Ths snvenuon relates to an apparatus for and method of packaging ariscies. paruculady but no? exclusively to a method of and an apparatus tor grouping articles and even more specifically but not exclusively to a method of and an apparatus for packaging secondary packages sn a iertiasy package such as a tray.

Currently primary packages such as bottles or cans are packaged ;n multiples sn secondary packages such as cartons, and those cartons are subsequently transported to a separate location away from or oil the secondary packaging hπe where the cartons are packaged in tertiary packages such as trays.

There ;s a need to improve me ergonomics of existing packaging isnes and to integrate a fertiary packaging module snto an exsstsng secondary packaging line whilst minimizing the space dedicated <o secondary packaging and tray packing on existing packaging ϋnes

The present invention snerefore seeks to provsde a packaging machine that comprises a combined secondary packaging isne and tertiary packaging line.

Accordingly, a first as pect of the invention provides an appasaius lor rr;aniρuiating a piuiaiity of articles, in e apparatus capabie of receiving a single-file stream of articles and comprising a di\ ding element operable Io split a received ssngle-hie stream of articles ϋito t^o or Tsore adsaoent streams and compπ&inq an ahqnsnq ei&meni operable io collate articles in adjacent steams into an aiiqned rank of articles.

Preferably the apparatus is a iert-ary packaging apparatus and wherein the apparatus is structured and arranged such that it is coupiabie to a secondary packaging machine.

Preferably an input of the apparatus Is coupiable to an output of a secondary packaging machine such that a single-file stream of articles output from the secondary packaging machine is directiy receivable by the tertiary packaging apparatus.

Preferably the aligning element comprises a lug for retarding the passage of secondary packages in each of said two or more streams such that adjacent streams of secondary packages are arrangesbie and alignabie mto a contiguous batch Optionally two GO- linear lugs are disposed on separate return conveyors.

Preferably the or each lug forms a leading lug of the contiguous batch if forms and is. coupled Io a lug conveyor mechanism. Preferably said leading lug additionally forms a trailing lug for engaging and transferring a preceding contiguous batch of articles.

Optionally the or each k.sg is operable at a lower velocity than thai rate of output of secondary packages from the secondary packaging machine. Preferably the or each lug is operable at a fraction of the rate of output of the secondary packaging machine inversely proportional to the number of streams formed by the dividing element

Optionally the apparatus comprises a transfer element for transferring a contiguous batch of secondary packages into a tray,

Preferably the apparatus comprises a tray conveyor for providing successive trays, each for loading with a contiguous batch of secondary packages, me iray conveyor being structured and arranged to flow in the opposite direction relative to the output flow of me secondary packaging machine. Optionally the transfer element and one of said slop bars ere carried a\ong the same return path

Preferably, the dividing element comprises a guide whsch is moveabie alternately Into a series of positions to divide the output packages into two or more streams of secondary packages.

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Alternatively or additionally said guide is rπoveable in a first sequence of positions and successively moveaoϊe in a reverse sequence of positions. Preferably sasd moveable guide is pivoisbie.

According to a second aspect me invention provides a method of manipulating a plurality of articles, the method composing: receiving a single-fiie stream of articles; splitting the received single-file stream of articles into two or more adjacent streams and co! ia ting articles in adjacent streams Into an aligned rank of articles.

Preferably the steps of receiving, splitting and aligning are carried out by a tertiary packaging apparatus and the method comprises coupling the apparatus to a secondary packaging machine.

i s Preferably the apparatus comprises a lug bar lor retarding the passage of secondary packages sn each of said two or more streams and the method comprises arranging and aligning secondary packages of adjacent streams into a contiguous Patch

Optionally the method comprises transferring a contiguous ba?cn of secondary :o packages into a fray

Preferably the method comprises providing successive trays, each for loading with a contiguous Patch of secondary packages.

