BACKGROUND

[0001] This disclosure is directed to automatic wrapping machines and in particular the disclosure is directed to a machine for wrapping soft enrobed food items with discrete wrapping sheets.

[0002] Some food items, such as coated marshmallow treats (a.k.a. Malomars,

Mohrenkopf , Schokokuss, Krembo) can be comprised of a baked cookie base on which, (optionally flavored) marshmallow is deposited and is finally enrobed with a very thin chocolate.

[0003] Typically, the treat has a round nose bullet shape and is very sensitive to handling,

Moreover, due to the sensitivity of the treats, most packaging methods are manual, which can be labor intensive, relatively slow and may have a large footprint.

[0004] In those treats that are individually wrapped with foil, a step whereby the individual items are loaded onto a turntable mold is done manually.

[0005] Consequently, there is a need for an effective, efficient, low-cost automatic machine that overcomes the deficiencies of the prior art.

SUMMARY OF THE DISCLOSURE

[0006] Disclosed, in various embodiments are machines and methods for wrapping soft enrobed food items with discrete wrapping sheets.

[0007] In an embodiment, provided herein is a package wrapping machine for encasing a package with wrapping material comprising in combination; a first conveyor means for supporting the package and conveying it from the package's loading zone; a package dispensing means for depositing the package within a mold; a second conveyor means for supporting a plurality of a wrapping material sheets and transporting the plurality of wrapping material sheets to the mold; a wrapping dispensing means for the plurality of wrapping material sheets each sheet having a substantially consistent dimensions, wherein the dispensing means for the plurality of wrapping material sheets being operably coupled to the mold and configured to couple the sheet to the mold, leaving a margin amount of wrapping sheet; and folding each of the wrapping sheet margin over the package; an impeller, configured to insert a portion of each of the wrapping material sheets into the mold; the mold configured to: receive and selectably engage each of the plurality of wrapping material sheets; receive and selectably engage the package; and transport a wrapped package onto a third conveyor means; and the third conveyor means for supporting the wrapped package and optionally conveying it to a boxing zone.

[0008] In another embodiment, provided herein is a method of wrapping a package with a discrete wrapping material comprising: providing a packaging machine comprising, in combination: providing a packaging machine comprising, in combination: a first conveyor means for supporting the package and conveying it from the package's loading zone; a package dispensing means for depositing the package within a mold; a second conveyor means for supporting a plurality of a wrapping material sheets and transporting the plurality of wrapping material sheets to the mold; a wrapping dispensing means for the plurality of wrapping material sheets each sheet having a substantially consistent dimensions, wherein the dispensing means for the plurality of wrapping material sheets being operably coupled to the mold and configured to couple the sheet to the mold, leaving a margin amount of wrapping sheet; and folding each of the wrapping sheet margin over the package; an impeller, configured to insert a portion of each of the wrapping material sheets into the mold; the mold configured to: receive and selectably engage each of the plurality of wrapping material sheets; receive and selectably engage the package; and transport a wrapped package onto a third conveyor means; and the third conveyor means for supporting the wrapped package and optionally conveying it to a boxing zone; using the first conveyor means, transporting the package toward the mold; using the second conveyor means, transporting the plurality of wrapping material sheets to the wrapping dispensing means; using the wrapping dispensing means coupling a wrapping sheet to the mold; using the impeller, conforming the wrapping sheet to the mold; using the package dispensing means, depositing the package into the mold; folding the margin amount of wrapping sheet over the packaging, forming a wrapped package; and depositing the wrapped package onto the third conveyor means.

BRIEF DESCRIPTION OF THE FIGURES [0009] A better understanding of the machines and methods for wrapping soft enrobed food items with discrete wrapping sheets, with regard to the embodiments thereof, reference is made to the accompanying drawings, in which like numerals designate corresponding elements or sections throughout and in which:

[00010] FIG. 1A is a schematic representing an embodiment of conveying the food item and wrapping sheets to the mold, with FIG. IB, illustrating coupling of the wrapping sheet on the mold and FIG. 1C, illustrating deposition of the food item into the mold;

[00011] FIG. 2A, is a schematic representing the conforming sheet and the food item in the mold, with FIG. 2B illustrating the completion of the wrapping, and FIG. 2C illustrating deposition of the wrapped item on a conveyor belt; and

[00012] FIG. 3, illustrates a flow chart of an embodiment of the steps for wrapping soft enrobed food items with a discrete wrapping sheets.

