US20090277139A1 - Automated System Of Protective Packaging - Google Patents

Automated System Of Protective Packaging Download PDF

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Publication number
US20090277139A1
US20090277139A1 US12/436,405 US43640509A US2009277139A1 US 20090277139 A1 US20090277139 A1 US 20090277139A1 US 43640509 A US43640509 A US 43640509A US 2009277139 A1 US2009277139 A1 US 2009277139A1
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US
United States
Prior art keywords
order
box
volume
cushioning product
desired quantity
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US12/436,405
Inventor
Thomas George Eckel
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STOROPACK Inc
Original Assignee
STOROPACK Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by STOROPACK Inc filed Critical STOROPACK Inc
Priority to US12/436,405 priority Critical patent/US20090277139A1/en
Priority to PCT/US2009/043568 priority patent/WO2009140247A1/en
Assigned to STOROPACK, INC. reassignment STOROPACK, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ECKEL, THOMAS GEORGE, MR.
Publication of US20090277139A1 publication Critical patent/US20090277139A1/en
Abandoned legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B61/00—Auxiliary devices, not otherwise provided for, for operating on sheets, blanks, webs, binding material, containers or packages
    • B65B61/20—Auxiliary devices, not otherwise provided for, for operating on sheets, blanks, webs, binding material, containers or packages for adding cards, coupons or other inserts to package contents
    • B65B61/22—Auxiliary devices, not otherwise provided for, for operating on sheets, blanks, webs, binding material, containers or packages for adding cards, coupons or other inserts to package contents for placing protecting sheets, plugs, or wads over contents, e.g. cotton-wool in bottles of pills
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B55/00—Preserving, protecting or purifying packages or package contents in association with packaging
    • B65B55/20—Embedding contents in shock-absorbing media, e.g. plastic foam, granular material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B57/00—Automatic control, checking, warning, or safety devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B57/00—Automatic control, checking, warning, or safety devices
    • B65B57/10—Automatic control, checking, warning, or safety devices responsive to absence, presence, abnormal feed, or misplacement of articles or materials to be packaged
    • B65B57/12—Automatic control, checking, warning, or safety devices responsive to absence, presence, abnormal feed, or misplacement of articles or materials to be packaged and operating to control, or stop, the feed of wrapping materials, containers, or packages
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B59/00—Arrangements to enable machines to handle articles of different sizes, to produce packages of different sizes, to vary the contents of packages, to handle different types of packaging material, or to give access for cleaning or maintenance purposes
    • B65B59/001—Arrangements to enable adjustments related to the product to be packaged
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B59/00—Arrangements to enable machines to handle articles of different sizes, to produce packages of different sizes, to vary the contents of packages, to handle different types of packaging material, or to give access for cleaning or maintenance purposes
    • B65B59/003—Arrangements to enable adjustments related to the packaging material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31D—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
    • B31D2205/00—Multiple-step processes for making three-dimensional articles
    • B31D2205/0005—Multiple-step processes for making three-dimensional articles for making dunnage or cushion pads
    • B31D2205/0011—Multiple-step processes for making three-dimensional articles for making dunnage or cushion pads including particular additional operations
    • B31D2205/007—Delivering
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B2210/00—Specific aspects of the packaging machine
    • B65B2210/04—Customised on demand packaging by determining a specific characteristic, e.g. shape or height, of articles or material to be packaged and selecting, creating or adapting a packaging accordingly, e.g. making a carton starting from web material