^ Preferably the step of sphrtlng said two of more streams of secondary packages comprises moving a guide alternately into a series of positions Even more preferably moving said guide ss conducted in a Hrsϊ sequence of positions and successively conducted in a reverse sequence of positions

^ According to a turther aspect the present invention provides a packaging machine comprising a combined secondary packaging ϋne and tertiary packaging ime h&vino

(a) a secondary carton packaging section for packaging primary packages in secondary packaging cartons: ih) an assembly section for receiving the cartons containing primary packages and assenting ihem into groups of cartons: λ i.c > a collecting section for receiving the groups of cartons and assembling the groups smo spaced columns,

{ύ) a batch assembly section for receiving a plurality of columns and assembling them into a batch of contiguous cartons,

(e) a tray loading section for assembling each batch or cartons onto a tray, and, o if) an off-loading station for off-loading trays onto a pallet

Preferably sections (a) to (d) of the machine are parts of a continuously moving conveyor system

> According to yet a further aspect of the present invention there is provided a method of packaging comprising the steps of.--

(g) packaging primary packages ;n secondary packaging cartons, f in assembling the cartons containing pnmary packages into groups of cartons; o) collecting the groups of cartons and assembling the groups info spaced columns; H; ij) assembling the columns info a batch of contiguous cartons; ih) loading each batch of cartons onto a tray; and, i h off-loading the trays onto a pallet.

Preferably the steps (a) to (d) of the method are carried out on a continuously ;3 moving conveyor system,

Exemρla?γ embodiments of the present invention Will now be described, by way of example o^ly. with reference to the accompanying drawings in which ^'

Figure 1 shows., schematically, a plan view of a ternary packaging apparatus disposed at the output of a secondary packaging machine, according to a first embodiment; of the invention

Figure 2 shows a tertiary packaging apparatus according io a second embodiment of the present invention disposed at the output of a secondary packaging apparatus and illustrating a dividing section of the ternary packaging apparatus in use.

F _^ gure 3 shows the tertiary packaging apparatus of Figure 2 showing two lines oi divided secondary packages,

Figure 4 shows the- tertiary packaging apparatus of Figure 2 showsng three sines of divided secondary packages;

Figure 5 shows the assembly of a first contiguous batch of secondary packages.

Figure 6 shows the assembled Patch being conveyed by the tertiary packaging apparatus and a next, successive batch be-ng formed,

Figure 7 shows a transfer element of the tertiary packaging apparatus coming into alignment with the first contiguous batch of secondary packages.

Figures 8, 9 and 10 are upstream illustrations of the packaging machine of Figure 7 showing the first batch being lifted and transferred to a tray,

Figure 1 1 shows a tray sn feed section of the tertiary packaging apparatus and a step in the loading of a tray With the first Patch of secondary packages and

Figure " 2 shows a Uay packed with the hrst Patch and the loading of a successive trey.

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Referring to Figure 1 of the accompanying drawings there is shown a ternary packaging apparatus S constructed in accordance with (he present invention, that comprises, in sequence an assembly secrion 12. a batch assembly section 14, a tray loading- section 16, and a pallet loading section 18. The tertiary packaging apparatus 9 is disposed at the output of a secondary packaging machine 10 such that secondary packages such as cartons 21 are directly received by the tertiary packaging apparatus. In other embodiments *he secondary and tertiary packaging apparatus are integrally formed as a unitary machine, in other embodiments the tertiary packaging apparatus 9 is added on to an existing secondary packaging apparatus 10.

The secondary packaging apparatus 10 is or a weli known conventional secondary packaging apparatus of the type used for packaging primary packages such as bottles or cans {not shown), into secondary packaging such as cartons 21 Conventionally in one form of secondary packaging she secondary packaging cahons 21 are formed by folding a carton blank (not shown) made from a flexible foidabie sheet of materials such as paper board, around a plurality of phmary packages (not shown). The specific design of the secondary packaging apparatus 10 is not important to (he present indention providing that it operates to supply a succession of secondary packages 21 to the tertiary packaging apparatus 9

Once completed the cartons 21 are output individually from the secondary packaging apparatus 10 in a continuous moving single-file stream Qi cartons 21 and are received in the assembly section 12 where the cartons 21 are grouped into a plurality of groups 22, 24 and 26 each made up of ?oυr cartons 21 by a guide means 27 Three groups 22, 24, 26 each made up of four cartons 21 are shown In Figure 1 . In other embodiments the groups 22, 24, 26 contain only one carton 21. Indeed it is envisaged that any number of cartons 21 could be formed into such a group 22, 24, 26. In this embodiment [he groups are equally sl^ed, however ;n other embodiments the groups may contain a different number of cartons 21 according Io pecking

requirements, in older embodiments fewer or greater thar ^; three groups 22, 24, 26 are formed Preferably at least two separate groups are formed

