The present invention concerns an apparatus for the filling and closing of containers, and a method for filling and closing of containers in a continuous process. In particular, the present invention provides an apparatus and method for filling containers which allows containers of various shapes and sizes to be filled without significant alteration of the apparatus being required.

The automatic filling of containers is well known in the art. In European Patent Application EP-A-597 334, a packaging machine which readily permits alteration of the layout of component devices is described. If a change of size or shape of containers to be filled is desired, the packaging machine provides a structure for alteration of the layout of component devices. The machine does not allow filling and sealing of the containers while these are moving.

In German Patent document DE-A-38 09 347 an apparatus for the filling of containers described, with which a process is obtained for filling containers in a continuous process and for which no discontinuity of velocity is required. No means for closing the containers is provided.

The present invention provides an apparatus and method for the providing of containers, filling thereof and closing thereof in a continuous process for which no change in transport velocity of the containers is required. In a very preferred embodiment, the containers comprise a rim near by or at the opening of the container.

Furthermore, the present invention provides an apparatus and method for such a continuous process, whereby shape and size

of the containers can be varied without significant alteration of the apparatus is required.

Accordingly, the present invention provides an apparatus for the filling and closing of containers in a process for which no discontinuity of transport velocity of the containers is required, said apparatus comprising a transport means and a container insert unit, a filling unit, and a closing unit, the units being placed at a distance above the transport means, and the transport means extending in one line. To allow an even further practical manner for filling and closing, the present invention provides an apparatus which comprises a container insert unit capable of the placing of at least two containers next to eachother, and the transport means, filling unit and closing unit being capable of transporting, filling and closing at least two parallel placed containers. Accordingly, the invention also encompasses a method for the providing, filling and closing of at least two parallel placed containers, and suitably of at least three or four containers placed next to eachother.

The transport means can be a conventional transport means such as a conveyor or cell plates. The conveyor movement can be arranged by a shaft, or by chains, or any other suitable means therefore. In a preferred embodiment, the transport means comprises a set of bars which preferably have a smooth surface, such as iron or steel bars, which extend parallel to the direction of transport, and pushing means which are located at regular distance of eachother, perpendicular along the parallel bars. The bars extending parallel to the direction of transport are support bars, onto which the containers to be filled are placed. The pushing means can suitably be rods placed at a desired distance which allows pushing forward without turning the containers over. A suitable distance is, for example, 5-50 mm above the parallel bars. The pushing rods preferably are at the height just below the rim of the containers to be pushed forward. If a relatively large container is to be transported, it is

preferred to have at least two pushing rods for pushing each container, whereby one can be positioned just above the parallel bars, and one just below the rim of the container to be transported. It is furthermore preferred that the pushing means extend across the entire width of the transport lane provided by the parallel bars. This is in particular suitable where an apparatus is provided for the simultaneous filling and closing of containers which are placed next to eachother. The pushing means, and in particular the rods, can be moved by any suitable means, such as chains, ropes, and the like driven by a motor around a shaft.

It is preferred that the surface onto which the bottom of the containers is placed, can be adjusted in height to ensure that the surface of the containers is at a particular level, irrespective of the size of the containers to be filled. Accordingly, a significant flexibility of the filling line for containers of different size is provided. In that embodiment, the containers placed onto the parallel bars are transported by them being slided on their bottom over the bars, e.g. a set of rails, by the pushing means, e.g. by the rods. By the use of side guides, which preferably are adjustable in width from eachother, the location perpendicular to the transport direction can be ensured.

At a specific distance above the transport means, a container insert unit, a filling unit and closing unit are positioned, along the length of the transport means. By the term above, also a position close by and at a height above the transport means, but not right above is included. For example, the insert unit for releasing the containers onto the transport means can be positioned in front of the transport means. In another example, the containers are released on a surface not being part of the transport means and then being pushed by a pusher onto the transport means. In a preferred embodiment however, the insert unit is a unit for inserting containers which are obtained from a storage zone, such as a magazine,

for example a magazine filled with plastic tubs stacked into another. The magazine size and shape can be adjusted or replaced to enable variation of the size and shape of the containers to be filled. The magazine is preferably a magazine which holds at least two piles of containers, so that easy release of at least two containers next to eachother onto the transport means can be obtained.

