[0001] The present invention relates to an apparatus for handling powder, e.g. emptying powder from a large bag in an industrial operation. BACKGROUND TO THE INVENTION

[0002] Many processing industries require bags of powder, e.g. weighing 10kg and upwards, to be emptied into a receptacle for further processing. While automated machines exist to perform the emptying function, the operation is still commonly undertaken manually by a semi-skilled operator who must lift and manoeuvre heavy bags around a tipping area/chute. The operator then uses a sharp knife or box cutter blade to slice through the bag and plastic liner to allow powder to fall from the bag into the chute. It will be apparent that, from a health and safety perspective, moving and opening such bags manually is physically demanding and relatively dangerous. There have been many instances of operators receiving repetitive strain injuries as well as cuts.

[0003] The rates at which bags need to be emptied has also increased, particularly in the dairy industry where many nutritional powders are now re-blended. Given the requirement for speed and safety, manual operators cannot perform such tasks effectively over a long period.

[0004] As mentioned, automated processes are known for performing a bag emptying operation. Examples of automated devices include those described by prior patent publications NZ540013, GB2537407 and US6293318. These devices normally have some kind of container/bag support means, a cutting blade and a chute. In the case of NZ540013 powder is evacuated from an inclined bag by piercing with a spear and injecting air in order to fluidise powder contents prior to cutting open the bag. Such prior devices can present various benefits dependent on the intended end-use but there is ample scope for alternative solutions to the general field of automating the dispensing operation from bags of powder material.

SUMMARY OF THE INVENTION

[0005] The present invention seeks to address the problems identified above when manually emptying powder/granular type contents from a bag or the like and/or provide a useful alternative to known automated solutions.

[0006] In a broad aspect the present invention consists of an apparatus for opening a package to release flowable material comprised of: a holding means configured for receiving and holding a package in an upright position; a puncturing means configured for puncturing the package when located in the upright position; and a cutting means configured for engaging with and cutting a lower surface of the package.

[0007] Optionally the holding means is a clamping device.

[0008] Optionally the clamping device is configured for clamping a sealed package incoming to the apparatus and orienting it into the upright position.

[0009] Optionally the clamping device is comprised of a back plate or support and at least two fingers, each arranged for pivoting movement about axes defined proximate opposite edges of the back plate or support, said fingers moveable toward each other for clamping a package against the back plate.

[00010] Optionally there are a plurality of fingers located along the axes at opposite edges of the back plate.

[00011] Optionally the puncturing means is a spike element.

[00012] Optionally the spike element is comprised of a plurality of spikes extending from a spike support.

[00013] Optionally the spike element is stationary relative to the holding means such that, in use, the holding means is moveable to engage the package into an upright position and onto the spike element.

[00014] Optionally the spike element is moveable toward and away from the holding means and package held therein when in the upright position.

[00015] Optionally the cutting means is an elongate blade configured to engage upwardly for cutting across a width of a lowermost surface of the package.

[00016] Optionally the apparatus includes a locator element for adjusting a position of the package relative to the cutting means prior to cutting or for adjusting a position of the cutting means relative to the package prior to cutting.

[00017] Optionally the locator element is located proximate to the cutting blade, at a lowermost end of the upright package.

[00018] Optionally the locator element is comprised of at least one plate and/or finger actuatable to engage with and push or pull a surface of the package.

[00019] Optionally the holding means is configured for receiving and holding an elongate package in an upright position where upright is defined as substantially vertical.

[00020] Optionally the apparatus includes an exit chute located below the cutting means for receiving contents emptied from the package.

[00021] Optionally the apparatus includes a conveyor for delivering a package.

[00022] Optionally the apparatus includes a receiving station for receiving a package from the conveyor, ready for said package to be positioned upright by the holding means.

[00023] Optionally the receiving station incorporates a conditioning device for conditioning contents of the package. [00024] Optionally the conditioning device comprises square rollers and/or a vibration device.

[00025] Optionally the apparatus includes an end stop to limit conveyance of a package.

[00026] Optionally the end stop is moveable into and out of use by raising and lowering into and out of the path of the package.

[00027] Optionally the apparatus comprises a powder vibration device for assisting powder emptying from a package and/or build up on surfaces of the apparatus.

[00028] Optionally the apparatus comprises a removal chute configured for removing a package once released by the holding means.

