The present invention relates to an apparatus and a method for automatic organizing of items, in particular foodstuff items, on a packaging element, such as a container or a tray.

In the food industry, food items, such as meat or meat products, manual labour is often used for packaging. The food items have been processed, where the items have been de-boned, trimmed and/or cut into portions. After this processing, the packages of items must be formed and packaged in a tray or similar packaging container.

The extensive manual handling of food items during the processing and the packaging involves a risk of microbial contamination. Besides this, the costs of preparing the food packages are considerable due to the labour costs, just as the packaging capacity is limited.

In order to reduce these drawbacks various packaging machines for specific types of products have been developed. Examples of such systems are known from WO-A- 95/25431 and US-A-6,536,599.

In relation to packaging of sliced food products, an apparatus for inserting sliced food into a packing machine is known from US-A-5,078,259. From US 2003/0167738, a device for slicing and forming imbricated or stacked packages of sliced food products and transferring this package to a support product.

However, these packaging machines are limited to handling of sliced products, i.e. small and regular food products.

From US-A-6,349,526, a food packaging system is known where the items are detected and categorised and rejected if they are not usable for the packaging. This allows for automated packaging of items with irregular shape and size. In this system, a package of items is formed on a tray, where the items may be placed in alignment or a particularly desired location or orientation in the package. This analysis and selection of items to the packaging means that the rejection rate may be high and is likely to increase the more irregular the items are in shape and size.

The food processing plant, the packaging process, whether it is done manually or on automated equipment, has a limited capacity and therefore, there is a desire to increase the capacity of the automated packaging system and the preparatory item organizing system.

Moreover, in the known packing machines, the items may be placed somewhat irregularly in the supporting tray. This is in particular the case if the items are irregular in shape and size and/or if the items or a group of items is to be transferred into a packaging element since this typically includes that the transfer may include a pick and place action where the items are dropped. Thus, in order to produce package with orderly and neatly arranged food items, in particular if the items are of irregular shape and size, it may be that the only way to achieve a satisfactory result is to perform a manual packaging of such food products.

The items are grouped in portions and transferred to manual packaging. This group organizing may be performed on a batching equipment building up a number of groups of products at the same time. Several systems are known for performing this function automatically and without producing groups of products within predefined tolerances, such as total weight, number of items, etc. Examples of such so-called batching systems are known from WO 96/08322, GB-A- 2 116 732 and PCT/DK2005/000195 (not yet published).

However, although the items may be grouped together automatically, the groups must be rearranged for packaging. On this basis, it is the object of the invention to provide an apparatus and a method for automated organising of food items having a high capacity suitable for achieving an automated packaging of the items. This object is achieved by an apparatus for automatic organizing of items, in particular food items, on a packaging element, said apparatus comprising: a separation conveyor means including a separation conveyor having an inlet for receiving a stream of substantially aligned items; and an outlet shiftable in a direction essentially transverse to the conveying direction of the items; means for shifting the conveyor outlet making said separation conveyor capable of distributing the items individually to a multiple of parallel packing lines for filling the items into packaging elements.

By the present invention, batching out items in packages and item packing can be performed simultaneously in an apparatus according to the invention. This results in savings in production costs. This means that packing of several packages on packaging elements, such as trays, may be carried out in parallel, just as different packing jobs may be performed simultaneously on different packing lines. This reduces the amount of item rejected and reduces overweight in the packages in the trays. Furthermore, the quality of the packages may be improved, as the items may be well prearranged for being filled on a packaging element, i.e. the items are aligned or otherwise neatly arranged for being transferred in this orderly arrangement into a packaging element, such as onto a tray.

In a method and an automatic packing machine according to the invention, items are received in a row on a separation conveyor, distributing the items on a multiple of parallel packing lines.