Definitions

  • This relates generally to protective packaging, and more particularly to an automated system of protective packaging.
  • WMS warehouse management software
  • the WMS system determines an appropriate size of box in which to ship the order.
  • This appropriate box size will be of a larger volume than the volume of the order to permit protective packaging material to be added to the box to cushion and protect the order during shipment.
  • the WMS system sends the box size information to a picking/packing operator.
  • the operator picks the appropriate size box from the inventory of boxes on hand and places the order in the box.
  • the operator then makes a visual inspection of the order within the box, noting the “void” to be filled, i.e. the volume of the box not taken up by the order.
  • the operator operates a cushioning material producing and dispensing machine (or dispensing-only machine in the case of pre-produced cushioning material) at the packaging station to manually produce and dispense (or just dispense) the required or desired volume of cushioning material with which to pack the order in the box to provide adequate protection of the order during shipment.
  • the cushioning material used could be air pillows, for example AIRplus® air pillows, paper pads, for example PAPERplus® paper pads, loosefill, for example PELASPAN® loosefill, or foam-in-bag cushions, all of which are commercially available from the assignee, or any other suitable cushioning material or dunnage.
  • a method of automating a packaging system comprises receiving from a customer an order to be shipped to the customer, determining a volume of the order, selecting a shipping box having a volume sufficient to contain the order and a desired quantity of cushioning product, determining a difference in the volumes of the box and the order, generating a signal based on the difference in the volumes, and causing, with the signal, a cushioning product producing and/or dispensing machine to produce and/or dispense the desired quantity of cushioning product.
  • the method can be embodied in software adapted to run on a computer.
  • the steps of receiving an order from a customer, determining a volume of the order, and selecting a box having a volume that can contain the order and a desired quantity of cushioning product can be embodied in pre-existing software.
  • the cushioning product can be air pillows, paper pads, loosefill, or foam-in-bag cushions.
  • the method can further comprise the steps of identifying the box and confirming the identity of the box prior to producing and/or dispensing the desired quantity of cushioning material.
  • FIG. 1 is a diagrammatic view of the automated system of protective packaging to be described below.
  • FIG. 2 is a block diagram of the system of FIG. 1 .
  • a customer 2 places an order with a business that ships the order from a warehouse 4 .
  • the warehouse 4 has a computer 6 .
  • the computer 6 selects an appropriately sized box 8 from an inventory 10 of differently sized boxes.
  • a packer 12 packs the order in the appropriately sized box 8 with cushioning material 14 produced and/or dispensed by and/or from a cushioning material producing and/or dispensing machine 16 .
  • the cushioning material 14 could be, for example, air pillows such as AIRplus® air pillows, paper pads such as PAPERplus® paper pads, loosefill such as PELASPAN® loosefill, or foam-in-bag cushions, produced and/or dispensed by and/or from the machines of, or otherwise the subject of, for example, U.S. Pat. Nos.
  • FIG. 2 illustrates the steps performed by the system.
  • the warehouse 4 receives an order from a customer 2 as indicated at 20 .
  • the computer 6 determines the volume of the order as indicated at 22 .
  • the computer 6 selects an appropriately sized box 8 from an inventory 10 of differently sized boxes that are kept on hand or otherwise in inventory at the warehouse 4 as indicated at 24 .
  • the appropriately sized box 8 will be of a volume sufficient to contain the order and a quantity of cushioning product sufficient to prevent damage to the order during shipment.
  • the computer 6 may communicate the appropriately sized box 8 to the packer 12 so that the packer 12 can manually retrieve the box from inventory, or alternatively automation may be employed whereby the appropriately sized box 8 is automatically delivered to the packer 12 .
  • the box 8 is identified, as indicated at 26 .
  • the box 8 can be labeled or otherwise designated with a unique identifier such as a simple label, hand mark, etc. applied to the box that can be visually identified by a packer, or a machine readable label such as a bar code or the like that can be read by the machine 16 .
  • a unique identifier such as a simple label, hand mark, etc. applied to the box that can be visually identified by a packer, or a machine readable label such as a bar code or the like that can be read by the machine 16 .
  • the computer 6 determines the difference in the volumes of the box and the order, as indicated at 28 .
  • the computer 6 generates a signal based on the difference in the volumes of the box and the order, as indicated at 30 .
  • This signal is then sent to the machine 16 , as indicated at 32 .
  • the box identity is confirmed, as indicated at 34 . This can be accomplished manually by the packer simply making a visual inspection of the label, hand mark, etc. previously applied to the box to confirm its identity.
  • the machine 16 can be outfitted with a bar code reader to read the bar code label previously applied to the box to confirm its identity
  • the machine 16 produces and/or dispenses automatically the required/desired quantity of cushioning material into the box with the order contained therein. This is shown at 36 .
  • Blocks 20 - 26 are embodied in currently existing and commercially available warehouse management software.
  • the difference value at block 28 can be readily determined and then fed into an additional software algorithm represented by blocks 30 - 36 running on the computer 6 and/or machine 16 .
  • the signal based on the difference in volumes of the box and order could be embodied in the machine readable bar code label placed on the box.
  • the machine 16 both a) confirms the identity of the box, and b) receives the signal based on the difference in the volumes, from the bar code label. All such changes, modifications and embodiments are embraced by the claims. Accordingly, the scope of the right to exclude shall be limited only by the following claims and their equivalents.