The containers may be provided by any type of supply means, including even by hand. Such a supply means will normally comprise a storage zone where a pile of containers is stored, means for the individual release from the storage zone, such as knives and fingers, a means through which the individual containers can be transported, and, optionally, a holding member, which prevents uncontrolled movement of the containers. For the method of the present invention, however, any other type and arrangement of the supply means can be used as well. Thus, in one embodiment of the invention, the apparatus of the invention has a container insert unit comprising a storage zone, a dispenser unit capable of releasing at least one container per cycle per lane from said storage zone, optionally a buffer zone, and another dispenser for release of the container onto the transport means . Optionally a buffer zone is present between both dispenser units into which the containers are stored for a short period. By this buffer zone, the reliability of the container supply unit is improved. If a buffer zone is present, such a zone can be obtained by the use of another holding member which blocks transport of the containers for a period considered suitable. Such a holding member will provide additional benefits in that it allows a precise positioning of the containers onto the transport means. Optionally, the buffer zone can also comprise a decontamination zone, so that containers can be treated for decontamination just prior to them being filled. If the containers are transported in vertical direction, i.e. the opening side facing the moving

direction or the opposite thereof, a means for rotating the containers prior to their positioning onto the transport means will be required to ensure that the containers are inserted onto the transport means with the bottom side facing downwards. Such a rotating means can be provided by another or the same holding member, said holding member blocking the container at the end facing downwards, and releasing the end of the container facing upwards, so that partial rotation through gravity is obtained, or it can be a wheel, or a robot, or the like.

The filling of the line can be performed by any suitable filling unit, such as two parallel dosing units for the simultaneous filling of the containers positioned next to eachother on the transport means, and a mechanism capable of tracking the container positions. Such systems are commonly known in the art. The dosing unit should be capable of moving along the transport means at the same speed as the transport means and backwards, and enables filling of the containers while these can move at continuous velocity without change of direction being required.

For a large number of consumer goods it is desired that a thin sheet, i.e. a leaf, is applied onto the product or onto the container prior to closing the container to protect the product . The present invention encompasses a further embodiment in which the filling and closing apparatus comprises a thin sheet dispenser means . Such a thin sheet dispenser means is preferably a means which comprises a thin sheet supplier and a conveyor system having an endless, porous belt and an air flow providing means, wherein the belt can be moved by a shaft, and the air flow providing means is capable of providing a pressure difference between the two sides of the belt. Preferably, at least one of the thin sheet supplier and the conveyor means can be moved over a short distance back and forth. If, in a further preferred embodiment, the thin sheet supplier is positioned so that

the sheet to be supplied is located adjacent to the conveyor belt, a system is provided which allows easy picking up of sheets, and whereby the short distance movement desired can be a relatively simple straightforward movement. Construction of the means can be relatively simple as well, in particular if the sheet supplier is positioned adjacent and about parallel to the position of a sheet to be supplied. The thin sheet supplier can be a magazine capable of comprising a pile of sheets, and can also be, in another embodiment, a reel and cutting means. In the latter case, the reel comprising thin material can be partially unrolled, and the cutting means can cut the desired shape out of the thin material. The so cut cut shape can than be provided to the belt in accordance with the presently proposed method. Preferably, the thin sheet supplier means is a magazine capable of holding a pile of sheets, wherein at the bottom of the magazine a holding means, e.g. a set of fingers, can be present capable of holding and releasing one or more sheets present in the magazine.

The thin sheet dispenser means can be used for transporting and positioning leaves by picking them up one by one from a magazine or the like or from a reel from which sheets are being cut, and releasing the sheets one by one on a place different than said magazine. The new found system is very suitable for placing a thin sheet from a stacked pile onto a surface such as a container or a belt in a continuous and reliable manner. The system provides a large flexibility with respect to the size and the shape of the sheets, whereas the speed of handling is significantly higher than that of the presently known systems .

The conveyor system of the thin sheet dispenser means is preferably made so that is can move over a short distance forwards and backwards from a thin sheet supplier means comprising at least one sheet. The thin sheet supplier means can be, for example, a magazine comprising a pile of thin sheets, or a reel from which a sheet is cut prior to it

being sucked onto the belt. In the case a magazine is used, the sheets can be held by a holding member such as a set of fingers, in between or against which the conveyor is moved. The belt preferably does not move around its shaft (s) at the moment a sheet is being picked up from the magazine.