[00029] Optionally the removal chute is vacuum operated.

[00030] Optionally the removal chute is moveable close to or in contact with the package to engage the vacuum and suck the package away via the removal chute.

[00031] Optionally a nozzle end of the removal chute is locatable with an uppermost or mid portion of the upright package.

[00032] Optionally the vacuum operation includes at least partially pulsed.

[00033] Optionally the removal chute includes a package sensor for activation or deactivation of the vacuum.

[00034] Optionally the apparatus includes a package discharge device.

[00035] Optionally the package discharge device is an air nozzle configured to direct air into the opened bag and, optionally, pulse to aid flow out of the bag as well as bag dislodgement from the puncturing means.

[00036] Optionally the apparatus comprises a controller.

[00037] Optionally the controller is configured to operate the apparatus in a sequence of steps.

[00038] In a second broad aspect there is provided a method for opening and releasing flowable material from a bag or the like, the method comprising the steps of: conveying a package to a receiving station; orienting the package in an upright orientation; engaging a piercing element to puncture an upper side wall of the package; engaging a cutting element to cut across a lower wall of the package; and allowing flowable material to fall by gravity from the package toward a downstream receptacle or further processing.

[00039] Optionally the cutting means is an elongate blade and further comprising the step of locating the package or blade prior to cutting such that the blade is substantially centred across a width of the package.

[00040] Optionally the method further comprises the step of engaging a vacuum chute for removal of an empty package. [00041] Optionally the step of orienting the package in an upright position comprises clamping the package with a clamping device when it is laying flat in the receiving station and raising it to a substantially vertical position. [00042] Also described is a gripper/clamper or more generally a holder for receiving and holding the package, said holder further configured to orient the package into an upright position, a puncture element configured for puncturing the package when located in the upright position, a cutting blade configured to engage with a lower surface of the package. There will likely be a chute or similar directing means underneath the package for receiving contents emptied from the package. Preferably the puncture element is engaged to puncture the package as it orients into an upright position, e.g. a bag is moved into position and forced onto spikes. In alternate forms the puncture element may be actuated to engage at a timed stage of operation and/or withdraw during removal of the package.

[00043] It should be noted that the apparatus in its preferred form is intended to be gravity assisted in its dispensing function. In other words the package is up-ended into a generally vertical position to take maximum advantage of gravity for the flowable material, e.g. particulate material like powder, to flow out of the lowest side of the package. Emptying by gravity is optimised when a generally elongate rectangular package (e.g. a sealed bag such as a 25kg sack of powder known to many processing industries) is positioned 'upright' as opposed to 'flat' or merely at an incline in the apparatus for the cutting operation. One form of the invention may incorporate square rollers or an equivalent as part of the infeed to help condition/loosen the powder in the package prior to being oriented vertically. This stage could additionally include a vibrating aspect to assist conditioning. There may also be instances where the package is a cube that has no discernible 'upright' position and thus the term 'upright' should not be considered unduly limiting in the context of the invention.

[00044] Also described are cutting means that engages upwardly with the package to result in optimum opening and, hence, emptying by gravity.

[00045] Also described is a conveyor integral or associated with the apparatus for conveying packages substantially horizontally toward a station where the gripper is engaged. Preferably an end stop is engageable to limit conveyance in the grip station. The end stop may be moveable into and out of engagement by raising and lowering.

[00046] Also described is a locator element for centralising the package relative to the cutting blade prior to cutting. Preferably the locator element is positioned proximate to the cutting blade, i.e. at a lowermost end of the upright package. The location of the cutting blade across the middle of the package during cutting can be viewed as an independent aspect of the invention. In principle locating the blade/package can be achieved by movement of the package to be cut relative to the cutting blade or moving the blade relative to the package by use of distance sensors or tactile means.

[00047] Also described is a removal chute configured for removing a package once released by the holder. The removal chute may be vacuum operated. In a preferred form the removal chute is moveable close to or in contact with the package to engage the vacuum and suck the package away from the work area via the chute. Preferably the removal chute would be locatable with an uppermost end of the upright package. In one form the removal/vacuum operation may be pulsed in order to shake any remaining material from the package.