Abstract

A method of automating a packaging system comprises receiving from a customer an order to be shipped to the customer, determining a volume of the order, selecting a box having a volume sufficient to contain the order and a desired quantity of cushioning product, determining a difference in the volumes of the box and the order, generating a signal based on the difference in the volumes, and causing, with the signal, a cushioning product producing and/or dispensing machine to produce and/or dispense the desired quantity of cushioning product.

Description

    FIELD
  • This relates generally to protective packaging, and more particularly to an automated system of protective packaging.
    • BACKGROUND
  • Large warehouses that ship goods to customers upon receipt of the customers' orders typically use warehouse management software (“WMS”). Upon receipt of a customer order, a typical WMS system first determines the volume of the goods making up an order.
  • Next, the WMS system determines an appropriate size of box in which to ship the order. This appropriate box size will be of a larger volume than the volume of the order to permit protective packaging material to be added to the box to cushion and protect the order during shipment.
  • Next, the WMS system sends the box size information to a picking/packing operator. The operator picks the appropriate size box from the inventory of boxes on hand and places the order in the box. The operator then makes a visual inspection of the order within the box, noting the “void” to be filled, i.e. the volume of the box not taken up by the order. Finally, the operator operates a cushioning material producing and dispensing machine (or dispensing-only machine in the case of pre-produced cushioning material) at the packaging station to manually produce and dispense (or just dispense) the required or desired volume of cushioning material with which to pack the order in the box to provide adequate protection of the order during shipment. The cushioning material used could be air pillows, for example AIRplus® air pillows, paper pads, for example PAPERplus® paper pads, loosefill, for example PELASPAN® loosefill, or foam-in-bag cushions, all of which are commercially available from the assignee, or any other suitable cushioning material or dunnage.
  • Rather than rely upon manual methods, it would be desirable to provide a system that automates the step or steps of producing and/or dispensing the required or desired amount of cushioning product. Such a system would tend to prevent overfilling the box with cushioning material, resulting in waste, or under-filling the box with cushioning material, resulting in potential damage to the order during shipment.
    • SUMMARY
  • A method of automating a packaging system comprises receiving from a customer an order to be shipped to the customer, determining a volume of the order, selecting a shipping box having a volume sufficient to contain the order and a desired quantity of cushioning product, determining a difference in the volumes of the box and the order, generating a signal based on the difference in the volumes, and causing, with the signal, a cushioning product producing and/or dispensing machine to produce and/or dispense the desired quantity of cushioning product.
  • The method can be embodied in software adapted to run on a computer.
  • The steps of receiving an order from a customer, determining a volume of the order, and selecting a box having a volume that can contain the order and a desired quantity of cushioning product can be embodied in pre-existing software.
  • The cushioning product can be air pillows, paper pads, loosefill, or foam-in-bag cushions.
  • The method can further comprise the steps of identifying the box and confirming the identity of the box prior to producing and/or dispensing the desired quantity of cushioning material.
    • DRAWINGS
  • FIG. 1 is a diagrammatic view of the automated system of protective packaging to be described below.
  • FIG. 2 is a block diagram of the system of FIG. 1.
    •  DESCRIPTION
  • Referring first to FIG. 1, a customer 2 places an order with a business that ships the order from a warehouse 4. The warehouse 4 has a computer 6. The computer 6 selects an appropriately sized box 8 from an inventory 10 of differently sized boxes. A packer 12 packs the order in the appropriately sized box 8 with cushioning material 14 produced and/or dispensed by and/or from a cushioning material producing and/or dispensing machine 16. The cushioning material 14 could be, for example, air pillows such as AIRplus® air pillows, paper pads such as PAPERplus® paper pads, loosefill such as PELASPAN® loosefill, or foam-in-bag cushions, produced and/or dispensed by and/or from the machines of, or otherwise the subject of, for example, U.S. Pat. Nos. 6,508,611, 6,453,644, 6,398,460, 6,341,473, 6,296,424, 6,170,227, 6,004,637, 5,413,855, 5,108,673, 5,028,470, 4,970,040, 4,627,947, 6,534,148, 6,106,452, 6,033,354, 5,897,481, and 5,766,736, all hereby incorporated by reference herein as if fully set forth in their entirety.
  • FIG. 2 illustrates the steps performed by the system. The warehouse 4 receives an order from a customer 2 as indicated at 20. The computer 6 determines the volume of the order as indicated at 22. The computer 6 selects an appropriately sized box 8 from an inventory 10 of differently sized boxes that are kept on hand or otherwise in inventory at the warehouse 4 as indicated at 24. The appropriately sized box 8 will be of a volume sufficient to contain the order and a quantity of cushioning product sufficient to prevent damage to the order during shipment. The computer 6 may communicate the appropriately sized box 8 to the packer 12 so that the packer 12 can manually retrieve the box from inventory, or alternatively automation may be employed whereby the appropriately sized box 8 is automatically delivered to the packer 12. The box 8 is identified, as indicated at 26. For example, the box 8 can be labeled or otherwise designated with a unique identifier such as a simple label, hand mark, etc. applied to the box that can be visually identified by a packer, or a machine readable label such as a bar code or the like that can be read by the machine 16.
  • The computer 6 determines the difference in the volumes of the box and the order, as indicated at 28. The computer 6 generates a signal based on the difference in the volumes of the box and the order, as indicated at 30. This signal is then sent to the machine 16, as indicated at 32. To ensure that the machine 16 produces and/or dispenses the required/desired quantity of cushioning material, in response to the signal received, into the correct box with order therein, the box identity is confirmed, as indicated at 34. This can be accomplished manually by the packer simply making a visual inspection of the label, hand mark, etc. previously applied to the box to confirm its identity. Alternatively, the machine 16 can be outfitted with a bar code reader to read the bar code label previously applied to the box to confirm its identity
  • Once the identity of the box has been confirmed, either manually or by automation, and in response to the signal received, the machine 16 produces and/or dispenses automatically the required/desired quantity of cushioning material into the box with the order contained therein. This is shown at 36.
  • The methodology of the system can be embodied in software adapted to run on the computer 6. Blocks 20-26 are embodied in currently existing and commercially available warehouse management software. The difference value at block 28 can be readily determined and then fed into an additional software algorithm represented by blocks 30-36 running on the computer 6 and/or machine 16.
  • The inefficiencies, inconsistencies, and labor costs of the heretofore manual system of producing and/or dispensing the desired/required quantity of cushioning material are thus reduced. Overfilling the box with cushioning material, resulting in waste, or under-filling the box with cushioning material, resulting in potential damage to the order during shipment, are also reduced.
  • And, no complicated and expensive probe apparatus and associated software are needed to sense the void volume and to determine the volume of cushioning material desired/required.
  • The embodiments shown and described are for illustrative purposes only. The drawings and the description are not intended to limit in any way the scope of the claims. Those skilled in the art will appreciate various changes, modifications, and alternative embodiments. For example, the signal based on the difference in volumes of the box and order could be embodied in the machine readable bar code label placed on the box. In that case, the machine 16 both a) confirms the identity of the box, and b) receives the signal based on the difference in the volumes, from the bar code label. All such changes, modifications and embodiments are embraced by the claims. Accordingly, the scope of the right to exclude shall be limited only by the following claims and their equivalents.