The cartons 21 leaving the secondary packaging section 10 are conveyed at a first pitch P ; arid are divided by dividing means 33 into three continuous streams to produce the groups 22, 24, and 26 as illustrated. The grouped cartons 22, 24, 26 are manipulated and conveyed at a second pitch P-x

At the assembly section 14 the groups 22, 24, 26, each of four cartons 21 . are assembled In ϊt\(ee spaced apart columns that advance along the same direction as staggered columns on a continuously moving conveyor system, As the columns 22, 24. 26 move together in a common direction, their movement Is arrested by a stop bar 28 located in the collection section 16 The spaced columns 22, 24, 26 are brought together by moving the columns 22, 24 sideways to form a balch 30 of twelve contiguous cartons 21 as shown.

It is envisaged In alternative embodiments thai the columns 22 _: 24, 2 6 may be accelerated sucn that they are brought together to form a batch 30, In this way the relative speed between the columns is adjusted such that each ot the columns *s brought into alignment

At the tray loading section 18 the individual batches 30, each comprising twelve cartons 21 _: are stacked onto a tray 32, and the trays 32 are otf-ioaded from a continuously moving conveyor system (not shown) and stacked onto each other to form a pallet (not shown) comprising a plurality of trays 32. h is envisaged thai a series of vacuum suction cups could be used to lift the individual batches 30 for loading onto the tray 32.

A second embodiment Is illustrated in Figures 2 *o 12, In Figures 2 to 12 ϋke reference numbers are used to identify features which are similar to those of the fsrsi embodiment The like reference numbers are raised by a factor of 100 to distinguish between the fsrst and second embodiments. Since the subseouent embodiments

share similar features to (he first embodiment only certain differences will be oescnbed \n detail

Referring Io Figures 1 and 2, a tertiary packaging apparatus 109 is coupled to a 3 secondary packaging apparatus 1 10 by a conveyor element 140 such that the tertiary packaging apparatus 109 can directly receive a strearn of secondary packages {or other articles) as they are output frorπ the secondary packaging machine 1 10.

κ> A dividing element 133 is provided to guide successive articles into separate adjacent lines, in operation, a leading secondary package 122 is directed into a leftmost line, thereafter a subsequent secondary package or oiher article 124 Is directed into a central line or column and a further successive package 126 ss guided and directed into a rightmost line. The successive packages, 122, 124 ,126 are each i;: conveyed at an output velocity V i of the secondary packaging machine 1 10 such that as the successive packages 122, 124, 126 pass through the dividing element 133 rhey are arranged in a staggered fashion on a conveyor element 140. Thts ss partially shown in Figure 3

::u First and second return conveyors 150, 152 (see figures 1 - 12} are provided With a series of stop bars (alternatively called flight bars or lugs) 12S which are conveyed around the return path of the first and second return conveyors 15O ₁ 152.

The fl-ght bars or lugs 128 are arranged to interrupi the flow of secondary packages

:.5 or articles as they exit rhe path of the dividing element 133. This is illustrated in

Figure 3 where the leading and leftmost package 122 is slowed or retarded by the stop bars 128 The successive packages 124, 128 catch up with me leading package

122 (see Figure 4) until ail three packages 122, 124. and 126 are aligned wlfh ieading edge abutting the stop bars 128 such that a rank of three adjacent packages

?o 122, 124. 126 is formed. This Is Illustrated sn Figure 5 wherein a first rank of aligned. adjacent and contiguous packages forms a batch 130a. Tne stop bans) or lug(s) 128 sequentially act upon each package 122, 124, 126 of the rank to retard that package

122, 124, 126. In an alternative embodiment packages 124 and 126 each may De accelerated to catch up with package 122.