[00048] In practice, operation of the invention to remove powder or other flowable contents from a bag, package or the like can be controlled by a controller to perform a sequence of steps. Generally the complete sequence is described as:

• conveying (e.g. on a timed belt or by manual placement on a horizontal surface or 'receiving station') a package to the apparatus;

· optionally conditioning the powder in the package (e.g. by use of a square roller on the conveyor belt and/or vibration);

• engaging the clamp/holder to at least one side wall of the package;

• lifting the held package into an upright (e.g. substantially vertical) orientation, such that the transfer from horizontal to vertical adds weight (via bag contents) and tension to the lowermost wall of the liner in the vertical direction;

• engaging onto or by at least one piercing element, e.g. a spike, laterally into an upper side wall of the package which both assists holding the package stationary (i.e. from falling under its weight) and breaks the vacuum in the package, equalising pressure with atmospheric. Engagement of the piercing element may occur during lifting of the package and forcing it onto spikes or by a separate actuation to a package once upright;

• optionally engaging a locator centralising a lowermost wall of the package with the blade prior to cutting;

• engaging the cutting blade to cut the package preferably in an upwards motion centrally across its width, while the package liner is tensioned downwards, against the subsequent flow of powder down an exit chute;

• optional automatic engagement and removal by a vacuum chute (e.g. 'snorkel') which moves close to or in contact with an empty bag and sucks it away. Spikes are withdrawn before, during or after this process.

[00049] By operation of the apparatus of the invention the package has been entirely controlled during the emptying process. Therefore, the process can be monitored and timed from delivery to dispense to make efficiency improvements.

[00050] Also described is a method that generally follows the controller steps listed above. [00051] An alternative form of the invention may convey (e.g . on a conveyor) packages to drop into an upright position in a holding means where spikes are introduced to puncture the package and for optional centring by a locator element and cutting by a blade, to release flowable material into a chute. Therefore, in a broad aspect the invention can be defined as an apparatus for opening and releasing flowable material from a package or the like, comprised of: a holding means for receiving and holding the package in an upright position, a puncture element configured for puncturing the package when located in the upright position, a cutting blade configured to engage upwardly with a lower surface of the package, and a chute for receiving contents emptied from the package. It is preferable to puncture the bag in its upright orientation because any loss of material will be minimised. Powder will fall from side wall puncture holes through the apparatus to the exit chute below.

[00052] In embodiments, the combination of how the bag is gripped, inverted and presented for cutting provides an improved solution. This combination of actions also means in at least some embodiments, the machine maintains control of the bag throughout the entire gripping, inverting and cutting process.

[00053] The apparatus can be provided in different configurations. There can be a basal standard configuration, which can be customised to handle variations in the package (e.g. type, shape, size) and material handled.

[00054] In embodiments, the apparatus can be used in food grade end-use applications or other applications where hygiene or cleanliness is required, such as in food processing, milk-powder applications or the like. The apparatus operates in a manner to reduce the risk of contamination. That said, the apparatus can be used in other industries too.

[00055] The invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more of said parts, elements or features, and where specific integers are mentioned herein which have known

equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.

[00056] The term "comprising" as used in the specification means "consisting at in part of". When interpreting each statement in this specification that includes the term "comprising", features other than that or those prefaced by the term may also be present. Related terms such as "comprise" and "comprises" are to be interpreted in the same manner. BRIEF DESCRIPTION OF THE DRAWINGS

[00057] Figures 1 to 12 illustrate a sequence of operational steps for an apparatus for opening packages for the release of powder according to the invention, each in perspective view; and

[00058] Figures 13 to 15 illustrate a more detailed underneath perspective view of the locating means and cutting step.

DETAILED DESCRIPTION OF THE INVENTION

[00059] The invention, its components and operation, is best described by the sequence of steps illustrated by the series of drawing figures.

[00060] Figure 1 illustrates an apparatus for opening packages to release powdered contents according to the invention. The main components include: a housing 10 (shown in dotted lines so internal components are visible); a receiving station 11 for receiving a package P from a conveyor C generally delivering packages in a direction of conveyance D; a gripping or holding means 12 comprised of closable fingers 13 and a back plate 14; puncturing elements 15 that extend through back plate 14 when it is in an upright position; a locating means 16 positioned below the gripping means 12; a cutting means 17 extending laterally across the apparatus relative to the conveyance direction D; an exit chute 18 (shown in dotted lines) and subsequent downstream component, such as a sifter, blender B or the like; and a package removal chute 19 that is extendable into close proximity with an empty package to remove it from housing 10 after the contents have been emptied.