Claims (5)

1. A method of automating a packaging system comprising:
receiving from a customer an order to be shipped to the customer,
determining a volume of the order,
selecting a shipping box having a volume sufficient to contain the order and a desired quantity of cushioning product,
determining a difference in the volumes of the box and the order,
generating a signal based on the difference in the volumes, and
causing, with the signal, a cushioning product producing and/or dispensing machine to produce and/or dispense the desired quantity of cushioning product.
2. The method of claim 1 wherein the method is embodied in software adapted to run on a computer.
3. The method of claim 2 wherein the steps of receiving an order from a customer, determining a volume of the order, and selecting a box having a volume that can contain the order and a desired quantity of cushioning product, are embodied in pre-existing software.
4. The method of claim 1 wherein the cushioning product is air pillows, paper pads, loosefill, or foam-in-bag cushions.
5. The method of claim 1 further comprising the steps of identifying the box and confirming the identity of the box prior to producing and/or dispensing the desired quantity of cushioning material.
US12/436,405 2008-05-12 2009-05-06 Automated System Of Protective Packaging Abandoned US20090277139A1 (en)

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PCT/US2009/043568 WO2009140247A1 (en) 2008-05-12 2009-05-12 Automated system of protective packaging

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US9102429B2 (en) 2008-12-31 2015-08-11 Storopack Hans Reichenecker Gmbh Apparatus for dispensing and inserting packaging material in containers and method therefore
EP2918514A1 (en) * 2014-03-12 2015-09-16 Mondi Consumer Packaging Technologies GmbH Method for packaging piece goods in a packaging envelope, piece good packaging assembly and fluid cushion
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US20170008654A1 (en) * 2015-07-09 2017-01-12 FoldedPak, Inc. Automated packing systems and methods
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