An example of a very useful air providing means is a vacuum chamber placed in between the shaft and axe or shafts around which the belt is moved. By the pressure difference provided between the two sides of the belt at least one straight part of the belt at the moment the belt is near by, for example, at less than 5 or 3 mm of the magazine filled with thin sheets, the sheet provided by the sheet supply means is released, e.g. from a pile of such thin sheets, by the pressure difference causing the sheet being sucked onto the porous belt. As the belt moves, eg by a shaft, the sheet is transported with it, and at the round end where the belt moves around an axis, and where the chamber is not present, the sheet is released. This mechanism provides a change of transport direction, which preferably is around 75-105°. By correct timing, the thin sheet is being slowly released or unrolled from the belt at the moment the containers arrive, and so, the sheet is deposited onto the container while the container moves at continuous velocity. The belt is made of a porous material and/or can be provided with holes to allow an air flow through the belt. In this application, both are indicated with the term porous. The porous belt is part of a conveyor system, and is moved by a shaft, and comprises preferably an air pressure difference providing means such as a vacuum chamber. Said air pressure difference providing means can provide a constant air pressure difference through the belt, and preferably extends around a part of one shaft and/or axe. Preferably, the size of the air providing means is such that it provides an air pressure difference over the entire width of the belt and at at least one sheet length.

As many types of containers, in particular those containing consumer products such as personal products, e.g. cremes, lotions, and the like, and food products such as spreads and mayonnaise, are preferably sealed with a leaf before closing these containers with a lid for hygienic reasons, the present invention provides in another embodiment an apparatus and method as claimed herein, which also encompasses a sealing unit. In this preferred embodiment, a sealing unit is present above the transport means, said sealing unit being capable of picking up a thin sheet, positioning it and placing it onto a container while this container can move at continuous velocity.

The leaves may be put onto the contents of the container, but can also be placed onto the upper surface of the container and sealed thereon. If sealing is desired, the sealing unit also may comprise a sealing head comprising a pressure exerting means being movable towards and from the transport means, the lower end of the pressure exerting means being flat and heatable. The sealing head is positioned above the transport means and follows after the conveyor of the foil dispnser unit belt. It provides a sealing process which is very versatile with regard to the different sizes of containers to be sealed. By having a pressure and activatable sealing material present at least on the spot of the rim, the sheet positioned at the opening of the container is sealed thereon. Said method and sealing head provides a method and means for both heating and pressuring in one step which fits different container sizes and types of closure means. For the sealing of containers of flexible or not very stiff material such as tubs, it is preferred that an elastic pressuring element is arranged between the transport means and the means for exerting pressure on the sealing means. For example, springs can be arranged between the pressure means and sealing head, or a flexible material layer can be arranged therebetween. In another embodiment, the elastic pressuring element can be provided by the shape of the rim of the container, the material of the rim being flexible. E.g. by

the rim extending slightly upwards, e.g. 2-8°, flexibility is obtained which may inhibit the undesired deformation of the container by the pressure being applied onto it.

The apparatus for filling and closing containers further comprises a closing unit, said closing unit comprising a supply means and a pusher bar closes the containers with the provided lids, while the containers can move at a continuous velocity. Preferably, also a lid release unit is present by which lids are released from a pile of lids and provided to the lid supply means.

The closing unit is capable of placing lids on moving containers, and comprises a supply means for lids which preferably is positioned at an angle between 80 and 100° of the transport means, and a pusher bar being positioned above the transport means. In a further preferred embodiment, the apparatus also comprises a release member positioned close to the end of the supply means. In a further preferred embodiment, the pusher bar is bar that can hinge around a pivot point over a small distance.

If a lid release unit is present, this suitably comprises a storage zone where a pile of lids is stored, and a means for the individual release from the storage zone such as knives and fingers. In a suitable embodiment, the storage zone comprises a pile of lids of a shape fitting the containers to be closed, whereby the bottom lid is held by a set of fingers which can move forwards and backwards. By correct timing of the movement, each stroke forwards and backwards releases one lid. A double knife system is in particular a suitable lid release system which can provide the lids to the supply means comprising a transport means, and, optionally, a buffer zone and a holding member. In addition, also a decontamination means can be present to clean the lids just prior to them being adjusted onto the container. In another embodiment, the lid release unit comprises a vacuum head, as known per se in the art .

The lids can be transported in a relatively simple manner by use of gravity forces, whereby the lids slide along rails. The lids can be buffered, for example on a flat plate with side guides, to increase the reliability of the system. A lid can be separated from the buffer by the use of an escapement, such as a release member, or any other suitable means therefore.