[00061] It should be noted that 'package' P is a catch-all term for a receptacle, container, bag or the like which would be used for supply of materials in a

flowable/powdered state. The likely form of package P is a rectangular bag comprised of a Kraft paper outer material for durability and protection against the outside environment and a plastic inner liner material (e.g. polyethylene or other polymer) that is in direct contact with the contents, typically a foodstuff or other material that should be protected from moisture or other contaminants. The package P may be stripped down to the inner liner, i.e. Kraft paper removed, for use with the apparatus of the invention. This could for example be a plastic pouch.

[00062] Conveyor C can be an integral component of the apparatus or a separate device positioned against an opening 20. In general it is intended that packages P be automatically delivered to the apparatus, but delivery into opening 20 could be a manual operation.

[00063] Figure 1 shows the apparatus housing in an empty state, ready to accept a package P while Figure 2 shows a next step where a package P has been received through opening 20 and conveyed a short distance over rollers 21 of the receiving station 11 to a position ready for processing. Rollers 21 may provide some

conditioning/loosening of powder within the package, particularly when the rollers have a square form as illustrated. An additional vibrating feature may be incorporated to the infeed for bag conditioning assistance if required. Receiving station 11 is pictured as a generally horizontal surface, although it could be slightly inclined if necessary to encourage receipt of package P. Preferably an end stop plate 22 is in a raised position to limit the travel of package P as it travels into housing 10. End stop 22 would be actuated by suitable means and at an appropriate time by a process controller that controls all sequence steps.

[00064] Figure 3 illustrates movement of the clamping means 12 toward an engagement position. Particularly, back plate 14 has swung downwards in an arc A toward the package P displacing it approximately 90 degrees about a pivot axis X proximate its lower edge, bringing fingers 13 located on either side of back plate 14 into proximity with each side wall of a flat lying package P. Fingers 13 must be spread wide enough to clear package P as the clamping means lowers. In general terms this step can be described as a bag clamp or gripper lowering over a bag.

[00065] Figure 4 illustrates clamping/gripping or generally holding of the package by virtue of fingers 13 that extend from the back plate 14. A plurality of fingers 13 are mounted from a common rod 23 providing an axis of rotation along an edge of back plate 14. Two sets of pivoting fingers are provided, spanning each side of the package P, and close toward each other to perform a clamping motion. The clamping force must be sufficient to securely hold the bag for subsequent raising in the reverse direction to arc A as the back plate 14 lowered over the bag. At this step stop plate 22 remains in a raised position.

[00066] According to Figure 5 the end stop 22 is lowered so as not to inhibit the upward-orienting movement of package P where the back plate 14 of the clamping means 12 has returned to an upright position (last seen in Figure 2) bringing with it the clamped package P. Particulate material within package P will naturally shift slightly under gravity to put tension on the bottom end of the package liner. Since packages of this type are usually very full and/or may be vacuum packed the side walls are relatively firm and can easily be gripped and held in a vertical position by the gripping mechanism 12. However, preferably the fingers and clamping force are such that the side walls remain intact and not pierced . In general terms the bag is now raised to a 'tip' position. Also visible in Figure 6 is a further package P2 coming into view upon conveyor C.

[00067] Figure 7 illustrates package P2 taking a position upon the rollers 21 of the receiving station, ready for further processing. Meanwhile, as package P was raised to an upright position, puncturing elements 15 have engaged through back plate 14 to pierce the surface of package P and break the vacuum or otherwise equalise pressure within the package P with the external environment. Any small amount of egressed flowable material can fall immediately toward exit chute 18 below. In the illustrated form there are several rows of spikes 15 that are mounted on an elongate plate for being forced into the bag, although it will be appreciated that these could take many forms, yet be functionally equivalent. Puncturing the package P will likely loosen material therewithin and exert more tension on the lower side but clamping fingers 13 in concert with spikes 15 hold the bag in position. As previously, the timing of the raising operation onto spikes 15 to pierce the bag is controlled by a controller. The piercing step occurs by fixed spikes located near the maximum travel to the upright position, but could alternatively be achieved by powered actuation. Either way a package is forced onto the spikes (or spikes forced into the package) as it reaches an upright orientation.