At each packing line, the items are received individually on a receiving conveyor where a group of items to be laid into a tray package is collected. This batch of items, i.e. the individual group of items, is forwarded to a tray, which is provided on a tray conveyor. The tray conveyor is provided with empty trays underneath the receiving conveyor and a buffer conveyor. The tray conveyor is arranged so that the trays are forwarded in an upwardly inclined path after they are provided on the tray conveyor in such a way that the items meet the tray at the end of the buffer conveyor and the batch of items is delivered in the tray. From the tray conveyor the trays with item batches therein are forwarded to further processing, such as wrapping and storage. Preferably, a transversely oriented tray-providing conveyor is provided for supplying empty trays for the tray conveyors of each of the pacldng lines.

In the packing lines, the receiving conveyors are moved individually and controlled in accordance with the requirements of the actual packaging job. The movements include forward, stop, reverse and conveying velocity of these receiving conveyors. The receiving conveyors are controlled so the portions can be placed according to set-up criteria, e.g. defined in the packaging job order, which is communicated to the control system of the packing machine. Hereby, it is possible to form a package of items in a well-orderly arrangement, e.g. a tile arrangement, an imbricked arrangement, on the receiver conveyor in an automated packing machine.

In order to achieve a precise delivery of the items on the receiving conveyors of the packing lines, it is important to know the positions of the items on the separation conveyor. This could be achieved by deflecting the stream of items into a predefined row before the entry to the separation conveyor. However, by the invention it is realised it is advantageous to provide sensor means for recording the positions of the items on the separation conveyor. An image detection device, e.g. a CCD camera or other suitable item position detection devices may preferably be arranged in the vicinity of the inlet of the separation conveyor. The transverse position of each item is then recorded and the separation conveyor outlet is positioned in accordance with the recorded item position and the predetermined item package configuration to be formed.

In a first embodiment, the separation conveyor outlet is shiftable in a horizontal direction and wherein the receiving sections of the packaging lines are provided adjacent each other. Besides being capable of shifting the separation conveyor outlet between the packing lines, the shifting means are also capable of delivering the individual items in a predetermined transverse precise position on the receiving conveyor of each of the packing lines. According to this embodiment, the shifting means controls the position of the separation conveyor outlet in two steps, a "course positioning" action, where the outlet of the separation conveyor is positioned at a predetermined packing line, and a "fine positioning" action, where the outlet is precisely positioned so that the actual item to be delivered onto the receiving conveyor of the packing line is delivered in the predetermined position.

According to a second embodiment, it is realised that the separation conveyor outlet may be shiftable in a vertical direction and wherein the receiving sections of the packaging lines are provided above each other.

In a preferable embodiment, the stream of items is forwarded to the inlet of the separation conveyor from a grader, whereon the weight on the items is recorded. Moreover, a set of deflection wings may be arranged for removing rejected items not suitable for packing by taking the identified individual items to be rejected out of the stream.

These and other preferred embodiments of the invention are defined in the dependent claims 2 to 18 and 20 to 32.

The invention is described in detail with reference to the accompanying drawings, in which:

Fig. 1 shows a side view of an apparatus for automated organizing and packaging of items according to a first embodiment of the invention; Fig. 2 shows a top view of same; Fig. 3 shows an end view of the apparatus; and Figs. 4 to 6 show different packaging configurations of items packed on a tray by performing a method according to some embodiments of the invention; Fig. 7 shows a side view of a second embodiment of an apparatus according to the invention; Fig. 8 shows a top view of the apparatus in fig. 7; Fig. 9 shows a schematic side view of a third embodiment of the invention; Fig. 10 shows a schematic side view of a fourth embodiment of the invention; Fig. 11 shows a schematic top view of the apparatus of fig. 10; Fig. 12 shows a schematic detailed side view of a sixth embodiment of the invention; Fig. 13 shows a schematic detailed side view of a seventh embodiment according to the invention; Fig. 14 shows another detail in an embodiment of the invention; and Fig. 15 shows a schematic illustration of the invention.

As shown in the figures 1 to 3, the items are forwarded onto the separation conveyor means 1 over a weighing unit 11 where the items are weight individually. The items are then forwarded to a first conveyor 13 where the items pass one or more deflector wings 17, where items not suitable for the actual packing job are taken out of the items stream. The deflecting means 17 may be used for removing trimmings which are not usable item portions, such as end portions, as well as other portions not suitable for the batching job, i.e. the packing of items in predetermined package sizes, from the item stream.