DEATILED DESCRIPTION

[00013] In several embodiments, provided herein are machines and methods for wrapping soft enrobed food items with discrete wrapping sheets.

[00014] A more complete understanding of the components, processes, and devices disclosed herein can be obtained by reference to the accompanying drawings. These figures (also referred to herein as "FIG.") are merely schematic representations based on convenience and the ease of demonstrating the present disclosure, and are, therefore, not intended to indicate relative size and dimensions of the devices or components thereof and/or to define or limit the scope of the exemplary embodiments. Although specific terms are used in the following description for the sake of clarity, these terms are intended to refer only to the particular structure of the embodiments selected for illustration in the drawings, and are not intended to define or limit the scope of the disclosure. In the drawings and the following description below, it is to be understood that like numeric designations refer to components of like function.

[00015] Turning now to FIG. 1A-1C, illustrating (FIG. 1A) package wrapping machine 10 for encasing unwrapped item lOOi with wrapping material comprising in combination; first conveyor means 150 for supporting unwrapped item 100i and conveying it from the package's loading zone; a package dispensing means (not shown) for depositing unwrapped item lOOi within mold 300. The machine also comprises second conveyor means 250 (see e.g., FIG. IB) for supporting plurality of a wrapping material sheets 200/ and transporting j plurality of wrapping material sheets 200/ to mold 300; a wrapping dispensing means (not shown) for plurality of wrapping material sheets 200/ each sheet having a substantially consistent dimensions, wherein the dispensing means (not shown) for the plurality of wrapping material sheets 200/ being operably coupled to mold 300 and configured to couple the sheet to mold 300, leaving a margin amount of wrapping sheet; and folding each of the wrapping sheet margin over 2 ^th package lOOi. Mold 300 can be configured to: receive and selectably engage each of plurality of wrapping material sheets 200/; receive and selectably engage 2 ^th package 100 ₍ ; and transport a wrapped package onto third conveyor means 375 (see e.g., FIG. 1C) for supporting the wrapped package and conveying it to, for example a boxing zone.

[00016] Conveyor means 150 (and/or 250) can be in one embodiment of conventional design and is merely illustrated one form of a conveyor means which may be used. Conveyor means 150 comprises a frame means 155 (not shown) which supports a head pulley 151 and tail pulley 152. A conveyor belt 153 extends around pulleys 151 and 152 as illustrated in the drawings. Conveyor means 150 may also be in communication with vacuum means 350 such that orifices 154„, disposed along conveyor belt 153, can impart better hold on both unwrapped item lOOi (e.g., a soft, chocolate enrobed food item), or wrapped item 101; (See e.g., FIG. 2C). In another embodiment, conveyor belt 153 can define depressions 155p therein, configured to receive at least a portion of the base of unwrapped item 100;, or wrapped item 101; thereby assisting in the indexing of unwrapped item 100;, or wrapped item 101; relative to mold 300. Moreover, (see e.g., FIG. 5) conveyor means 150 can be comprised of plates I60 _q coupled to each other, forming conveyor belt 153. Each plate 160q, can define a circular depression 161 therein with a plurality of apertures 162 _m , maintaining communication with vacuum means 350. Each depression 161 having a diameter that is larger than the base of unwrapped item 100;, or wrapped item 101;, thus assisting in indexing relative to unit processes adapted to handle unwrapped item 100;, or wrapped item 101;, for example mechanical fingers configured to seal unwrapped item 100;, by manipulating corners 220, 220' , 221, and 22 . Or, in another embodiment, by twisting corners 220, 220', 221, and 221 ' .