[00068] In the step illustrated by Figure 7 the locating means 16, consisting of such as linear moving shafts (such as pairs of fingers) or plates or any other suitable actuator 24 (better seen in Figures 13 to 15), move to engage a lowermost end of the upright package P to nudge it into a 'centred' position, e.g. in the direction of arrow N, where it is best placed for slicing by the cutting edge 17.

[00069] Figures 13 to 15 illustrate the bag cutting configuration. Particularly, locating means 16 is visible which comprises fingers that actuate linear moving shaftsE 24 and contact a free hanging end of package P (not seen in Figures 13 and 14). A knife or more generally cutting edge 17 is mounted from a chassis 25 that is actuated for a generally upward movement centrally across the greater width of the package P.

According to Figure 13 the blade has cut upwards and, in use, entered a short distance into the middle of the bag base, thereby releasing particulate material to flow by gravity in the direction of arrow G into exit chute 18. According to Figure 14 the blade 17 has withdrawn downwardly again. Variations on the geometry of cutter 17 are possible, but with the general requirement to avoid fragmentation of paper or plastic from the package P that could contaminate powder being released; i.e. it should be a clean cut but there may be variations in the exact angle. For example, the blade cutting action may be a rising slicing action (in an arc) that provides a relatively jagged free edge to the cut, minimising potential plastic debris being released into the particulate stream. The location aspect of the invention could implement distance sensors to cause movement of chassis 25 and find an optimum middle cutting position for blade 17.

[00070] Figure 15 is a cross-section view along line A-A of Figure 14. Figure 15 illustrates the linear moving shafts 24 engaging the lowermost end of the upright package P and holding the package in the centred position ready for cutting edge 17 to slice package P.

[00071] Referring to Figure 7, the bag is in an emptying or emptied state and the blade 17 and centreing fingers 24 are yet to retract away from package P. Particulate material has been delivered to a sifter B or other downstream receptacle. The air blow assist involves air being injected into the bag after the bag has been cut open and powder released. Air is injected via nozzles that pierce the bag simultaneously with the spikes.

[00072] Referring to Figure 8, the fingers 13 of clamping means 12 have swung open about their respective axes, however, package P remains suspended in place by engaged spikes 15. Finger release allows particulate in the bag to drain freely. It is possible the fingers can pulse in short bursts, in both directions as they open, to aid emptying. A bag vibration device 28 labelled in Figure 9 may have been activated to assist powder emptying and reduce material build up on surfaces. When package P is empty it is relatively light and ready for removal.

[00073] According to Figure 10, removal chute 19 extends further into housing 10 to remove the empty package P (e.g. an empty plastic liner) by a nozzle end 29 configured with a wide/flat opening for best engagement with a bag liner. Removal is preferably by vacuum but could be by alternate means such as a gripping device to grab/pull the bag clear of the apparatus. Package P is preferably removed, e.g . by vacuum through chute 19, while spikes 15 remain engaged. Meanwhile end stop 22 has raised to limit incoming movement of next package P2. The suction through chute 19 may be deactivated once a sensor 27 has confirmed an empty liner has passed by onto a waste station. Bag removal may be assisted by an air blow feature 26 to urge an empty liner off the back plate for evacuation through chute 19.

[00074] According to Figure 11, chute 19 is withdrawn and spikes 15 are then exposed through back plate 14. Package P will have already been sucked away by chute 19 to waste or could have been held in place temporarily by the vacuum. In this step (Figure 10) it is possible that the vacuum is pulsed to shake the bag of any remnants of particulate material therewithin, before a prolonged final removal back pressure is applied. Other mechanical methods of finally shaking the bag could also be applied.

[00075] Figure 12 illustrates next package P2 raised to an upright position and a yet further package P3 being lined up for emptying according to the above described method steps. This is essentially an equivalent state of the apparatus according to earlier steps where the removal chute 19 has withdrawn and end stop 22 is raised, ready for lowering of clamping means 12 onto a package for re-orienting to an upright position.

[00076] Materials for construction of the apparatus according to the invention are chosen to ensure the structure is suited for purpose, i.e. food grade or according to other processing standards.

[00077] Improvements and alternative structural components will be possible without departing from the scope of the invention as defined by the appended claims.