is configured so that the longitudinal side edges of the precursor body (6) and the film plastic (11), in correspondence with the packaging assembly (20), are free and not engaged by any part of the drive assembly (60); or - the drive assembly (60) includes a first active portion positioned on either side of the operating path and configured to grip: longitudinal side edges of a longitudinal portion only of the plastic film (11) extending longitudinally downstream of the packaging assembly (20), longitudinal side edges of a longitudinal portion of the plastic film (11) longitudinally in correspondence with the packaging assembly (20), wherein the drive assembly (60) is configured so that the side edges longitudinal parts of the precursor body (6), in correspondence with the packaging assembly (20), are free and not engaged by any part of the drive assembly (60).
[0009]
9. Apparatus according to claim 8, characterized in that the first active portion is configured to grip longitudinal side edges of the longitudinal portion of the precursor body (6), and in which: - the drive assembly (60) includes a second active portion positioned between the forming station (12) and the packaging assembly (20) on either side of the operating path and configured to grip longitudinal side edges of an extending portion of the precursor body (6). longitudinally between the forming station (12) and the packaging assembly (20), wherein the drive assembly (60) is configured so that the longitudinal side edges of the precursor body (6), in correspondence with the formation (12), are free and not engaged by any part of the drive assembly (60); or- the drive assembly (60) includes a second active portion positioned between the supply assembly and the packaging assembly (20) on either side of the operating path and configured to grip the side edges of a portion of the precursor body. (6) extending longitudinally from the included forming station (12) and the packaging assembly (20).
[0010]
10. Apparatus according to claim 8 or 9, characterized in that the drive assembly (60) includes at least one elongated drive body on each side of the operating path, wherein each elongated drive body is mounted in the support structure (2) defining a closed path having a drive branch and a return branch; - a plurality of grippers carried by the elongated drive body and configured to grip opposite longitudinal side edges of the precursor body (6) and/ or the plastic film (11); and - at least one motor connected to the drive body and controlled by the control unit (100), the latter being configured to operate the motor so as to move the elongated drive body along said closed path, with the drive branch moving in accordance with the machine direction and the return branch moving opposite to the machine direction; wherein the elongated body is configured in said closed path so that the elongate body driving branch continuously comprises a first segment that engages extends according to one of the following configurations:- parallel to the operating path downstream of the packaging assembly (20);- parallel to the operating path in the packaging assembly (20) and downstream of the packaging assembly (20);- transverse to the operating path, between the film supply assembly (9) and the packaging assembly (20), and parallel to the operating path, in the packaging assembly (20) and downstream of the assembly. and package (20); wherein the grip elements carried by said first segment are adapted to grip the side edges of the precursor body (6) longitudinally downstream of the package assembly (20) and/or are adapted to grip the edges plastic film sides (11); and wherein the first active portion of the drive assembly (60) comprises grip elements carried by said first segment.
[0011]
11. Apparatus according to claim 10, characterized in that the elongated body is configured in said closed path such that the actuating branch of the elongated body continuously comprises a second segment extending parallel to the operating path by the less than downstream of the forming station (12) to upstream of the cutting tool (26), wherein the grip elements carried by said second segment are adapted to grip the longitudinal side edges of the precursor body (6) which extends longitudinally between the forming station (12) and the packaging assembly (20); wherein the second active portion of the drive assembly (60) comprises grip elements carried by said second segment; and/or that the elongated body drive branch continuously comprises a third segment connecting a downstream end of the second segment to an upstream end of the first segment, the third segment extending along a path that is sufficiently remote from the path of operation in correspondence with the packaging (20) and cutting tool assembly (26), wherein the handle elements carried by said third segment do not engage the longitudinal side edges of either the precursor body (6) or the plastic film (11) at least in correspondence with the packaging assembly (20) and in correspondence with the cutting tool (26).
[0012]
12. Apparatus according to claim 11, characterized in that the actuating branch of the continuously elongated body comprises: - a fourth segment extending parallel to the operating path of at least the supply assembly upstream of the supply station. forming (12), wherein the handle elements carried by said fourth segment are adapted to grip the longitudinal side edges of the precursor body (6) extending longitudinally between the supply assembly and the forming station (12); the second active portion of the drive assembly (60) comprises grip elements carried by said fourth segment- and a fifth segment connecting a downstream end of the fourth segment to an upstream end of the second segment, the fifth segment extending along of a trajectory which is sufficiently remote from the operating path in correspondence with the forming station (12), whereby the and handle elements carried by said fifth segment do not engage the longitudinal side edges of the precursor body (6) at least in correspondence with the forming station (12).
[0013]
13. Apparatus according to any one of the preceding claims, characterized in that the control unit (100) is configured to carry out the following cycle: command the forming station (12) to form said elements in the form of a tray (8) to the precursor body (6) coming from the supply assembly in the form of a plastic web; command the drive assembly (60) to move said precursor body (6) in a step-by-step manner, so to sequentially bring the portions of the packaging assembly (20) from the precursor body (6) having a preset number of tray-shaped elements (8) formed thereon; command the cutting tool (26) to act on the body of precursor (6) in correspondence with a zone of the predefined path comprised between the web supply assembly (3) and the packaging assembly (20) and forming said through opening; commanding the packaging assembly (20) to pass from open position to aa closed position, command the vacuum arrangement to remove gas and/or command the controlled atmosphere arrangement to inject a gas or a mixture of gases, command the packaging assembly (20) to securely attach the plastic film (11) to the said tray-shaped elements (8) in the packaging assembly (20) command the separation assembly to transversely separate the closed tray-shaped elements (8) and form a series of closed trays.
[0014]