At the end of the supply means, the holding means, which can for example be a release member or a release lever, is meant to allow the release of the lid from the supply means at the correct timing. In a preferred embodiment, the release member is found at the side of the lid which faces the container moving direction. The release member is capable of releasing the lid, for example by a forwards and backwards moving mechanism.

The release member can also serve as a pivot point for the lid being held and placed onto the moving container. Furthermore, it allows a precise positioning of the lid, so that the rim of the lid can touch the rim of the container and the lid can be taken on by the container while the container moves forward. The release is suitably found at the side of the lid which faces the container moving direction, and is capable of releasing the lid by, eg., a forwards and backwards moving mechanism.

Very little space is used if the supply means is positioned so that the lids are transported at an angle between 80 and 100° of the transport means. In one specific embodiment thereof found to be of high practical use, the lid is provided so that the side meant to be the upper side faces the direction the containers moves to.

The closing unit further comprises a pusher bar, and, in the case more than one container is to be closed simultaneously, it is preferred that a pusher bar is present for each of the

lanes of the container filling line. Optionally, a means for applying further forces for closing the container is present. For example, such a means may comprise one or more pusher means, for example bars or rods, which apply forces onto the lid while the container with the lid on it moves underneath the pusher means.

The container to be closed has a rim at the opening of it . In a specific embodiment of the present invention, the lid provided is, by the use of the supply means described above, positioned so that the rim (at the side of the lid pointing downwards) can touch the rim of the container (at the side of the container pointing forwards) , the lid being positioned by a pusher bar to allow the rims to grip, the lid being released from the supply means, the pusher bar providing forces onto the lid to maintain the gripping of the rims of said lid and said container, the lid so being positioned onto the opening of the container.

The pusher bar which positions the lid so that the rims of lid and container touch is preferably a stick of irregular shape, but can also have a square, triangle, or any other kind of shape. Depending on the type of lid transport and providing angle, the pusher bar is either fixed, or it is mounted to a device allowing some movement of the position of the pusher bar. In a further preferred embodiment, the axe of the pusher bar is mounted on a shaft which hinges around a pivot point. In its preferred embodiment, the pusher bar is mounted onto a device allowing horizontal and vertical movement thereof. This is in particular suitable where the containers are moved in horizontal direction, and the lids are provided by gravity at a providing angle of between 80 and 100° . In a very preferred embodiment, the pusher bar hinges around a pivot point, and moves slightly while the container and lid are transported underneath it . While the container is moved underneath it, horizontal and vertical forces are applied

onto the lid. The forces are applied in such a manner that the gripping of the rims of the lid and container is maintained. The forces can be obtained by gravity, e.g. by using a pusher bar of sufficient weight, or by active driving {e.g. by a motor) . Slight movement of the pusher bar is highly preferred to increase reliability of placing the lids and preventing damaging of the lids, and, where desired, for closing the container.

The pusher bar at its position where it does not touch the lid is positioned above the transport means at a suitable distance, and at least at a distance above the surface of the transport means which is similar to the height of the container to be closed. Care should be taken that the pusher bar does not hold the container when it is transported, so, the pusher bar is highly suitably located at a distance larger than the height of the container when placed on the transport means. The position can be at a greater distance from the transport means. It is preferred, however, that the distance is chosen such that sufficient forces can be applied onto the lid while lid and container are transported underneath the pusher bar, and further preferred the distance is chosen such that the pusher bar is in contact with the lid as long as possible while the lid moves underneath the pusher bar.

As all embodiments described hereinabove allow that the containers to be filled and closed can move at containuous velocity and direction, some means even requiring that, the present invention provides a highly suitable method for filling and closing of containers with a lid and/or leaf without for which no change in velocity and direction of movement are needed. In a highly preferred embodiment, the filling line is based on a multi lane concept, where the containers are transported with a continuous velocity. A relatively simple and therefore easy to produce and maintain line is based on a frame

structure with modules connected to it . The frame can be based on two or more parallel plates, e.g. steel plates, which extend from the floor up to a level slightly above the rim of the containers when these are placed on the transport means. In between such plates, support plates can be mounted as well as distance shafts to ensure stability. Above the support plates, a horizontal plate can be mounted, so that a clean box is obtained where the container transport is obtained.

The containers filled and closed by the apparatus and method of the invention can be glass containers, tubs, cups, and the like. It is in particular very suitable for the filling and closing of tubs, such as used for containing margarine or other kind of spreads, fresh cheese or molten cheese, yogurt, mousses, and other desserts.