Field of the Invention

The invention relates to apparatus and methods for placing fruit into packaging, and in particular, but not exclusively, to apparatus for packing apples into cylindrical containers.

Background of the Invention

Place packing produce, for example packing of fruit, can be a relatively labour intensive activity. After the fruit is automatically graded and sorted it moves on a conveyor belt to a collation area. The fruit is then typically placed into packaging by hand.

It would be advantageous to be able to automate one or more of the packing steps, but this involves overcoming a number of difficulties. Some produce may be desired to have a uniform orientation within the packaging. Further, fruit is often prone to bruising, and so placing the fruit into the packaging must be done gently. It is also important that the packing be performed at a sufficiently high speed, and that the packing equipment is reliable and does not malfunction in such a way as to require the entire sorting and packing system to be shut down.

Further, there is a trend for fresh fruit items to be presented to consumers in smaller take-home packages, as opposed to traditional bulk bin format presentation in markets and supermarkets. This has led to a growing need to pack fruit at source into consumer or retail ready packaging containers. Depending on the type of consumer-ready packaging involved, the packing process can become very labour-intensive. The prior art has gone some way toward automating packaging fruit items into smaller take-home packages, however these are relatively complex and expensive systems involving robotics or highly mechanised apparatus.

These principles can be applied to many varieties of produce including apples, stone fruit, citrus and the like, most of which use some form of packaging. It is an object of the present invention to provide a packing apparatus or at least provide the public with a useful choice. Other objects of the invention may become apparent from the following description which is given by way of example only.

In this specification, where reference has been made to external sources of information, including patent specifications and other documents, this is generally for the purpose of providing a context for discussing the features of the present invention. Unless stated otherwise, reference to such sources of information is not to be construed, in any jurisdiction, as an admission that such sources of information are prior art or form part of the common general knowledge in the art. Disclosure of the Invention

According to one aspect of the invention there is provided a packaging apparatus configured to allow fruit articles to be packed into a tubular container with a uniform orientation, wherein the apparatus comprises a plurality of support blades extending transversely from an end of each blade supported by a blade conveyor assembly, the blades configured to allow the deployment of the tubular container about the blade and any fruit articles supported thereon. According to a further aspect of the invention there is provided a packaging apparatus substantially as described above wherein the blade conveyor assembly is configured to move the array of transversely orientated blades in synchronisation with at least one support surface moved by a support surface conveyor assembly and the array of blades are arranged to move away from said at least one support surface to allow a packaging sheath to be deployed over the end of the blade to enclose and package articles supported by the blade.

According to another aspect of the invention there is provided a packaging apparatus comprising:

an array of transversely orientated blades configured to move in

synchronisation with a supporting conveyor surface; wherein the array of blades move past one end of the supporting conveyor surface to allow a packaging sheath to be deployed over the end of the blade to enclose and package articles supported by the blade. According to another example embodiment there is provided a fruit packing apparatus which defines a packaging zone comprising an array of blades adapted for aligning articles of fruit, and

a fruit collection zone comprising a corrugated surface, wherein the

corrugated surface comprises a combination of an array of blades and at least one support surface interposed about the blades.

According to a further aspect of the invention there is provided a blade configured for attachment for a fruit packing apparatus comprising a substantially concave upper surface and a first end adapted for attachment to a blade conveyor assembly in a transverse orientation and a second end substantially open for envelopment of a tubular packaging container.

According to yet another aspect of the invention there is provided a method of packaging articles of fruit characterised by the steps of:

i. receiving articles of fruit on an array of transversely orientated blades configured to move in synchronisation with at least one support surface, the array of blades being configured to move away from said at least one support surface when moving from a fruit collection zone to a packaging zone of a fruit packing apparatus, and

ii. deploying a packaging sheath over the end of the blade to enclose and package articles supported by the blade.

In preferred embodiments this method includes the further intermediate step of aligning fruit on the blades in a uniform orientation prior to deploying a packaging sheath over the end of the blade.

In some embodiments a support surface defines a corrugated surface forming complimentary depressions, each depression being arranged to receive a support blade.

In some embodiments an upper surface of the blades is substantially concave. In some embodiments an upper surface of the support surface or surfaces is substantially convex. In some preferred embodiments the packing apparatus includes a plurality of support surfaces formed from a plurality of rollers aligned such that the upper portion of the roller extends above the plurality of blades.

In some embodiments, the rollers are supported by a support surface conveyor assembly that spans the collection zone.