14. Process for packaging products (P) using an apparatus as defined in any one of claims 1 to 13, characterized in that it comprises the following steps: - providing a plastic precursor body (6) in the form of a web of plastic; - driving at least the precursor body (6) in a machine direction (MD) along the operating path; - receiving the precursor body (6) in said plastic web shape and forming the same in a series of cavities, so that the precursor body (6) comprises: - one or more longitudinal rows of adjacent tray-shaped elements (8), - longitudinal strips transversely delimiting each of said rows of tray-shaped elements ( 8),- transverse strips delimiting longitudinally and consecutively joining adjacent tray-shaped elements (8) of the same longitudinal row, the transverse strips and longitudinal strips delimiting upper openings of the elements in shape tray (8) and crossing one another in a plurality of transverse regions; - loading one or more of said products (P) into a respective cavity of said tray-shaped elements (8); - providing a plastic film (11);- firmly attach the plastic film (11) to close the upper opening of said tray-shaped elements (8) from the precursor body (6);- transversely separate the tray-shaped elements (8) closed, thereby forming separate closed trays or groups of trays; - before firmly affixing the plastic film to the tray-shaped elements (8) forming a through opening located in correspondence with at least one of: - a side wall of each one of said tray-shaped elements (8), and a plurality of said transverse regions between the longitudinal and transverse bands, wherein the passage opening in the side wall of each of said tray-shaped elements (8) and / or to open A passage structure in the plurality of said transverse regions between the longitudinal and transverse bands is created - after the formation of said number of cavities and definition of the adjacent tray-like elements (8) in the precursor body (6) - by a cutting tool (26) operating upstream of a packaging station configured to securely attach the plastic film (11) to the tray-like elements (8).
[0015]
15. Process according to claim 14, characterized in that it comprises forming said plastic precursor body (6) with two or more parallel rows of tray-shaped elements (8), in which:- each one of said tray-shaped elements (8) has a substantially rectangular upper opening defined by two longitudinal side walls and two transverse side walls of the tray-shaped elements (8), and the transverse strips cross perpendicularly the longitudinal strips delimiting said rectangular upper openings, so that said transverse regions are located in correspondence with corner zones of the tray-shaped elements (8); and wherein forming a through opening comprises forming said through opening in a plurality of said transverse regions; wherein said through opening is formed in the form of a cutaway portion removed from the plastic precursor body (6) by removing a part of a transverse strip in correspondence with a midline between two longitudinally adjacent tray-shaped elements of a same row, and- each of said cut-out portions is symmetrically located between two adjacent tray-shaped supports, and- each one of said cutout portions is in the form of one of a triangular opening delimited by three sides - straight or arc-shaped - and a quadrangular opening delimited by four sides - straight or arc-shaped.
[0016]
16. Process according to claim 14 or 15, characterized in that it comprises: - retaining a portion of the plastic film (11) in correspondence and above a corresponding tray-shaped element, - heating the film portion of plastic (11) at least up to a temperature comprised between 150°C and 260°C, - removing gas from an interior of said tray-shaped elements (8); and/or- injecting a gas or gas mixture into said tray-shaped elements (8) to form a controlled atmosphere within said tray-shaped elements (8); wherein the gas or gas mixture includes an amount of one or more of N2, O2 and CO2, which is different from the amount of these same gases when present in the atmosphere at 20°C and at sea level (1 atmosphere of pressure). - firmly fix the plastic film (11 ) to the respective tray-shaped element.
[0017]
17. Process according to any one of claims 14 to 16, characterized in that the activation of the precursor body (6) comprises: - grasping longitudinal lateral edges of the precursor body (6) in correspondence with a portion where the precursor body (6) fixedly received the plastic film (11), while leaving free the longitudinal lateral edges of the precursor body (6) in correspondence with a portion of the precursor body (6) where the fixing of the plastic film ( 11) to the tray-shaped elements (8) and, where the formation of the through openings takes place; or- grasping the longitudinal side edges of the plastic film (11) in correspondence with a portion where the precursor body (6) has fixedly received the plastic film (11), while leaving free the longitudinal side edges of the precursor body (6) in correspondence with a portion of the precursor body (6) where the fixing of the plastic film (11) to the tray-shaped elements (8) and, where the formation of the through openings occurs, where the plastic film (11 ) has a measured width perpendicular to the machine direction greater than the width of the precursor body (6); or- grasping longitudinal lateral edges of the plastic film (11) in correspondence with: a portion of the plastic film (11) extending longitudinally where the precursor body (6) has fixedly received the plastic film (11), a portion of the plastic film (11) extending longitudinally in the packaging assembly (20) and a portion of the plastic film (11) extending longitudinally between the film supply and the plastic film attachment (11) to the precursor body (6), although leaving free the longitudinal side edges of the precursor body (6) in correspondence with a portion of the precursor body (6) where the fixing of the plastic film (11) to the tray-shaped elements (8) takes place, and where formation of the through openings occurs, in which the plastic film (11) has a width measured perpendicular to the machine direction greater than the width of the precursor body (6); or- grasping longitudinal lateral edges of the precursor body (6) and the plastic film (11) in correspondence with a portion where the precursor body (6) has fixedly received the plastic film (11), while leaving the lateral edges free longitudinal sections of the precursor body (6) in correspondence with a portion of the precursor body (6) where the fixing of the plastic film (11) to the tray-shaped elements (8), and where the formation of the through openings takes place.
[0018]
18. Process according to any one of claims 14 to 17, characterized in that driving the precursor body (6) comprises grasping longitudinal side edges of the precursor body (6) in correspondence with a portion where the precursor body (6) has not yet received the formation of the through openings, although leaving free the longitudinal side edges of the precursor body (6) in correspondence with a portion of the precursor body (6) where the formation of the through openings takes place; and/or that driving the precursor body (6) comprises gripping longitudinal side edges of the precursor body (6) in correspondence with a portion where the precursor body (6) is still in the form of a plastic web prior to forming the cavities, while leaving free the longitudinal lateral edges of the precursor body (6) in correspondence with a portion of the precursor body (6) where formation of the cavities takes place.