The deflector wings 17 or similar deflection means may also be used for aligning the items into a single stream in a predetermined position on the separation conveyor 12.

The items could be meat portions, which are cut into specific portions on a portion cutting apparatus, and the registered weight of the items may be communicated back to the automatic portion cutting apparatus, so that the average portion size may be maintained. Hereby, a further reduction of items that have to be rejected or recycled at the packaging stage may be achieved. Similarly, other parameters could be measured and the batching and packaging job could be organized in accordance with these measurements, such as the surface texture or the structure of the food item, its size, its weight, etc.

In a preferred embodiment, sensor means 16 (see figs. 9, 10 and 12) may be provided, such as a camera or a photo sensor beam across the first conveyor 13 downstream the separation conveyor 12 or at the inlet of the separation conveyor 12. From these sensor means 16, the control system receives position data of where the individual items are sitting on the separation conveyor 12 and how they are orientated.

The item separation conveyor means 1 include a separation conveyor 12, which has a stationary inlet 12a and an outlet 12b, which is shiftable between a number of packing lines. In the embodiment shown in figures 1 and 2, there are three lines parallelly arranged next each other. The shiftable separation conveyor 12 can place the individual items precisely on the packing lines by a separate fine adjustment side shift of the inlet and/or the outlet of the separation conveyor 12 relative to the receiving conveyor 2 and/or relative to the first conveyor 13.

With reference to figures 1 and 2, the separator conveyor 12 may include a flexible conveyor band, which is stationary positioned at the inlet 12a and which at the outlet end 12b is moveable in a transverse direction relative to the item direction movement by shifting means 14.

By the shiftable separation conveyor means 1 according to the invention, the conveyor means is shiftable between three positions and may preferably also be fine adjusted in outlet position within the main positions, i.e. the delivery positions for the parallel packing lines.

At the end of each packing lines, i.e. adjacent outlet 12b of the separator conveyor 12, a receiving conveyor 2 is provided, which is moveable in both directions (forward and reverse). In cooperation with the separation conveyor 12, the items are being delivered in a predetermined configuration, e.g. a tile arrangement, on the receiving conveyor 2, e.g. for building a package as shown in figs. 4, 5 and 6.

The position of the items on the separation conveyor belt 12 is known, since the items have been scanned by the sensor means and/or aligned by the deflection means 17. Controlling the deflection means 17 and/or the fine adjustment of the outlet 12b of the separation conveyor 12 by the shifting means 14 can deliver the items delivered in a precise predetermined pattern, so that the package of items have an attractive appearance in the finished package (see e.g. figs. 4, 5 and 6). Hitherto, this has only been achievable by manual packing of items in the packaging elements, such as trays in order to ensure a nice presentation of the food items.

When a batch of items, a batch, is finished on the receiving conveyor 2, this batch 20 may be forwarded to a buffer conveyor 3, which serves the function of being a waiting station where the items for the package remain in the previously arranged pattern when they are transferred to a packaging element 40 on a packaging conveyor 6. When the package of items 20 has been laid into the packaging element 40, the filled packaging element 40 is forwarded for further processing, such as closing, foil wrapping, etc. A conveyor system 42 may be provided for collecting packages from the packing lines and transferring them to further processing (see figures 7 and 8).

The tray-providing packaging conveyors 6 of each packing line transport the empty trays 40 from a tray-providing supply conveyor 4, which is being supplied with trays from a central storage 41 (see fig. 3). The tray-providing conveyor 4 is moved in a direction substantially perpendicular to the other conveyors. The empty trays 40 are transferred from the supply conveyor 4 to the tray conveyors 6 by suitable means, such as pushers or the like. In this example, the packaging elements are trays. However, it is realised that the packaging elements may also be container or other kinds of packaging elements. It is also realised that different packaging elements may be supplied for forming different item packages on the parallel packing lines. The packing lines may preferably be arranged as a packing unit 5 placed immediately after the separation conveyor means 1. The packing lines may be accommodated in a housing 51, as shown in fig. 3.