In preferred embodiments the support surface conveyer moves individual rollers through the fruit collection zone to position the upper surface of the roller above the upper surfaces of adjacent blades, and moves individual rollers downwards and away from adjacent blades where the blades travel from the fruit collection zone to the packaging zone. This arrangement ensures that the rollers are clear of the blades in the packing zone to allow deployment of a packaging sheath. In preferred embodiments the rollers are rotated by the support surface conveyor assembly when moved through the fruit collection zone.

In some embodiments, the upper surface of the blades and the support surface or surfaces together form a substantially corrugated surface.

In some embodiments, the apparatus further comprises a limit bar arranged to span the blades at a depth relative to the transverse extension of the blades, the depth corresponding to the depth of the packaging sheath. The present invention is arranged to provide a packaging apparatus suitable for the packaging of fruit articles. In preferred embodiments the

arrangement of the invention facilitates a packaging method where a collection of fruit can be provided with the same uniform alignment when installed in a package. The invention can therefore facilitate the rapid packaging of fruit articles with the fruit all being aligned consistently to provide an attractive package to consumers. The apparatus provided by the invention defines a fruit collection zone and a packaging zone. The fruit collection zone provides an array of support blades with an intervening support surface or support surfaces interposed between these blades. The packaging zone consists of or incorporates an array of support blades in isolation to facilitate loading of fruit supported by the blades into a package.

This intervening support surface or support surfaces may be implemented in a number of different ways in various embodiments.

For example in one alternative embodiment a fruit collection zone may incorporate a single support surface formed from a conveyor belt running in the same direction as the support blades and underneath the support blades. In yet other embodiments this conveyor belt may include a sequence of concave depressions on its upper surface with a form complimentary to the underside of a support blade, allowing the intervening upper surface of the belt to sit above or flush with or above the upper surface of the blades. In yet other alternative embodiments the intervening portions of such a conveyor belt may be raised with a convex form above the upper surfaces of adjacent blades to urge fruit under gravity towards these blades.

However reference in general throughout this specification will be made to the invention incorporating a number of distinct support surfaces, formed in preferred embodiments by individual support rollers. The upper surface of these rollers can be positioned above the upper surfaces of adjacent blades to urge fruit under gravity towards these blades. In a further preferred embodiments an additional drive structure can be provided connected to these support rollers to induce the rollers to rotate, again urging fruit on the upper surface of the rollers towards the upper surfaces of adjacent blades.

The apparatus includes a number of assemblies used to facilitate the movement of both blades and support surfaces. A blade conveyor assembly is provided in combination with a support surface conveyor assembly to allow both of the above components to be moved in synchronisation but independent from one another within the fruit collection zone. Once a blade is moved to the transition between the collection zone and packaging zone the blade conveyer assembly will move this blade into the packaging zone while the support surface conveyor will move any adjacent support surface or surfaces away from the blade.

The following embodiments may relate to any of the above aspects. Other aspects of the invention may become apparent from the following

description which is given by way of example only and with reference to the accompanying drawings.

As used herein the term "and/or" means "and" or "or", or both.

As used herein "(s)" following a noun means the plural and/or singular forms of the noun.

The term "comprising" as used in this specification means "consisting at least in part of". When interpreting statements in this specification which include that term, the features, prefaced by that term in each statement or claim, all need to be present but other features can also be present. Related terms such as "comprise" and "comprised" are to be interpreted in the same manner.

This 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.

Brief description of the drawings

Additional and further aspects of the present invention will be apparent to the reader from the following description of embodiments, given in by way of example only, with reference to the accompanying drawings in which : · Figure 1 shows a top view of an apparatus.

• Figure 2 shows a side cross section view of the apparatus of Figure 1. • Figure 3 shows a perspective view of a portion of a fruit packaging apparatus provided in accordance with an embodiment of the invention.

• Figure 4a, 4b and 4c show enlarged side cross section views of drive components of the apparatus of Figure 1.

• Figure 5 shows a perspective view of example blades and guide

surfaces extending from a conveyor of an example apparatus.

• Figure 6 shows perspective view of a portion of the fruit packaging zone of an example of the apparatus. · Figure 7 shows a perspective view of apples arriving from upstream supply apparatus and being supplied to the blades.

• Figure 8 shows a perspective view of articles uniformly aligned and orientated on a blade ready for packaging.

• Figure 9 shows a perspective view of a tubular container having an open end adapted for insertion over a blade and a closed end.

• Figure 10 shows a perspective view the container placed over a blade.