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同族专利:

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公开号 | 公开日

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KR102256848B1|2021-05-27|

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AU2014264668B2|2017-10-19|

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BR112015028070A2|2017-07-25|

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RU2653085C2|2018-05-07|

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US20160194101A1|2016-07-07|

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EP2994393A1|2016-03-16|

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AU2014264668A2|2016-03-10|

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RU2015151446A|2017-06-13|

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US10065755B2|2018-09-04|

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WO2014180823A1|2014-11-13|

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PL2994393T3|2017-08-31|

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NZ713930A|2018-11-30|

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MX2015015401A|2016-03-15|

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ES2627737T3|2017-07-31|

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CN105209341A|2015-12-30|

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EP2994393B1|2017-03-08|

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KR20160006734A|2016-01-19|

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MX367062B|2019-08-05|

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AU2014264668A1|2015-11-19|

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法律状态:
2018-11-13| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2019-12-17| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2021-03-09| B06A| Patent application procedure suspended [chapter 6.1 patent gazette]|

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2021-06-29| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2021-07-13| B350| Update of information on the portal [chapter 15.35 patent gazette]|

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2021-08-10| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 06/05/2014, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

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EP13166773.5|2013-05-07|

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EP13166773|2013-05-07|

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PCT/EP2014/059196|WO2014180823A1|2013-05-07|2014-05-06|Apparatus and process for packaging a product.|

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