The items 20 may be delivered in a predetermined pattern. As shown in fig. 4, the package is formed, where one item 201 is delivered to the left and the next item 202 to the right and so forth. This arrangement of the batch of items 20 is then transferred onto a package tray 40. As shown in fig. 5, it is also possible by a method and an apparatus according to the invention, to deliver all the items in the package 20 in an alignment, e.g. a right-hand side alignment 21, as shown in fig. 5. The package tray 40 may then be provided with a cover covering the left-hand side of the items. In fig. 6 another example of package arrangement is shown. In this embodiment, the items 20a-20e are arranged in a tile arrangement. This may be advantageous e.g. for building a compact package, just as it is possible to arrange the items so that they are well presented in the finished package, e.g. uniform looking. By packing on parallel packing lines simultaneously, items may be directed to different packages depending on their individual characteristics. It is also realised by the invention, that the "direction" of the tile arrangement may be altered by reversing the receiving conveyor during the delivery of items. Moreover, it is also realised that items may be arranged in many other arrangements by controlling the delivery of the items from the separator conveyor and the receiving conveyor of the packing line.

In figures 7 and 8, an embodiment is shown, wherein individually spaced items arrive from the equipment provided upstream and transferred onto a vertically moveable separation conveyor 12, which distributes the items between a series of transfer conveyors 15 having their conveyor inlets 15a provided above each other. The sideways position of the items on the conveyor 12 has been registered by the sensor array 16 (see figs. 9 to 12). In order to provide the item in a correct position on the receiving conveyor 2 downstream the transfer conveyor 15, the inlets 15a are moveable sideways to insure the items are placed exactly in the desired positions on the conveyors 15. The transfer conveyors 15 are arranged such that the inlets 15a are stacked above each other in a vertical configuration and the outlets 15b are arranged beside each other, i.e. a horizontal configuration.

The items are transferred from the outlets 15b of the transfer conveyors 15 to corresponding receiving conveyors 2 of parallel packing lines. These receiving conveyors 2 are moved intermittently forwards and backwards and function as stacking stations, so that the items that are distributed by the separation conveyor 12 to the transfer conveyors 15 are automatically stored or stacked in a predetermined arrangement. The conveyor belt moves backwards and forwards to ensure the items are placed correctly on the receiver conveyor and since the receiving conveyor 2 is capable of these movements it may also be ensured that the items do not fold. The particular stacking formation or arrangement is determined by packaging programme cooperating with the batching system determining the distribution of the items between the transfer conveyors 15 and consequently the packing lines. Downstream the receiving conveyors 2, a buffer conveyor 3 may be provided. The organized portion of items built up on the receiving conveyor 2 is then transferred onto the buffer conveyor 3 when the last item in the organized portion is placed in the portion. The buffer conveyor 3 may be advantageous in order to gain capacity, because the item stacking receiving conveyor 2 cannot commence the build-up of a new portion while the finished portion is being discharged.

As explained with reference to figs. 1 and 2, empty packaging elements 40 are dispensed onto the inlet of a supply conveyor from a tray dispenser. The packaging element conveyor 6 moves the trays 40 individually to one of the filling stations, i.e. where the buffer conveyor 3 delivers the organised portion of items into the tray. The conveyor belt of this conveyor 6 is provided with indexed flights so the position of the empty packaging element arriving at the filling station is known.

After the packaging elements 40 have been filled with the organized portions, transfer means 42 may be provided for collecting the finished packages for transferring them onto further processing equipment. In figure 9, an embodiment of the invention is shown schematically, where a grader unit 11 is provided and items are weighted and then transferred to a first conveyor path 13. The sideways position of the item on the conveyor belt 13 is detected by a scanning unit 16. The items are transferred to a swingable separation conveyor 12 which distributes the items between a series of vertically disposed transfer conveyors from which the items are delivered to the receiving conveyors 2.

In figure 10, an alternative embodiment is shown, where the first conveyor path is diverted into two sections, a first transfer section 13a and a discharge sorting path 13b. In the discharge path 13b, one or more deflector wings 17 may be provided together with associated bins 18. Hereby, items that are not suitable of the batching and packing are taken out of the stream of items. A number of discharge bins could be arranged, e.g. one for too small items, one for too big items and one for items having a unpleasant surface texture or a very irregular shape.