• Figure 11 shows a perspective view of a tubular container inserted over a row of fruit articles that have been aligned on a blade in the packaging zone. · Figure 12 shows a perspective view of an arrangement of the final packaging with the tubular container with articles for display to consumers in a desirable upright and uniformly orientated

arrangement. Further aspects of the invention will become apparent from the following description of the invention which is given by way of example only of particular embodiments. Best modes for carrying out the invention

Referring to Figures 1 to 4, a fruit packing apparatus is generally referenced by arrow 10. In particular, Figure 1 shows a top view of an apparatus, Figure 2 shows a side cross section view of the apparatus of Figure 1, while Figure 3 shows a perspective view of a portion of a fruit collection zone 1, and Figure 4a, 4b and 4c show enlarged side cross section views of the

apparatus of Figure 1 including drive components of a dual conveyor assembly 6.

The dual conveyer assembly 6 forms a blade conveyer assembly 6A and a support surface conveyer assembly 6B. The blade conveyer assembly is arranged to move an array of blades 2 in synchronisation with a number of support surfaces moved by the support surface conveyer 6B. In the embodiment shown these support surfaces are formed by the upper surfaces of a number of support rollers 3. However in alternative embodiments a single support surface may be provided by a conveyer belt.

In some embodiments the dual conveyor assembly 6 is continuous and in other embodiments comprises a combination of multiple segments of conveyors. Where multiple conveyor segments are used, the segments can be overlapping. Such conveyer assemblies are operated by the use of a drive system such as an electric motor and appropriate control unit. The fruit collection zone 1 receives fruit from a suitable source, typically an output of a grading and/or sorting machine. The fruit collection zone is defined by the presence of both blades 2 and intervening support rollers 3 moving in synchronisation with each other. The dual conveyer assembly moves the blades and support rollers in a direction which facilitates movement of the fruit away from the collection zone 1 and toward the packaging zone 4. Parts of the grading/sorting machine upstream from the apparatus are not shown.

Figure 6 shows a portion of the fruit packaging zone 4 downstream of the fruit collection zone 1 where the support rollers 3 are not present. Removal of the support rollers from the packaging zone is facilitated by the use of the two aligned conveyors where the blade conveyer 6A supports and moves the blades, while the support surface conveyer 6B independently supports and moves the support rollers.

The support surface conveyor 6B is configured to overlap with the blade conveyor 6A in the fruit collection zone 1 and return the support rollers 3 to the start of the fruit collection zone before they before enter the packaging zone 4. Figures 1 and 2 each show the blade conveyor 6A extending between the collection zone 1 and the packaging zone 4. As indicated above the apparatus 10 further comprises a plurality of support blades 2 arranged as an array and adapted to assemble fruit in the collection zone 1 for packaging in the packaging zone 4. The blades 2 are transversely orientated by connection to the blade conveyor assembly 6A at a supported end and extending outward to provide a surface upon which articles of fruit can be assembled.

The array of blades is configured to allow a packaging sheath to be deployed over the end of the blade and slid toward the supported end of the blade to enclose and package articles supported by the blade. To promote stability of articles on the blade, the upper surface of the blade is channelled or concave. The apparatus 10 is especially suited for use with tubular

containers which are open at one end, closed at the other and designed to display fruit as a stack. The blades have an adequate depth to allow a desired number of fruit articles to be inserted into a packaging sheath. For example, the blade could be sized to support between two and six items of fruit.

In use, fruit is packaged by being arranged on a blade and an open end of a tubular container is slid over the fruit. The tubular container can then be removed from the blade with the fruit contained within. Figure 9 shows a view of a tubular container 20 having an open end 21 adapted for insertion over a blade and a closed end 22. Figure 10 shows the container 20 placed over a blade 2. The container 20 is closed when desired by application of a cap, such as a press fit of screw cap, to the open end 21.

A side wall 5 may optionally be provided on one or both sides of the dual conveyor assembly 6 in the fruit collection zone 1 to help collect fruit on the blades. However, it is preferable that the packaging zone has no side wall at the unsupported end of the blades to allow the entry of tubular packaging containers. The collection zone 1 distributes fruit directly to the blades 2. To aid with guiding the fruit to the blades the interleaved support rollers 3 are

interspersed between each of the blades 2. The support rollers 3 are shaped so as to promote guidance of incoming fruit articles to the blades, for example, by having a sloped upper surface.

In this embodiment the support rollers are mounted to the support surface conveyer 6B by rotatable axles which are coupled to a further drive system by a drive chain (not shown). This additional chain drive rotates the rollers which promotes distribution of incoming fruit articles on to the blades 2.