[00017] As indicated, unwrapped item lOOi, can be, a soft, chocolate enrobed food item a soft, chocolate enrobed food item, that can have a flat base cylinder round nose bullet shape item (in other words, a domed 135 cylindrical 130 shape, see e.g., FIG. 1A), having a substantially soft core (e.g., any edible foam) over a substantially hard (relative to the core) baked item base.

[00018] In addition, and as illustrated in FIG. 1C, the packaged item dispensing means 175 (not shown) for depositing unwrapped item lOOi within mold 300 can be configured to flip unwrapped item lOOi upside down. In other words, from a position on first conveyor means 150, where the 2 ^th package 100i, is positioned on first conveyor means 150 base 130 down on conveyor means 150, whereby packaging 100i dispensing means 175 (not shown) can be configured to engage unwrapped item lOOi and position it within mold 300 round nose 135 dome down.

[00019] As illustrated in FIG. 1A, mold 300 can comprise housing 313 having apical aperture 310, with internal cavity 311 having a floor that can be substantially complementary to round nose 135 contour. The term "complementary" as used herein refers to the floor of cavity 311 having substantially the surface contour as the apical tip 135 of the soft, enrobed item. Furthermore, cavity 311 is configured to accommodate package 100i. The term "accommodate" refers in an embodiment to a state in which substantially the entire 2 ^th package 100i, or, in another embodiment, the wrapped package, is located within mold 300 cavity 311. Mold 300 can further comprise bore 312 defined in the floor. Bore 312 can be configured to be in communication with vacuum means 350. As used herein, the term "in communication", refers to a state whereby one member is coupled to another member, allowing for the transfer of gas or fluid between members, for example, using gas lines, pipes, conduits or ducts. The transfer can be one directional or bidirectional. Other components can be present between the members and comprise, for example, valves, pumps, sensors and the like. In an embodiment, the vacuum means can be a vacuum pump, operably coupled to cavity 311 through bore 312, with shut off valve 320 disposed between cavity 311 and vacuum means 350, and be configured to operate between a closed position (see e.g., FIG. IB), and an open position (see e.g., FIG. 1C).

[00020] The wrapping material sheet 200j, can be made of aluminum foil, or in another embodiment, from other quadrilateral (in other words, having 4 sides), metalized laminate film.

[00021] In an embodiment and as illustrated in FIG. 1C, packaging dispensing means 175 (not shown) can be configured to position each sheet of plurality of wrapping material sheets 200 _; , to cover apical aperture 310 of mold 300 with wrapping material sheet 200/, such that wrapping material 200/, forms a seal (in other words, sealingly) over apical aperture 310. Mold 300 can also be configured receive and selectably engage (in other words hold against inadvertent force, albeit not unlimited force) each sheet of plurality of wrapping material sheets 200/ by applying vacuum to mold cavity 311, for example via bore 312, by opening shut- off valve 320 and using vacuum means 350. As further illustrated in FIG. IB, impeller 275 can be used to conform each sheet of the wrapping material 200/ to mold 300 cavity 311.

Impeller 275 can comprise driver means 276, impeller arm 277, an impeller head 280 having distal surface 278, that can be complementary to the curvature of mold 300 cavity 311 floor.

[00022] In an embodiment, impeller 275 is stationary, while wrapping sheets 200j, having corners 220, 220', 221, and 22 Γ are coupled to apical aperture 310 using vacuum means 350 through bore 312. Mold 300 can then be configured to be positioned above impeller 275, and lowered onto stationary impeller, conforming each sheet of the wrapping material 200/ to mold 300 cavity 311 and hold each sheet of the wrapping material 200/ in place.

[00023] Impeller 275 can also be used in an embodiment together with vacuum means 350 (e.g., pump) to conform each sheet of the wrapping material 200/ to mold 300 cavity 311 and hold each sheet of the wrapping material 200/ in place. The term "impeller" as used herein is intended to represent a member which has an impeller-like structure made by impeller head member(s) coupled to an arm configured to have programmable reciprocal motion allowing the impeller head member to repeatedly enter and exit the mold bore and conform at least a portion of the wrapping material to the bore.