As shown in fig. 11, the first transfer path 13a could be provided as a set of parallel conveyor belts 13al5 13a2 so that items with a wrong orientation may be aligned so that the item is positioned correct for the organizing job. The position is scanned upstream this alignment conveyor path. It is realised that other turning actions may be performed in this transfer path 13 a. An additional sensor or camera arrangement may be provided to surveying this orientation action.

In another embodiment, the swingable separation conveyor 12 may be provided with a cooperating upper belt 12d for holding the items 20 in the detected position on the conveyor belt 12. This may be important as the separation conveyor 12 swings with a relative high angular velocity which may cause a displacement of the item 20 on the conveyor, in particular during a downward swing. By providing a cooperating upper belt 12d, this problem could be avoided. In order to reduce this problem of displacement of the items on the swinging separation conveyor 12, cooperating swinging conveyors 12e and 12f could be provided, as shown in fig. 13. Hereby, the length of the "swing arm" is reduced and thereby the risk of throwing the items off or displacing the items on the separation conveyors is reduced.

In fig. 14, a detail view of the transfer of items between the transfer conveyor 15 and the receiving conveyor 2 is shown. An item transfer member 19 is provided to ensure that the item 20 being transferred does not roll, fold or otherwise is displaced relative to the conveyor belts. The transfer conveyor 15 ends its path in a conveyor outlet conveyor belt 15b which is slightly declined. The items 20 are dropped from the outlet 15b to the receiving conveyor 2 underneath. This dropped is small but in order to ensure that the items are not displaced during the delivery onto the receiving conveyor 2, the item transfer member 19 is provided. This member 19 includes two rotating arms which can be used to retain the items 20 and thereby control the transfer by controlling the rotation of the item transfer member 19.

By providing an automated batching and packing operation which may be controlled by common computer means, traceability of each of the items in a final package can be performed. Thus, the origin of each food item can be documented and/or the item origin can subsequently be tracked.

As mentioned above, a vision inspection system may be provided, including camera means for providing image data of the items and an automatic visual inspection system for detecting if an item is unsuitable for packing and should be removed or rearranged on the conveyor. Besides using image data for determining which packing line the individual items shall be destined for, the visual inspection of the items may also be used for quality control so that the surface texture and/or the inner texture of the items may be examined. The camera means could include x-ray or ultrasound sensor equipment. Moreover, the camera means preferably include sensors inspecting the items from more directions, such from both the top and from below. In this embodiment, the camera means would preferably be arranged so that the visual inspection takes place in a small cap between two conveyors as the items are transferred from one conveyor to the next. It is realised that visual inspection measurements may substitute the weight measurements.

In figure 15, the basic principles of the invention are schematically shown. From a supplying first conveyor 13, items 20 are forwarded onto a separation conveyor 12 which distributes the items according to control means (not shown) to a multiple of receiving conveyors 2. Associated with each of the receiving conveyors 2, packing conveyors 6 are provided. Empty packaging elements 40 are supplied to the each packaging conveyor 6 and filled with the group of items formed on the associated receiving conveyor 2.

To ensure the correct formation of the items in the group formed on the receiving conveyor 2, the transverse position of the items 20 on the conveyor system is recorded by the sensor means 16. Subsequently, the separation conveyor and/or the supplying first conveyor 13 may be shifted sideways to change the transverse position of an individual item. This sideway shift for item position adjustment is controlled by the system control means in accordance with the running batching job so that each of the items are positioned for precise delivery on the receiving conveyor 2 in accordance with the final position in the group of items formed on the receiving conveyor 2. This side shifting may be provided by shifting the inlet and/or outlet of a conveyor or the entire conveyor depending on the configuration of the batching system.

The invention is described above with reference to some preferred embodiments. The food items could be pork chops, chicken fillets, fish products or the like. However, by the invention it is realised that other embodiments of the invention may be performed without departing from the scope of the invention as defined in the accompanying claims.