Successive packages are conveyed from tπe secondary packaging machine 1 10 ^; along the conveyor element 140 and through the dividing element 133 and the dividing process repealed such thai subsequent ranks or contiguous batches 130b are formed, in othet embodiments, a guiding element (not shown) of the dividing element 133 moves alternately from left to right and then returns dividing articles from rsght io left such thai the rightmost package 125 becomes the leading package u> sn alternate cycles through the dividing element 133. In yes a fanner embodiment, the dividing element dueets wote than one package 122 snto the IeH most line and then a similar number of packages "24 into the central line and so on such that a senes of ranks of packages 122. 124, 126 are formed into a successive contiguous batch 130b

The stop Pars or lugs 128 thai serve to retard ?he output packages 122, 124, 126 of the succeeding batch !3Ob. provide a leading lug for conveying the preceding batch 130a oi packages (as shown in Figure 6). As the leading lugs move away to propel the preceding batch 130a, the succeeding batch 130b is propelled by a further set of

^■ ϋ lugs 128 provided by the first and second conveyor elements 150. 152.

The ru.isT:ber ot articles or packages 122, 124, 126 sn any batch 130a, 130b {and therefore pitch of the tertiary packaging machine) is determined Dy the number of lines or columns formed by the dividing element, the ssze of the packages 121 themselves- and tne distance between successive slop bars or lugs 128 which

; ^< ■ corresponds to the number of packages wϋhin a column.

The siop bars 128 which snterruμ? tne flow of secondary packages or articles 121 as ihey e>it the pain of the dividing element 133 are conveyed by the f.rst and second return conveyors 150. 152 at a second velocity V _? in the present embodiment, the >■> velocity V- of the stop bars 128 is a fraction of the velocity V, (of the output stream of packages and conveyor etemens 140} which ss inversely proportional to the number

^■ I O ^■ of lines formed by the dividing element 133. Specifically the output velocity of arUoies V-i and veloci-y V _;: (of conveyance of the stop bars 128} is related as follows:

3

This applies when the secondary packaging machine pitch and tertiary packaging machine pitch are equal and therefore the tertsary packaging machine operates a* one third of the speed of the secondary packaging machine (three packages besng contained sn one pitch of the tertiary packaging apparatus).

in other embodiments where the pitches are not equal (because for example more than one package Is directed into each sine at a time as described above) lhe relationship between speeds is retained through the number of packages put Into a tertiary packaging machine pitcπ. For example, if me secondary packaging machine pitch is 400mm and the ternary apparatus pitch iβ oOOmm the tertiary packaging machine 109 advances 500mm while the secondary packaging machine 110 advances (3x400) 120Qmrn

A transfer element 154 Is conveyed over and brought into vertical alignment with the assembled ranks or batches of packages 130a, 130b as they are conveyed by the stop bars 128 down stream of the secondary packaging machine. This is shown in Figures 6-10. The transfer elerneni 154 comprises transfer means 156, which in this embodiment takes the form of vacuum suction cups 156. In other embodiments, other suitable transfer means for moving all packages 122, 124, 126 of batch 130a is

Tertiary packages such as trays 130 are fed into the packaging line by tray conveyor 160 (see figure 9) Optionally, the conveyor 160 is arranged such tha* the direction (X) of travei of successive trays 130 Is arranged oppositely Io the direction (Y) of lhe conveyed batches 130a, 130b In this way the floor space required to accommodate she tertiary packaging machine Is minimized.

The lerlsary packaging machine 109 in other embodiments comprises a tray assembly sechon. in this embodiment assembled trays 132 are loaded onto the conveyor 160 The trays 132 are structured to receive the assembled batch 13Oa ₁ 130b of packages and as such the pitch oi ^' a tray 132 matches or is substantially ssmslar Io that of a rank or contiguous batch 130a. The sn feed of the trays 132 ss synchronized with the formation and passage oi ^' batches 130a, 130b such thai, a transfer means 156 is operable to load a tray 132 with a batch of packages 130a. This is illustrated sn Figures 10-12.

if can be appreciated that various changes may be made without departing from the scope of the present invention. For example, the size and number of lines and packages and number of packages within a batch may be adjusted for a variety of packing requirements

The above-described embodiments are merely exemplary illustrations o? implementations set forth tor a clear understanding ot the principles of the invention Variations, modifications: and combinations may be made to the above-described embodiments without departing from the scope of the claims. Ail such variations, modifications, and combinations are included herein by the scope of thss disclosure and the following claims.