[00024] Turning now to FIG.s 2A-2C, following the positioning of packaging 100i, into mold 300 cavity 311 domed portion 135 down and as illustrated in FIG. 2A, packaging dispensing means 175 (not shown), can be configured to fold margins 210, 211, over flat base 130 (see e.g. FIG. 2B), whereupon mold 300 can be configured to transport a wrapped package onto third conveyor means 375 (see e.g., FIG. 2C) by, for example, maneuvering mold 300 housing 313 aperture 310 above third conveyor means 375. For example, mold 300 can be hingedly coupled to a bracket configured to turn mold 300 upside down, such that the wrapped packaging item is still held in place by vacuum means 350, with shut off valve 320 in the open position, and releasing the wrapped package onto third conveyor means 375, depositing the wrapped item right side up on base 130.

[00025] Turning now to FIG. 4, illustrating enlarged mold 300, having apical aperture 310 with a diameter that is larger than the diameter defined by cavity 311 walls 314 having convex floor 317, with bore 312 extending through housing 313. Apical aperture 310 is defined by apical surface 315, forming a running right angle 316, with cavity 311 walls 314. Running right angle 316 can be beneficial in preventing sheets 200/, each which can have thickness of between about 0.01 mm and about 0.25 mm, from tearing. Moreover, in another embodiment, apical surface 315, running right angle 316, and cavity 311 internal walls 314 can be coated with a resin (e.g., thermoplastic polymer or elastomeric polymer such as, for example LDPE, HDPE, PDMS and the like), facilitating the formation and hold of the cavity pattern following the application of vacuum with vacuum means 350.

[00026] The machines described herein are used in the methods described. Accordingly and in another embodiment, provided herein is a method of wrapping a package with a discrete wrapping material comprising: providing packaging machine 10 (see e.g., FIG. 1A) comprising, in combination: first conveyor means 150 for supporting unwrapped item lOOi and conveying it from the package's loading zone; a package dispensing means 175 (not shown) for depositing the package within a mold; second conveyor means 250 for supporting plurality of a wrapping material sheets 200/ and transporting the plurality of wrapping material sheets 200/ to mold 300; wrapping dispensing means 265 (not shown) for plurality of wrapping material sheets 200i each sheet having a substantially consistent dimensions, wherein wrapping dispensing means 265 (not shown) for plurality of wrapping material sheets 200/ being operably coupled to mold 300 and configured to couple the sheet to mold 300, leaving margin amount of wrapping sheet corners 220, 220', 221, and 221 ' ; and folding each corners 220, 220', 221, and 221'of wrapping sheet corners 220, 220', 221, and 22 Γ over the package; impeller 275, configured to insert a portion of each sheet of the wrapping material sheets 200/ into mold 300; mold 300 configured to: receive and selectably engage each of the plurality of wrapping material sheets 200/; receive and selectably engage package 100 _; ; and transport a wrapped package onto third conveyor means 375; third conveyor means 375 adapted for supporting the wrapped package and optionally conveying it to a boxing zone.

[00027] As illustrated in FIG. 3, the methods for of wrapping a package with a discrete wrapping material provided herein, can further comprise, using first conveyor means 150, transporting 103 unwrapped item lOOi toward mold 300; using second conveyor means 250, transporting (201) plurality of wrapping material sheets 200/ to wrapping dispensing means 265 (not shown); using wrapping dispensing means 265 coupling (202) wrapping sheet to mold 300; using the impeller conforming 203 j wrapping sheet to mold cavity 311 by further activating 204 vacuum means 350 through opening shut off valve 320 (see e.g., FIG. 1C), maintaining the sheet in mold 300 cavity 311; using package dispensing means 175 (not shown), depositing 103 unwrapped item lOOi into mold 300 cavity, with sheet formed in it, folding 104 the margin 210, 211 (see e.g., FIG. 2B) amount of wrapping sheet over 2 ^th packaging, forming a wrapped package; and depositing 301 the wrapped package onto third conveyor means 375.