These support surface rollers 3 are configured to extend along an upper region of the fruit collection zone 1 before pivoting around a drive or support wheel and returning via a lower region of the same zone. Figure 2 shows drive wheels and an array of blades 2 extending along an upper surface prior to pivoting and returning via the lower surface. As can be seen from figure 2 the blade conveyer assembly 6A spans the entire length of the apparatus 10, while the support surface conveyer assembly 6B spans only the fruit collection zone of the apparatus. As indicated above Figures 4a, 4b and 4c shows enlarged side cross section views of drive components of the apparatus 10. Figure 4a shows the blade drive wheel 11a and the support surface drive wheel l ib provided at the start of the fruit collection zone 1. Figure 4b shows the support surface drive wheel l ib provided at the end of opposite end of the fruit collection zone 1 at the transition to the packing zone 4, while Figure 4c shows the blade drive wheel 11a provided at the end of the packing zone 4.

As can be seen by these figures each of the support surface and blade conveyer assemblies are driven independently of each other. The provision of the dual conveyer assembly 6 ensures that both blades and support rollers can move together synchronised at the same speed in the fruit collection zone, and then be separated at the transition to the packing zone with the support rollers returning to the start of the fruit collection zone and the blades continuing to the end of the packing zone.

Figure 5 shows an example of the blades 2 and guide surfaces 3 interleaved together in the fruit collection zone 1. The blades and guide surfaces together form a substantially corrugated surface with the peaks of the corrugation formed from a substantially convex upper surface of the support rollers 3 and the valleys of the corrugation formed from the substantially concave upper surface of the blades 2. Fruit incident to the corrugated surface is guided under the assistance of gravity into the valleys provided by the position and shape of the blades 2.

In some embodiments, the blades 2 and guide surfaces 3 in the fruit collection zone are closely arranged so that gaps between these components are minimalized. However, in other embodiments the gaps between these components are spaced sufficient to allow a tubular container to be slid over a blade without being obstructed by adjacent guide ridges. In embodiments with large gaps between components, the gaps should be sized so as to substantially prevent articles of fruit from falling through or becoming lodged. When the apparatus is for use with small fruit articles, a close gap is preferable with the support rollers removed from the packaging zone 4 to allow easy access of tubular containers.

Figure 7 shows apples arriving from upstream supply apparatus and being supplied to the blades 2 in the collection zone 1. The support surface rollers 3 promote collection of each of the articles onto a blade. It may be desired that an operator may manually assist the collection process by filling gaps on a blade not automatically filled by the collection process. Further, it may be desired that an operator orientate each article of fruit uniformly upon the blade before the articles are packed in a tubular container.

Figure 8 shows a view of articles uniformly aligned and orientated on a blade ready for packaging. For example, in some embodiments the particular orientation of fruit on the blades could be such that the fruit have stalks aligned vertically when in a container. Figure 11 shows a tubular container inserted over a row of fruit articles that have been aligned on a blade 2 in the packaging zone 4. The fruit articles and container are able to be removed from the blade together by placing a finger over the open end of the container 21 and drawing the container from the blade with the articles captive inside the container. The prearrangement of fruit articles on the blade therefore allows careful orientation of each article before packaging. Figure 12 shows an arrangement of the final packaging with the tubular container 20 containing articles for display to consumers in a desirable upright and uniformly orientated arrangement.

The tubular container 20 can be placed on further packing apparatus such as a turntable for grouping before packing into cartons containing 30-40 tubes, all upright. Referring again to Figures 1 to 4, some embodiments incorporate an alignment bar 30 configured to span the conveyor at a transverse location that corresponds to the desired depth of the articles to be arranged on a blade by acting as a limit or stop for articles on the blade and the base of containers to be inserted over the blade. The alignment bar is supported by a plurality of support arms 31 that attach to the chassis of the apparatus or some other stable location. The position of the alignment bar 30 is ideally adjustable so that different depths of containers can be adapted for. For example, the support arms 31 may be adjustably positioned by utilising releasable clamps or similar devices. It is desirable that the length of the blades and the adjustable position of the alignment bar allows for between two and six items of fruit to be positioned for packaging.

Where in the foregoing description reference has been made to elements or integers having known equivalents, then such equivalents are included as if they were individually set forth. Although the invention has been described by way of example and with reference to particular embodiments, it is to be understood that modifications and/or improvements may be made without departing from the scope of the invention as set out in the claims. In the preceding description and the following claims the word "comprise" or equivalent variations thereof is used in an inclusive sense to specify the presence of the stated feature or features. This term does not preclude the presence or addition of further features in various embodiments.

It is to be understood that the present invention is not limited to the embodiments described herein and further and additional embodiments within the spirit and scope of the invention will be apparent to the skilled reader from the examples illustrated with reference to the drawings. In particular, the invention may reside in any combination of features described herein, or may reside in alternative embodiments or combinations of these features with known equivalents to given features. Modifications and variations of the example embodiments of the invention discussed above will be apparent to those skilled in the art and may be made without departure of the scope of the invention as defined in the appended claims.