[00028] The step of coupling wrapping sheet to mold 300 using wrapping dispensing means 265 (not shown) used in the methods for wrapping a package with a discrete wrapping material provided herein, can comprise sealingly covering apical mold aperture 310 of mold housing 313 (see e.g., FIG. 1A) with wrapping sheet (of plurality of wrapping sheets 200/), while the step of conforming the wrapping sheet to the mold by using impeller 275 can further comprise drawing vacuum 350 to mold cavity 311, for example, using bore 312.

[00029] Furthermore, and as indicated and illustrated in FIG. 1C, the step of depositing 103 2 ^th unwrapped item lOOi (e.g., Malomar, Mohrenkopf , Schokokuss, Krembo and the like), into mold 300 cavity 310 used in the methods for wrapping a package with a discrete wrapping material provided herein, can comprise flipping the flat base 130 round nose 135 (see e.g., FIG. 1A) item upside down (in other words, round nose 135 down) into mold 300 cavity 310.

[00030] The skilled person would readily recognize that, the step of conforming 203 the wrapping sheet to the mold and the step of depositing 103 the package into the mold used in the methods for wrapping a package with a discrete wrapping material provided herein, can be configured to occur substantially coincidental, or in other words, by partially conforming the wrapping sheet, or in an embodiment, foil, the partially formed (e.g., depressed foil) can act as a cushion for the packaging item (soft core, chocolate enrobed marshmallow column piped onto a biscuit e.g.,)

[00031] Likewise, as illustrated in FIG. 2C, the step of depositing 301 the wrapped package onto third conveyor means 375 can comprise a step of vertically rotating mold (in other words, flipping the mold upside down); and releasing 302 the wrapped food package.

[00032] All ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other (e.g., ranges of "up to 25 wt.%, or, more

specifically, 5 wt.% to 20 wt.%", is inclusive of the endpoints and all intermediate values of the ranges of "5 wt.% to 25 wt.%," etc.). "Combination" is inclusive of blends, mixtures, alloys, reaction products, and the like. Furthermore, the terms "first," "second," and the like, herein do not denote any order, quantity, or importance, but rather are used to denote one element from another.

[00033] The terms "a", "an" and "the" herein do not denote a limitation of quantity, and are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The suffix "(s)" as used herein is intended to include both the singular and the plural of the term that it modifies, thereby including one or more of that term (e.g., the sheet(s) includes one or more sheets). Reference throughout the specification to "one embodiment", "another embodiment", "an embodiment", and so forth, means that a particular element (e.g., feature, structure, and/or characteristic) described in connection with the embodiment is included in at least one embodiment described herein, and may or may not be present in other embodiments. In addition, it is to be understood that the described elements may be combined in any suitable manner in the various embodiments.

[00034] The term "selectably" means capable of being activated. In another embodiment, the term "selectably engage" is meant to indicate that the means for engaging the wrapping sheet can be activated if desired, but there is no specific requirement that engaging means is necessary for the operation of the machine. Other coupling/engaging means can also be used.

[00035] Accordingly and in an embodiment, provided herein is a package wrapping machine for encasing a package with wrapping material comprising in combination; a first conveyor means for supporting the package and conveying it from the package's loading zone; a package dispensing means for depositing the package within a mold; a second conveyor means for supporting a plurality of a wrapping material sheets and transporting the plurality of wrapping material sheets to the mold; a wrapping dispensing means for the plurality of wrapping material sheets each sheet having a substantially consistent dimensions, wherein the dispensing means for the plurality of wrapping material sheets being operably coupled to the mold and configured to couple the sheet to the mold, leaving a margin amount of wrapping sheet; and folding each of the wrapping sheet margin over the package; an impeller, configured to insert a portion of each of the wrapping material sheets into the mold; the mold configured to: receive and selectably engage each of the plurality of wrapping material sheets; receive and selectably engage the package; and transport a wrapped package onto a third conveyor means; and the third conveyor means for supporting the wrapped package and optionally conveying it to a boxing zone, wherein (i) the package comprises a soft, chocolate enrobed food item, which (ii) is a flat base round nose bullet shape item, having a substantially soft core over a

substantially hard baked item base, wherein (iii) the package dispensing means for depositing the package within the mold is configured to flip the package upside down, (iv) the mold comprises a housing having an apical aperture; an internal cavity having a floor substantially complementary to the round nose, the cavity configured to accommodate the package; and a bore defined in the floor, (v) the bore is operably coupled to a vacuum source, wherein (vi) each of the plurality of wrapping material sheets is a quadrilateral metalized laminate film, wherein (vii) the packaging dispensing means is configured to cover the apical aperture of the mold with a wrapping material sheet, (viii) the mold is configured receive and selectably engage each of the plurality of wrapping material sheets by applying vacuum to the mold, (ix) configured to transport a wrapped package onto the third conveyor means by maneuvering the mold housing aperture above the third conveyor means.

[00036] In another embodiment, provided herein is a method of wrapping a package with a discrete wrapping material comprising:

[00037] providing a packaging machine comprising, in combination: a first conveyor means for supporting the package and conveying it from the package's loading zone; a package dispensing means for depositing the package within a mold; a second conveyor means for supporting a plurality of a wrapping material sheets and transporting the plurality of wrapping material sheets to the mold; a wrapping dispensing means for the plurality of wrapping material sheets each sheet having a substantially consistent dimensions, wherein the dispensing means for the plurality of wrapping material sheets being operably coupled to the mold and configured to couple the sheet to the mold, leaving a margin amount of wrapping sheet; and folding each of the wrapping sheet margin over the package; an impeller, configured to insert a portion of each of the wrapping material sheets into the mold; the mold configured to: receive and selectably engage each of the plurality of wrapping material sheets; receive and selectably engage the package; and transport a wrapped package onto a third conveyor means; and the third conveyor means for supporting the wrapped package and optionally conveying it to a boxing zone; using the first conveyor means, transporting the package toward the mold; using the second conveyor means, transporting the plurality of wrapping material sheets to the wrapping dispensing means; using the wrapping dispensing means coupling a wrapping sheet to the mold; using the impeller, conforming the wrapping sheet to the mold; using the package dispensing means, depositing the package into the mold; folding the margin amount of wrapping sheet over the packaging, forming a wrapped package; and depositing the wrapped package onto the third conveyor means, wherein (x) the package comprises a soft, chocolate enrobed food item, having (xi) a flat base round nose bullet shape item, having a substantially soft core over a substantially hard baked item, wherein (xii) the mold comprises a housing having an apical aperture; an internal cavity having a floor substantially complementary to the round nose, the cavity configured to accommodate the package; and a bore defined in the floor, the bore coupled to vacuum means, wherein (xiii) the step of coupling the wrapping sheet to the mold using the wrapping sheets dispensing means comprises sealingly (in other words, completely covering the apical apertures), covering the mold aperture with the wrapping sheet, wherein (xiv) the step of conforming the wrapping sheet to the mold further comprises drawing vacuum to the mold cavity, wherein (xv) the step of depositing the package into the mold comprises flipping the flat base round nose item upside down into the mold, wherein (xvi), the step of conforming the wrapping sheet to the mold and the step of depositing the package into the mold occurs substantially coincidental, wherein (xvii) the step of depositing the wrapped package onto the third conveyor means comprises: vertically rotating the mold; and releasing the food package, and wherein (xviii) each of the plurality of wrapping material sheets is a quadrilateral metalized laminate film.

[00038] While particular embodiments have been described, alternatives, modifications, variations, improvements, and substantial equivalents that are or may be presently unforeseen may arise to applicants or others skilled in the art. Accordingly, the appended claims as filed and as they may be amended, are intended to embrace all such alternatives, modifications variations, improvements, and substantial equivalents.